Reinforced thermally stable polycrystalline diamond cutter

Abstract

A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a diamond table and a substrate. The diamond table may be attached to the substrate. The diamond table may include bonded diamond grains defining interstitial channels. The interstitial channels may be filled with at least two types of carbides in the first region. The interstitial channels in the second region may be filled with a metal catalyst from the substrate.

1 . A superabrasive compact, comprising:
 a substrate;   a diamond table attached to the substrate, wherein the diamond table has a first region and a second region, the second region is sandwiched between the first region and the substrate, wherein the diamond table includes bonded diamond grains defining interstitial channels, the interstitial channels are filled with at least two types of carbides in the first region, the interstitial channels in the second region are filled with a metal catalyst from the substrate.   
     
     
         2 . The superabrasive compact of the  claim 1 , wherein a first carbide in the first region comprises silicon carbide. 
     
     
         3 . The superabrasive compact of the  claim 1 , wherein a second carbide in the first region comprises aluminum carbide. 
     
     
         4 . The superabrasive compact of the  claim 1 , wherein the first region comprises an additive. 
     
     
         5 . The superabrasive compact of the  claim 4 , wherein the additive comprises an inert chemical. 
     
     
         6 . The superabrasive compact of the  claim 5 , wherein the inert chemical comprises glass or quartz. 
     
     
         7 . A method of making a superabrasive compact, comprising:
 providing at least a partially leached polycrystalline diamond table that comprises bonded diamond grains defining interstitial channels therein;   providing a composite material positioned near a surface of the at least partially leached polycrystalline diamond table;   providing a substrate near the at least partially leached polycrystalline diamond table such that the at least partially leached polycrystalline diamond table is sandwiched between the composite material and the substrate; and   subjecting the substrate and the at least partially leached polycrystalline diamond table and the composite material to conditions of elevated temperature and pressure suitable for producing the polycrystalline superabrasive compact;   wherein the composite material infiltrates into a first region of the at least partially leached polycrystalline diamond table and forms at least two carbides at a first temperature, wherein a catalyst from the substrate sweeps into a second region of the at least partially leached polycrystalline diamond table at a second temperature.   
     
     
         8 . The method of the  claim 7 , wherein the substrate is cemented tungsten carbide. 
     
     
         9 . The method of the  claim 7 , wherein the composite material is a eutectic material. 
     
     
         10 . The method of the  claim 7 , wherein the first carbide is silicon carbide. 
     
     
         11 . The method of the  claim 7 , wherein the second carbide is aluminum carbide. 
     
     
         12 . The method of the  claim 9 , wherein the eutectic material comprises about 87.5% aluminum and about 12.5% silicon eutectic composition. 
     
     
         13 . The method of the  claim 7 , wherein the first region occupies from about 20% to up to about 95% volume of the at least partially leached polycrystalline diamond table. 
     
     
         14 . The method of the  claim 7 , wherein the composite material is selected from a group consisting of as a powder, as a disk, as a ring, as a disk with perforated holes, as a triangle, as a rectangular. 
     
     
         15 . The method of  claim 7 , further comprising bonding the substrate to the second region of the at least partially leached polycrystalline diamond table. 
     
     
         16 . The method of  claim 7 , wherein the catalyst from the substrate is cobalt. 
     
     
         17 . A superabrasive compact, comprising:
 a substrate;   a diamond table attached to the substrate, wherein the diamond table has a first region and a second region, the second region is sandwiched between the first region and the substrate, wherein the diamond table includes bonded diamond grains defining interstitial channels, the interstitial channels are filled at least with aluminum carbide and additives in the first region, the interstitial channels in the second region are filled with a metal catalyst from the substrate, wherein the first region occupies from about 20% to up to about 95% volume of the diamond table.   
     
     
         18 . The superabrasive compact of the  claim 17 , wherein the diamond table further comprises silicon carbide. 
     
     
         19 . The superabrasive compact of the  claim 17 , wherein the additive comprises quartz or glass. 
     
     
         20 . The superabrasive compact of the  claim 17 , wherein the first region of the diamond table has about 87.5% aluminum and about 12.5% silicon. 
     
     
         21 . The superabrasive compact of the  claim 17 , wherein the substrate is cemented tungsten carbide. 
     
     
         22 . The superabrasive compact of the  claim 17 , wherein the metal catalyst is an iron group transitional metal. 
     
     
         23 . The superabrasive compact of the  claim 22 , wherein the iron group transitional metal is cobalt.