Pdc cutter and method of making it

Abstract

A superabrasive compact and a method of making the superabrasive compact are disclosed. A superabrasive compact may comprise a diamond body and a metallic substrate. The diamond body comprises a first phase comprising a binderless intercrystalline diamond-to-diamond bonded matrix extending throughout the diamond body; and a second phase comprising a binder/catalyst within interstitial regions of intercrystalline bonded diamond matrix. The first phase is substantially free of the binder/catalyst material. The metallic substrate is in direct contact with the diamond body. The diamond body includes a first region comprising the catalyst/binder material and a second region is substantially free of the binder/catalyst. The second region may be positioned along a wear surface of the superabrasive compact.

We claims: 
     
         1 . A superabrasive compact, comprising:
 a diamond body, wherein the diamond body comprises:
 a first phase comprising a binderless intercrystalline diamond-to-diamond bonded matrix extending throughout the diamond body; and 
 a second phase comprising a binder/catalyst within interstitial regions of intercrystalline bonded diamond matrix; 
 wherein the first phase is substantially free of the binder/catalyst material; 
   a metallic substrate in direct contact with the diamond body wherein the diamond body includes a first region comprising the catalyst/binder material and a second region is substantially free of the binder/catalyst, and wherein the second region is positioned along a wear surface of the superabrasive compact.   
     
     
         2 . The superabrasive compact of  claim 1 , wherein the binder/catalyst material comprises cobalt. 
     
     
         3 . The superabrasive compact of  claim 1 , wherein the second region is substantially free of porosity. 
     
     
         4 . The superabrasive compact of the  claim 1 , wherein the metallic substrate comprises a metal carbide. 
     
     
         5 . The superabrasive compact of the  claim 4 , wherein the metal carbide comprises tungsten carbide. 
     
     
         6 . The superabrasive compact of  claim 1 , wherein second region is substantially free of metal. 
     
     
         7 . The superabrasive compact of  claim 6 , wherein the metal comprises a catalyst. 
     
     
         8 . The superabrasive compact of  claim 7 , wherein the catalyst comprises cobalt. 
     
     
         9 . The superabrasive compact of  claim 1 , wherein an amount of catalyst/binder material within the first region of the body continuously increases with distance from the second region. 
     
     
         10 . A superabrasive compact, comprising:
 a diamond body comprising:   a first region;   a second region, wherein the first region comprises a catalyst/binder material and a second region is substantially free of the binder, and wherein the second region is positioned along a wear surface of the superabrasive compact, wherein the second region comprises a binderless polycrystalline diamond material, wherein the second region is substantially free of porosity.   
     
     
         11 . The superabrasive compact of  claim 10 , wherein the second region is substantially free of metal. 
     
     
         12 . The superabrasive compact of  claim 11 , wherein the metal comprises a catalyst. 
     
     
         13 . The superabrasive compact of  claim 12 , wherein the catalyst comprises cobalt. 
     
     
         14 . The superabrasive compact of  claim 10 , wherein an amount of catalyst/binder material within the first region of the body continuously increases with distance from the second region. 
     
     
         15 . The superabrasive compact of  claim 10 , wherein the diamond body comprises:
 a first phase comprising a binderless intercrystalline diamond-to-diamond bonded matrix extending throughout the diamond body; and   a second phase comprising a binder/catalyst within interstitial regions of intercrystalline bonded diamond matrix.   
     
     
         16 . A superabrasive compact, comprising:
 a diamond body, wherein the diamond body comprises:
 a first phase comprising a binderless intercrystalline diamond-to-diamond bonded matrix extending throughout the diamond body; and 
 a second phase comprising a binder within interstitial regions of intercrystalline bonded diamond matrix; 
   a metallic substrate in direct contact with the diamond body, wherein the diamond body includes a first region and a second region, and wherein the second region is positioned along a wear surface of the superabrasive compact, wherein the second region is substantially free of porosity and has substantially binderless intercrystalline diamond-to-diamond bonded matrix from a wearing surface.   
     
     
         17 . The superabrasive compact of  claim 16 , wherein the metallic substrate comprises carbide. 
     
     
         18 . The superabrasive compact of  claim 17 , wherein the carbide comprises tungsten carbide. 
     
     
         19 . The superabrasive compact of  claim 16 , wherein an amount of binder material within the first region of the body continuously increases with distance from the second region. 
     
     
         20 . The superabrasive compact of  claim 16 , wherein the second region comprises a plurality of diamonds with substantially free of metal.