METHODS OF FORMING POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS, CUTTING ELEMENTS SO FORMED AND DRILL BITS SO EQUIPPED

摘要

There is provided a method of forming a polycrystalline diamond element, wherein the method comprises forming a polycrystalline diamond compact (200, 200') from diamond particles at a temperature and a pressure sufficient to form diamond-to-diamond bonds in the presence of a catalyst comprising one of a Group VIII element and an alloy thereof; substantially removing the catalyst from an entirety of the polycrystalline diamond compact (200, 200'); and securing the polycrystalline diamond compact (200, 200') having the catalyst substantially removed therefrom to a supporting substrate (208) at a temperature and a pressure sufficiently high to maintain stability of diamond-to-diamond bonds in the polycrystalline diamond compact (200, 200') in the presence of a binder material (210) differing at least in part from a material of the catalyst and comprising one of a Group VIII element and an alloy thereof, and to introduce the binder material (210) into interstitial voids between diamond particles of the polycrystalline diamond compact (200, 200') and substantially fill the polycrystalline diamond compact (200, 200') with the binder material (210), wherein at least one of the temperature and pressure for forming the diamond compact (200, 200') is higher than a respective temperature and/or pressure for securing the polycrystalline diamond compact (200, 200') having the catalyst substantially removed therefrom to the supporting substrate (208).