A method for fabricating tungsten carbide cermet components or parts employs powder bed fusion of powder mixture of ceramic particles and metal binder. Some embodiments also include a step of hot isostatic pressing to increase the density of the part.

A method for fabricating tungsten carbide cermet components or parts employs powder bed fusion of powder mixture of ceramic particles and metal binder. Some embodiments also include a step of hot isostatic pressing to increase the density of the part.

Polycrystalline diamond compacts (PDCs) include a polycrystalline diamond (PCD) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. The PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.

A cemented carbide comprising a first hard phase composed of tungsten carbide particles and a binder phase including Co, the cemented carbide having a ratio Nt/Na of 0.9 or more, where, in any surface or any cross section of the cemented carbide, a region in which there is a distance X of 5 nm or less between surfaces respectively of tungsten carbide particles adjacent to each other, the surfaces facing each other along a length L of 100 nm or more, is referred to as a WC/WC interface, and Na represents a total number of WC/WC interfaces and Nt represents a number of WC/WC interfaces having distance X of 1 nm or more and 5 nm or less and having therein an atomic percentage of Co higher than an average value of atomic percentages of Co in the tungsten carbide particles.

In an embodiment, a polycrystalline diamond compacts (PDC) includes a substrate and a polycrystalline diamond (PCD) table bonded to the substrate. The PCD table defines an upper surface and at least one peripheral surface. The PCD table includes a plurality of bonded diamond grains. The PCD table includes a first region adjacent to the substrate that includes a metallic constituent disposed interstitially between the bonded diamond grains thereof, and a leached second region extending inwardly from the upper surface and the at least one peripheral surface that is depleted of the metallic constituent. The leached second region exhibits a leach depth profile having a maximum leach depth that is measured from the upper surface. A leach depth of the leach depth profile decreases with lateral distance from a central axis of the PCD table and toward the at least one peripheral surface.

Polycrystalline ultra-hard constructions comprise a polycrystalline ultra-hard material body and two or more support members attached to the body by braze material. The support members include a backside support member and a side support member. The side support member is a one- or two-piece construction, and is positioned circumferentially around and extends axially along the body or both the body and the backside support member such that a working surface of the body remains exposed. The support members can be configured to provide a mechanical attachment or interlocking attachment with the body or another support member. The braze materials used in the construction can be different and selected to enhance the attachment and/or reduce the creation of thermal stress within the construction during assembly. The support members can be selected having different thermal expansion characteristics that also operate to reduce the thermal stress during construction assembly.

Polycrystalline ultra-hard constructions comprise a polycrystalline ultra-hard material body and two or more support members attached to the body by braze material. The support members include a backside support member and a side support member. The side support member is a one- or two-piece construction, and is positioned circumferentially around and extends axially along the body or both the body and the backside support member such that a working surface of the body remains exposed. The support members can be configured to provide a mechanical attachment or interlocking attachment with the body or another support member. The braze materials used in the construction can be different and selected to enhance the attachment and/or reduce the creation of thermal stress within the construction during assembly. The support members can be selected having different thermal expansion characteristics that also operate to reduce the thermal stress during construction assembly.

Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body. The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body. The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

The present invention relates to a powder for three-dimensional printing of a cermet or a cemented carbide body. The powder has 30-70 vol % of the particles that are <10 m in diameter. The present invention also relates to a method of making a cermet or cemented carbide body. The method includes the steps of forming the powder, 3D printing a body using the powder together with a printing binder to form a 3D printed cermet or cemented carbide green body and subsequently sintering the green body to form a cermet or cemented carbide body.