Aluminum or aluminum carbide alternative catalyst for polycrystalline diamond compact formation

Abstract

A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a superabrasive volume comprising about 60 to about 99.5 weight % superabrasive particles, about 0.5 to 40 weight % catalysts. The catalyst comprises a non-transitional metal atom.

1 . A superabrasive compact, comprising:
 a substrate; and   a superabrasive volume attached to the substrate, wherein the superabrasive volume has a plurality of polycrystalline superabrasive particles and a first catalyst, wherein the first catalyst comprises a non-transitional metal atom.   
     
     
         2 . The superabrasive compact of the  claim 1 , wherein the superabrasive particle comprises diamond particle. 
     
     
         3 . The superabrasive compact of the  claim 1 , wherein the superabrasive volume comprises about 60 to about 99.5 weight % diamond, about 0.5 to 40 weight % aluminum carbide or aluminum. 
     
     
         4 . The superabrasive compact of the  claim 1 , wherein the non-transitional metal atom comprises aluminum. 
     
     
         5 . The superabrasive compact of the  claim 1 , wherein the substrate comprises a second catalyst for forming the superabrasive particle to particle bonding. 
     
     
         6 . The superabrasive compact of the  claim 1 , wherein the second catalyst is an iron group transitional metal. 
     
     
         7 . A method of making a superabrasive compact, comprising:
 mixing a metal with a plurality of diamond particles;   subjecting the metal and the plurality of diamond particles to conditions of elevated temperature and pressure suitable for producing the polycrystalline diamond compact; and   converting the metal to a metal carbide under the elevated temperature and pressure.   
     
     
         8 . The method of the  claim 7 , further comprising providing a substrate attached to a volume made of the metal and the plurality of diamond particles before subjecting the metal and the plurality of diamond particles to conditions of elevated temperature and pressure. 
     
     
         9 . The method of  claim 8 , wherein the substrate is cemented tungsten carbide. 
     
     
         10 . The method of the  claim 7 , wherein the metal comprises a non-transitional metal. 
     
     
         11 . The method of the  claim 7 , wherein the metal and the metal carbide are aluminum to aluminum carbide, respectively. 
     
     
         12 . The method of the  claim 7 , wherein the elevated temperature and pressure are about 1400° C. to about 2500° C. and about 10 to about 80 Kbar, respectively. 
     
     
         13 . The method of the  claim 7 , wherein the elevated temperature is about 2000° C. to about 2500° C. 
     
     
         14 . The method of the  claim 11 , wherein aluminum carbide or aluminum is used as a catalyst for diamonds to form diamond to diamond bonds. 
     
     
         15 . A superabrasive compact, comprising:
 a superabrasive volume comprising about 60 to about 99.5 weight % superabrasive particles, about 0.5 to about 40 weight % catalysts, wherein the catalyst comprises a non-transitional metal atom.   
     
     
         16 . The superabrasive compact of the  claim 15 , wherein the superabrasive particles are selected from a group of cubic boron nitride, diamond, and diamond composite materials. 
     
     
         17 . The superabrasive compact of the  claim 15 , wherein the non-transitional metal atom is aluminum. 
     
     
         18 . The superabrasive compact of  claim 15 , wherein the catalyst is aluminum or aluminum carbide. 
     
     
         19 . The superabrasive compact of  claim 18 , wherein the aluminum carbide is an intermediate forming from aluminum and diamond at elevated temperature and pressure. 
     
     
         20 . The superabrasive compact of the  claim 15 , further comprises a substrate attached to a superabrasive volume formed by the polycrystalline superabrasive particles. 
     
     
         21 . The superabrasive compact of the  claim 20 , wherein the substrate is a cemented tungsten carbide. 
     
     
         22 . The superabrasive compact of the  claim 15 , wherein the superabrasive volume is substantially free of a metal.