Polycrystalline diamond materials, methods of fabricating...

Details Polycrystalline diamond materials, methods of fabricating... Polycrystalline diamond materials, methods of fabricating...

2008-04-22

2011-11-15

Mayes, Melvin (Department: 1732)

Chemistry of inorganic compounds

Carbon or compound thereof

Elemental carbon

C175S434000, C051S307000, C051S309000, C264S125000

Reexamination Certificate

active

08057775

ABSTRACT:
Embodiments relate to methods of fabricating PCD materials by subjecting a mixture that exhibits a broad diamond particle size distribution to a HPHT process, PCD materials so-formed, and PDCs including a polycrystalline diamond table comprising such PCD materials. In an embodiment, a method includes subjecting a mixture to heat and pressure sufficient to form a PCD material. The mixture comprises a plurality of diamond particles exhibiting a diamond particle size distribution characterized, in part, by a parameter θ that is less than about 1.0, whereθ=x6·σ,x is the average particle size of the diamond particle size distribution, and σ is the standard deviation of the diamond particle size distribution. In an embodiment, the diamond particle size distribution can be generally modeled by the following equation:C⁢⁢P⁢⁢F⁢⁢T100=Dn-DSnDLn-DSn,wherein CPFT is the cumulative percent finer than, D is diamond grain size, DLis the largest-sized diamond grain, DSis the smallest-sized diamond grain, and n is a distribution modulus.

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