Polycrystalline diamond compact, drill bit incorporating same, and methods of manufacture

Abstract

Methods of making superabrasive elements may include forming a first superabrasive body, forming discrete components from the first superabrasive body, and then forming a second abrasive element from the discrete components. For example, microstructures (e.g., micro-cylinders or other geometries) may be formed from the first superabrasive element, catalyst materials may be removed from the microstructures, with the microstructures being recombined and bonded during a subsequent high-pressure, high-temperature (HPHT) process. In other embodiments, superabrasive elements may be formed to include microfeatures formed in a surface of a superabrasive body or table. For example, blind holes or slots may be formed in a surface of the element for use in attaching the superabrasive table to a substrate. The holes may be coated to provide an impermeable surface, or they may be filled with a metallic material to enhance the attachment to a substrate.

What is claimed is: 
     
         1 . A superabrasive element comprising:
 a body comprising a plurality of pre-formed, laser-cut, superabrasive microstructures, at least some of the microstructures being bonded to one another through a high-pressure, high-temperature (HPHT) process;   wherein a plurality of interstitial spaces between the plurality of bonded microstructures include a catalyst material disposed therein and wherein a plurality of interstitial spaces within at least one of the microstructures are substantially devoid of any catalyst material;   wherein the superabrasive element further comprises a plurality of diamond grains intermixed with and bonded to the plurality of plurality of microstructures.   
     
     
         2 . The superabrasive element of  claim 1 , further comprising a substrate attached to the body. 
     
     
         3 . The superabrasive element of  claim 2 , further comprising a plurality of microfeatures formed in a surface of the body that is attached to the substrate. 
     
     
         4 . The superabrasive element of  claim 3 , wherein the plurality of microfeatures include a plurality of blind holes. 
     
     
         5 . The superabrasive element of  claim 1 , wherein one or more of the microstructures include a material coating at least partially thereon. 
     
     
         6 . The superabrasive element of  claim 1 , wherein the plurality of microstructures comprises polycrystalline diamond. 
     
     
         7 . The superabrasive element of  claim 1 , wherein the superabrasive body exhibits a coercivity of about 115 Oersteds or more. 
     
     
         8 . The superabrasive element of  claim 1 , wherein the superabrasive body exhibits a specific magnetic saturation of about 15 Gauss·cm 3 /grams or less. 
     
     
         9 . The superabrasive element of  claim 1 , wherein the body is bonded to a ring, wherein the ring comprises a superabrasive material having a plurality of interstitial spaces being substantially devoid of any catalyst material. 
     
     
         10 . The superabrasive element of  claim 9 , wherein the ring comprises polycrystalline diamond. 
     
     
         11 . The superabrasive element of  claim 10 , further comprising a material coating on at least a portion of the ring. 
     
     
         12 . The superabrasive element of  claim 1 , wherein the plurality of pre-formed, laser-cut, superabrasive microstructures, includes a plurality of pre-formed, laser-cut superabrasive microstructures. 
     
     
         13 . A rotary drill bit for drilling a subterranean formation, the drill bit comprising:
 a shank;   a bit body attached to the shank;   at least one cutting element coupled with the bit body, the at least one cutting element comprising:   a superabrasive body comprising a plurality of pre-formed, laser-cut, superabrasive microstructures, at least some of the microstructures being bonded to one another through a high-pressure, high-temperature (HPHT) process;   wherein a plurality of interstitial spaces between the plurality of bonded microstructures include a catalyst material disposed therein and wherein a plurality of interstitial spaces within at least one of the microstructures are substantially devoid of any catalyst material;   wherein the superabrasive element further comprises a plurality of diamond grains intermixed with and bonded to the plurality of plurality of microstructures.   
     
     
         14 . The rotary drill bit of  claim 13 , wherein the superabrasive element is brazed to the bit body. 
     
     
         15 . The rotary drill bit of  claim 13 , further comprising a substrate attached to the superabrasive body, wherein the substrate is brazed to the bit body. 
     
     
         16 . The rotary drill bit of  claim 13 , wherein one or more of the microstructures include a material coating at least partially thereon. 
     
     
         17 . The rotary drill bit of  claim 13 , wherein the superabrasive body exhibits a coercivity of about 115 Oersteds or more. 
     
     
         18 . The rotary drill bit of  claim 13 , wherein the superabrasive body exhibits a specific magnetic saturation of about 15 Gauss·cm 3 /grams or less. 
     
     
         19 . The rotary drill bit of  claim 13 , wherein the plurality of pre-formed, laser-cut, superabrasive microstructures, includes a plurality of pre-formed, laser-cut superabrasive microstructures. 
     
     
         20 . The rotary drill bit of  claim 13 , further comprising a plurality of microfeatures formed in a surface of the superabrasive body that is attached to the substrate.