Doubled-sided and multi-layered PCD and PCBN abrasive articles

Abstract

A doubled-sided PCD or PCBN compact as well as a new multi-layered PCD and PCBN can be produced using high pressure high temperature processes allowing for increased effective thickness of abrasive tools. A polycrystalline compact can include a substrate having a first surface and a second surface which are non-contiguous. Additionally, a first polycrystalline layer can be attached to the first surface of the substrate and a second polycrystalline layer attached to the second surface of the substrate. The first and second polycrystalline layers can include superabrasive particles bonded together by sintering or chemical bonding with an additional metal. Such double-sided PCD and PCBN compacts as well as a new multiple layered PCD and PCBN allow for increased effective thickness of a tool without suffering from non-homogenous results typical of standard PCD and PCBN compacts, regardless of superabrasive particle size. Each polycrystalline layer can include superabrasive particles of varying particle sizes such that the final tool is tailored for specific abrading characteristics. Such doubled-sided and / or multiple layered PCD and PCBN compacts can be incorporated into a wide variety of abrasive tools for use in cutting, milling, grinding, polishing, drilling and other similar abrasive applications.

Description

FIELD OF THE INVENTION [0001] The present invention relates generally to abrasive tools and methods for producing such abrasive tools. Specifically, the present invention relates to high pressure high temperature polycrystalline diamond and polycrystalline cubic boron nitride articles and methods for producing these polycrystalline articles. Accordingly, the present application involves the fields of physics, chemistry, and material science. BACKGROUND OF THE INVENTION [0002] Polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) compacts are used extensively in the superabrasive industry for the production of cutting tools, drill bits, wire drawing dies, dressers, and a wide variety of other tools. The basic process of forming PCD / PCBN compacts was developed in the 1960's and has become a fundamental process in the superabrasive industry. A typical PCD compact is formed by loading a reaction cup assembly with small diamond grains, e.g., often from 1 μm to 50 μ...

AI Technical Summary

Benefits of technology

[0005] Accordingly, the present invention provides new PCD and PCBN materials especially designed for much wider applications than existing PCD / PCBN having limited product properties. The present invention also provides HPHT methods for producing tools and devices having increased effective thicknesses and tailored abrasive properties. Therefore, the PCD and PCBN materials of the present invention can be a viable alternative for existing products such as solid PCBN and drill-bit PCD cutters and have improved cutting and abrasive properties.

[0012] In a detailed aspect of the present invention, the multi-layer polycrystalline compact can be cut such that a plurality of polycrystalline tool inserts are formed having at least two polycrystalline surfaces. The polycrystalline tool inserts can be any desired shape such as but not limited to cylindrical, rectangular, or triangular, depending on the intended application. Further, such inserts can be contoured or otherwise shaped to provide predetermined abrading effects to a work piece.

Problems solved by technology

However, the thickness of a typical PCD / PCBN layer is often limited to less than about 1 mm, although some methods can increase this thickness somewhat.

Thus, typical thick solid and layered polycrystalline materials have certain limits to the available grain sizes for particular thicknesses.

Further, the non-homogenous sintering of the compacts leaves interior volumes of the compact which are weaker due at least in part to poorly bonded microstructures than exterior portions.

As a result, the compact is prone to premature chipping and / or cracking during use, or even during high pressure high temperature (HPHT) sintering stages, thus reducing the useful life of any tool formed therewith.

However, these methods also tend to increase production costs and manufacturing complexity and still have limitations on the achievable thickness of the PCD.

Such a solid PCBN is not easily processed with finer powders and results in a limited grade of products and is further limited in utility since most non-solid products are produced for use in a wide range of applications having various grades of PCBN products.

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