US Synthetic Corporation

C Eugene McMurray

Michael Alexander Vail

Kenneth Eugene Bertagnolli

David Paul Miess

Paul Douglas Jones

Debkumar Mukhopadhyay

Jason Keith Wiggins

Jiang Qian

In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table bonded to the substrate. The table includes bonded diamond grains defining interstitial regions. The table includes an upper surface, a back surface bonded to the substrate, and at least one lateral surface extending therebetween. The table includes a first region extending inwardly from the upper surface and the lateral surface. The first region exhibits a first interstitial region concentration and includes at least one interstitial constituent disposed therein, which may be present in at least a residual amount and includes at least one metal carbonate and/or at least one metal oxide. The table includes a second bonding region adjacent to the substrate that extends inwardly from the back surface. The second bonding region exhibits a second interstitial region concentration that is greater than the first interstitial region concentration and includes a metallic infiltrant therein.

Carbonate-catalyzed polycrystalline diamond elements, methods of manufacturing the same, and applications therefor

Embodiments of the invention relate to polycrystalline diamond compacts ('PDC') exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PDC includes a sintered substantially single-phase polycrystalline diamond ('PCD') body consisting essentially of bonded-together diamond grains exhibiting a morphology different than that of a PCD body formed by sintering diamond crystals. A substrate is bonded to the sintered substantially single-phase PCD body. Other embodiments are directed to methods of forming such PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Polycrystalline diamond compact including substantially single-phase polycrystalline diamond body and applications therefor

Embodiments of the invention relate to methods of fabricating a polycrystalline diamond compacts and applications for such polycrystalline diamond compacts. In an embodiment, a method of fabricating a polycrystalline diamond body includes mechanically milling non-diamond carbon and a sintering aid material for a time and aggressiveness sufficient to form a plurality of carbon-saturated sintering aid particles and sintering a plurality of diamond particles in the presence of the plurality of carbon-saturated sintering aid particles to form the polycrystalline diamond body.

Methods of fabricating a polycrystalline diamond body with a sintering aid/infiltrant at least saturated with non-diamond carbon and resultant products such as compacts

Embodiments of the invention relate to polycrystalline diamond compacts ('PDCs') comprising a polycrystalline diamond ('PCD') table including a thermally-stable region having at least one low-carbon-solubility material disposed interstitially between bonded diamond grains thereof, and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate, and a PCD table bonded to the substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions. The PCD table further includes at least one low-carbon-solubility material disposed in at least a portion of the plurality of interstitial regions. The at least one low-carbon-solubility material exhibits a melting temperature of about 1300&#xb0; C. or less and a bulk modulus at 20&#xb0; C. of less than about 150 GPa.

Methods of making a polycrystalline diamond compact including a polycrystalline diamond table with a thermally-stable region having at least one low-carbon-solubility material

Embodiments of the invention relate to methods of fabricating a polycrystalline diamond compacts and applications for such polycrystalline diamond compacts. In an embodiment, a method of fabricating a polycrystalline diamond compact includes at least saturating a sintering aid material with non-diamond carbon to form a carbon-saturated sintering aid material and sintering a plurality of diamond particles in the presence of the carbon-saturated sintering aid particles to form a polycrystalline diamond table.

Methods of fabricating polycrystalline diamond compacts

Polycrystalline diamond compact including a carbonate-catalyzed polycrystalline diamond table and applications therefor

Polycrystalline diamond compact including substantially single-phase polycrystalline diamond body, methods of making same, and applications therefor

Polycrystalline diamond compact including a polycrystalline diamond table with a thermally-stable region having at least one low-carbon-solubility material and applications therefor

Embodiments of the invention relate to polycrystalline diamond compacts ('PDCs') comprising a preformed polycrystalline diamond ('PCD') table including a thermally-stable region having a copper-containing material disposed interstitially between bonded diamond grains thereof, and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate, and a preformed PCD table having an interfacial surface bonded to the substrate and a generally opposing upper surface. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions. The preformed PCD table further includes a first region extending inwardly from the upper surface that includes a copper-containing material disposed therein and a second region extending inwardly from the interfacial surface that includes a nickel-containing material disposed therein.

Polycrystalline diamond compact including a polycrystalline diamond table with a thermally-stable region having a copper-containing material and applications therefor

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Galion, OH, United States of America

C Eugene McMurray