US 12,344,558 B2
Polycrystalline diamond compact cutting elements, earth-boring tools including such cutting elements, and related methods of making and using same
Andrew Robertson, The Woodlands, TX (US); and Nicholas J. Lyons, Houston, TX (US)
Filed by Baker Hughes Oilfield Operations LLC, Houston, TX (US)
Filed on Aug. 2, 2022, as Appl. No. 17/816,789.
Prior Publication US 2024/0043343 A1, Feb. 8, 2024
Int. Cl. C04B 35/528 (2006.01); B22F 7/06 (2006.01); C04B 35/645 (2006.01)
CPC C04B 35/528 (2013.01) [B22F 7/064 (2013.01); C04B 35/645 (2013.01); C04B 2235/427 (2013.01); C04B 2235/656 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A method of forming a polycrystalline diamond compact, the method comprising:
performing a first sintering process comprising sintering discrete diamond particles at a temperature of at least about 1400° C. at a pressure of at least about 10 GPa in the absence of a metal solvent catalyst to form direct diamond-to-diamond bonds between the discrete diamond particles so as to form a polycrystalline diamond compact;
providing a barrier material over at least a portion of the polycrystalline diamond compact;
providing a carbide material and a metal binder comprising at least one transition metal element over the barrier material and the polycrystalline diamond compact; and
performing a second sintering process comprising sintering the carbide material, the metal binder, the barrier material, and the polycrystalline diamond compact at a temperature of at least about 1400° C. at a pressure of at least about 5 GPa in the absence of a metal solvent catalyst to form a supporting substrate comprising the carbide material and the metal binder attached to the polycrystalline diamond compact, the barrier material located between the polycrystalline diamond compact and the supporting substrate,
wherein at least a portion of the polycrystalline diamond compact proximate an exposed exterior surface of the polycrystalline diamond compact is at least substantially free of the metal binder.