Superabrasive elements

Abstract

Embodiments of the invention relate to thermally-stable polycrystalline diamond (“PCD”) elements, polycrystalline diamond compacts (“PDCs”), and methods of fabricating such PCD elements and PDCs. In an embodiment, a method of fabricating a thermally-stable PCD element includes providing an at least partially leached PCD body including a plurality of interstitial regions, and infiltrating at least a portion of the interstitial regions of the at least partially leached PCD body with at least a portion of an infiltrant material. The infiltrant material may include at least one member chosen from the group of glass, silicone, and a ceramic having a negative coefficient of thermal expansion.

What is claimed is: 
     
         1 . A superabrasive element, comprising:
 a plurality of bonded superabrasive grains defining a plurality of interstitial regions;   at least one material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one material exhibits a coefficient of thermal expansion less than that of cobalt; and   a catalyst used to initially sinter the plurality of bonded superabrasive grains disposed in at least a portion of the plurality of interstitial regions.   
     
     
         2 . The superabrasive element of  claim 1  wherein the at least one material includes one or more of a ceramic having a negative coefficient of thermal expansion, glass, or silicone. 
     
     
         3 . The superabrasive element of  claim 1  wherein the at least one material includes glass, and further wherein the glass includes at least one member selected from the group consisting of a silicate, a borate, and a borosilicate. 
     
     
         4 . The superabrasive element of  claim 1  wherein the at least one material includes silicone. 
     
     
         5 . The superabrasive element of  claim 1  wherein the at least one material includes a ceramic having a negative coefficient of thermal expansion, and further wherein the ceramic includes at least one member selected from zirconium tungstate, beta spodumene, and beta eucryptite. 
     
     
         6 . The superabrasive element of  claim 1  wherein the catalyst includes iron, cobalt, nickel, or alloys thereof. 
     
     
         7 . The superabrasive element of  claim 1  wherein the catalyst includes a cobalt alloy. 
     
     
         8 . The superabrasive element of  claim 1  wherein the plurality of bonded superabrasive grains include a plurality of bonded diamond grains. 
     
     
         9 . The superabrasive element of  claim 1  wherein the at least one material exhibits a negative coefficient of thermal expansion over a temperature range from about −272° C. to about 775° C. 
     
     
         10 . The superabrasive element of  claim 1  wherein the plurality of bonded superabrasive grains is at least partially leached of the catalyst. 
     
     
         11 . A superabrasive compact, comprising:
 a superabrasive element including:
 a working surface; 
 an interfacial surface; 
 a side surface extending between the working surface and the interfacial surface; 
 a plurality of bonded superabrasive grains defining a plurality of interstitial regions; 
 at least one material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one material exhibits a coefficient of thermal expansion less than that of cobalt; 
 a catalyst used to initially sinter the plurality of bonded superabrasive grains disposed in at least a portion of the plurality of interstitial regions; and 
 a substrate bonded to the interfacial surface of the superabrasive element. 
   
     
     
         12 . The superabrasive compact of  claim 10  wherein the at least one material includes one or more of a ceramic having a negative coefficient of thermal expansion, glass, or silicone. 
     
     
         13 . The superabrasive compact of  claim 10  wherein the at least one material includes glass, and further wherein the glass includes at least one member selected from the group consisting of a silicate, a borate, and a borosilicate. 
     
     
         14 . The superabrasive compact of  claim 10  wherein the at least one material includes silicone. 
     
     
         15 . The superabrasive compact of  claim 10  wherein the at least one material includes a ceramic having a negative coefficient of thermal expansion, and further wherein the ceramic includes at least one member selected from zirconium tungstate, beta spodumene, and beta eucryptite. 
     
     
         16 . The superabrasive compact of  claim 10  wherein the catalyst includes iron, cobalt, nickel, or alloys thereof. 
     
     
         17 . The superabrasive compact of  claim 10  wherein the catalyst includes a cobalt alloy. 
     
     
         18 . The superabrasive compact of  claim 10  wherein the plurality of bonded superabrasive grains include a plurality of bonded diamond grains. 
     
     
         19 . The superabrasive compact of  claim 10  wherein the at least one material exhibits a negative coefficient of thermal expansion over a temperature range from about −272° C. to about 775° C. 
     
     
         20 . The superabrasive compact of  claim 10  wherein the superabrasive element is at least partially leached of the catalyst. 
     
     
         21 . The superabrasive compact of  claim 10  wherein the at least one material is an infiltrant. 
     
     
         22 . A superabrasive element, comprising:
 a plurality of bonded diamond grains defining a plurality of interstitial regions;   at least one material disposed in at least a portion of the plurality of interstitial regions, wherein the at least one material exhibits a negative coefficient of thermal expansion; and   a cobalt alloy catalyst used to initially sinter the plurality of bonded superabrasive grains disposed in at least a portion of the plurality of interstitial regions.   
     
     
         23 . The superabrasive element of  claim 22  wherein the at least one material includes a ceramic having a negative coefficient of thermal expansion. 
     
     
         24 . The superabrasive element of  claim 22  wherein the cobalt alloy includes a cobalt-iron alloy. 
     
     
         25 . The superabrasive element of  claim 22  wherein the at least one material is an infiltrant.