Methods of forming polycrystalline compacts and earth-boring tools including polycrystalline compacts

Abstract

Methods of forming polycrystalline compacts include subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The methods further comprise substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact; and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact. The polycrystalline cutting elements may be secured to a bit body of an earth-boring tool.

Claims

1. A method of forming a polycrystalline compact, comprising: polishing at least one surface of a leached portion of a polycrystalline material, from which a catalyst material has been substantially removed by leaching, to form a non-planar surface extending into the leached portion of an at least partially leached polycrystalline compact and having a surface roughness less than about 10 in. root mean square (RMS), the leached portion of the polycrystalline material comprising inter-bonded grains of hard material having interstitial spaces therebetween that are substantially free of material.

2. The method of claim 1, wherein the at least partially leached polycrystalline compact comprises an interface between a first volume of polycrystalline material and a second volume of polycrystalline material, the first volume of polycrystalline material having a first concentration of the catalyst material and the second volume of polycrystalline material having a second, substantially higher concentration of the catalyst material, and wherein polishing the at least one surface of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed comprises removing a portion of the first volume of polycrystalline material from the at least partially leached polycrystalline compact.

3. The method of claim 1, further comprising substantially removing the catalyst material from an additional portion of the polycrystalline material having substantial catalyst material therein after polishing the at least one surface of the leached portion of the polycrystalline material.

4. The method of claim 1, wherein polishing the at least one surface of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed comprises forming one or more non-planar surfaces in the front cutting face of the at least partially leached polycrystalline compact.

5. The method of claim 1, wherein polishing the at least one surface of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed comprises forming a recess extending into the leached portion of the polycrystalline material.

6. The method of claim 1, wherein polishing the at least one surface of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed comprises exposing the polycrystalline material to electromagnetic radiation to remove at least a portion of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed.

7. The method of claim 6, wherein exposing the polycrystalline material to electromagnetic radiation to remove at least a portion of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed comprises exposing the polycrystalline material to laser irradiation.

8. The method of claim 1, further comprising forming a chamfer adjacent a front cutting surface of the at least partially leached polycrystalline compact.

9. A method of forming an earth-boring tool, comprising: forming a polycrystalline cutting element, comprising: polishing at least one surface of a leached portion of a polycrystalline material, from which a catalyst material has been substantially removed by leaching, to form a non-planar surface extending into a front cutting face of an at least partially leached polycrystalline compact and having a surface roughness less than about 10 in. root mean square (RMS), the leached portion comprising inter-bonded grains of hard material having interstitial spaces therebetween that are substantially free of material; and securing the polycrystalline cutting element to a bit body.

10. The method of claim 9, further comprising substantially removing additional catalyst material in an additional portion of the polycrystalline material having substantial catalyst material therein after polishing the at least one surface of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed and before securing the polycrystalline cutting element to the bit body.

11. The method of claim 9, wherein forming the polycrystalline cutting element further comprises forming the polycrystalline material on a substrate.

12. The method of claim 9, wherein polishing the at least one surface of the leached portion of the polycrystalline material from which the catalyst material has been substantially removed comprises forming the front cutting face to comprise one or more non-planar surfaces in the front cutting face of the at least partially leached polycrystalline compact.

13. A method of forming a polycrystalline diamond compact, comprising: polishing a portion of a first portion of a diamond table from which a catalyst material has been at least partially leached to form a recess extending into the first portion of the diamond table, the first portion of the diamond table comprising inter-bonded grains of hard material having interstitial spaces therebetween that are substantially free of catalyst material; polishing a front cutting face of the at least partially leached diamond table to form a surface having a surface roughness less than about 10 in. root mean square (RMS); and at least partially leaching the catalyst material from a second portion of the diamond table.

14. The method of claim 13, wherein polishing the portion of the first portion of the diamond table from which the catalyst material has been substantially removed comprises forming one or more recesses extending into the first portion of the diamond table.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present disclosure, various features and advantages of embodiments of the disclosure may be more readily ascertained from the following description of example embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a simplified cross-sectional side view illustrating a method of forming a polycrystalline compact according to the present disclosure;

(3) FIG. 2 is a partial cutaway view showing a polycrystalline compact;

(4) FIG. 3 is a simplified drawing showing how a microstructure of the polycrystalline compact of FIG. 2 may appear under magnification, and illustrates inter-bonded and interspersed grains of hard material;

(5) FIG. 4 is a simplified drawing showing how the microstructure of FIG. 3 may appear after removal of catalyst material;

(6) FIG. 5 is a simplified drawing showing a perspective view of a polycrystalline compact having a cutting surface with non-planar portions;

(7) FIGS. 6 through 8 are simplified cross-sectional side views of partially formed polycrystalline compacts during processing, such as partially formed polycrystalline compacts used to form the polycrystalline compact shown in FIG. 5;

(8) FIG. 9 is a simplified cross-section of a polycrystalline compact during processing; and

(9) FIG. 10 is a perspective view of an embodiment of a fixed-cutter earth-boring rotary drill bit that includes a plurality of polycrystalline compacts like the polycrystalline compacts shown in FIGS. 2, 5, and 9.

DETAILED DESCRIPTION

(10) The illustrations presented herein are not actual views of any particular material, apparatus, system, or method, but are merely idealized representations that are employed to describe example embodiments of the present disclosure. Additionally, elements common between figures may retain the same numerical designation.

(11) Polycrystalline compacts may be formed by subjecting grains of hard material and a catalyst to high-temperature and high-pressure (HTHP) conditions to form intergranular bonds. A portion of the catalyst material may then be removed, and the compacts may be shaped, polished, or otherwise processed after removal of some of the catalyst material.

(12) As used herein, the term drill bit means and includes any type of bit or tool used for drilling during the formation or enlargement of a wellbore and includes, for example, rotary drill bits, percussion bits, core bits, eccentric bits, bi-center bits, reamers, expandable reamers, mills, drag bits, roller cone bits, hybrid bits, and other drilling bits and tools known in the art.

(13) As used herein, the term hard material means and includes any material having a Knoop hardness value of about 3,000 Kg.sub.f/mm.sup.2 (29,420 MPa) or more. Hard materials include, for example, diamond and cubic boron nitride.

(14) As used herein, the term intergranular bond means and includes any direct atomic bond (e.g., covalent, metallic, etc.) between atoms in adjacent grains of material.

(15) The term polycrystalline material means and includes any material comprising a plurality of grains (i.e., crystals) of the material that are bonded directly together by intergranular bonds. The crystal structures of the individual grains of the material may be randomly oriented in space within the polycrystalline material.

(16) As used herein, the term polycrystalline compact means and includes any structure comprising a polycrystalline material formed by a process that involves application of pressure (e.g., compaction) to the precursor material or materials used to form the polycrystalline material.

(17) As used herein, the term grain size means and includes a geometric mean diameter measured from a two-dimensional section through a bulk material. The geometric mean diameter for a group of particles may be determined using techniques known in the art, such as those set forth in Ervin E. Underwood, QUANTITATIVE STEREOLOGY, 103-105 (Addison-Wesley Publishing Company, Inc., 1970), the disclosure of which is incorporated herein in its entirety by this reference.

(18) As used herein, the term catalyst material refers to any material that is capable of substantially catalyzing the formation of intergranular bonds between grains of hard material during an HTHP process but at least partially contributes to the degradation of the intergranular bonds and granular material under elevated temperatures, pressures, and other conditions that may be encountered in a drilling operation for forming a wellbore in a subterranean formation. For example, catalyst materials for diamond include, by way of example only, cobalt, iron, nickel, other elements from Group VIIIA of the Periodic Table of the Elements, and alloys thereof.

(19) As used herein, the term leaching means and includes removing or extracting materials from a solid material (such as a polycrystalline material) into a carrier, such as by dissolving the materials into the carrier or by converting the materials into a salt.

(20) As used herein with regard to a depth or level, or magnitude of a depth of level, beneath a surface of a polycrystalline compact, the terms substantially uniform and substantially uniformly mean and include a depth of an area under the surface which is substantially devoid of significant aberrations such as spikes and/or valleys in excess of a general magnitude of such depth. More specifically, a substantially uniform depth when referring to a depth of catalyst removal beneath a surface of a polycrystalline compact means and includes a depth of such removal substantially free of significant aberrations such as spikes, valleys and other variations in the region below the surface. In other words, if catalyst is removed to a substantially uniform depth below, for example, a cutting face of a polycrystalline compact, the catalyst is removed from an area below the surface of the cutting face to a depth, the boundary of which with a remainder of the compact including such catalyst while not necessarily constant, is substantially free of significant aberrations such as spikes, valleys and/or other variations.

(21) FIG. 1 illustrates materials and devices that may be used in a method of forming a polycrystalline compact. A mixture 102 of a hard material 103, specifically diamond in this embodiment, interspersed with a catalyst 104 is placed into a container 110. The container 110 may be a canister used for HPHT processing to form polycrystalline compacts, and may include one or more generally cup-shaped members, such as an outer cup-shaped member 112, an inner cup-shaped member 114, and a cup-shaped cap member 116, which may be assembled and swaged and/or welded together to form the container 110. The mixture 102 and an optional cutting element substrate 106 may be disposed within the inner cup-shaped member 114, which may have a circular end wall and a generally cylindrical lateral side wall extending perpendicularly from the circular end wall, such that the inner cup-shaped member 114 is generally cylindrical and includes a first closed end and a second, opposite open end.

(22) The hard material 103 may be in the form or crystals of various sizes, such as micron- and/or submicron-sized hard material. The grains of the hard material 103 may form a hard polycrystalline material after sintering. The hard material 103 may include, for example, diamond, cubic boron nitride, etc. The catalyst 104 may include, for example and without limitation, cobalt, iron, nickel, or an alloy or mixture thereof. The catalyst 104 may be formulated to promote the formation of intergranular bonds during sintering.

(23) To form a polycrystalline hard material in an HTHP process, the mixture 102 may be subjected to elevated temperatures (e.g., temperatures greater than about 1,000 C.) and elevated pressures (e.g., pressures greater than about 5.0 gigapascals (GPa)). These conditions may promote the formation of intergranular bonds between the grains of the hard material 103. In some embodiments, the mixture 102 may be subjected to a pressure greater than about 6.0 GPa, greater than about 8.0 GPa, or even greater than about 10.0 GPa. The mixture 102 may be subjected to a temperature in the HTHP process from about 1,200 C. to about 2,000 C., such as a temperature greater than about 1,500 C. HTHP conditions may be maintained for a period of time from about thirty (30) seconds to about sixty (60) minutes to sinter the particles and form a polycrystalline hard material.

(24) In some embodiments, the mixture 102 may include a powder or a powder-like substance. In other embodiments, however, the mixture 102, which may comprise a solution, slurry, gel, or paste, may be processed by (e.g., on or in) another material form, such as a tape or film, which, after stacking to a selected thickness, and undergoing subsequent thermal and or chemical processes to remove the one or more organic processing aids, may be subjected to an HTHP process. One or more organic materials (e.g., processing aids) also may be included with the particulate mixture to facilitate processing. For example, some suitable materials are described in U.S. Patent Application Publication No. US 2012/0211284 A1, published Aug. 23, 2012, and titled Methods of Forming Polycrystalline Compacts, Cutting Elements and Earth-Boring Tools, the disclosure of which is incorporated herein in its entirety by this reference.

(25) FIG. 2 shows a polycrystalline compact 200 having intergranular bonds and interstitial spaces formed between adjacent grains of the hard material 103 during sintering. The polycrystalline compact 200 includes a polycrystalline table 202 and an optional substrate 206. The polycrystalline table 202 may include surfaces 210, 212 corresponding to inner surfaces of the container 110 used to form the polycrystalline compact 200. The polycrystalline table 202 and substrate 206 may be formed from the mixture 102 and the substrate 106, respectively, as shown in FIG. 1.

(26) FIG. 3 illustrates how a portion of the polycrystalline table 202 shown in FIG. 2 may appear under further magnification. The catalyst 104 may be disposed in at least some of the interstitial spaces in the polycrystalline compact 200 formed between grains of hard material 103 during sintering.

(27) After sintering the mixture 102 to form the polycrystalline table 202, at least a portion of the catalyst 104 may be removed from the interstitial spaces in the polycrystalline table 202 to form an at least partially leached polycrystalline compact. FIG. 4 illustrates a portion of the polycrystalline table 202 after removal of catalyst 104. The portion of the polycrystalline table 202 shown in FIG. 4 corresponds to the portion of the polycrystalline table 202 shown in FIG. 3. In some embodiments, some catalyst 104 may remain within the interstitial spaces. The catalyst 104 may be substantially or entirely removed from all or a portion of the polycrystalline table 202.

(28) Removal of the catalyst 104 may be performed by conventional means, such as by placing the polycrystalline compact in an acid bath. Such a process may be referred to in the art as leaching or acid-leaching. By way of example and not limitation, the polycrystalline table 202 may be leached using a leaching agent and processes such as those described more fully in, for example, U.S. Pat. No. 5,127,923, issued Jul. 7, 1992, and titled Composite Abrasive Compact Having High Thermal Stability; and U.S. Pat. No. 4,224,380, issued Sep. 23, 1980, and titled Temperature Resistant Abrasive Compact and Method for Making Same; the disclosure of each of which patent is incorporated herein in its entirety by this reference. Specifically, aqua regia (a mixture of concentrated nitric acid (HNO.sub.3) and concentrated hydrochloric acid (HCl)) may be used to at least substantially remove catalyst material from the interstitial spaces between the inter-bonded grains of hard material in the polycrystalline table 202. It is also known to use boiling hydrochloric acid (HCl) and boiling hydrofluoric acid (HF) as leaching agents. One particularly suitable leaching agent is hydrochloric acid (HCl) at a temperature of above 110 C., which may be provided in contact with the hard material of the polycrystalline table 202 for a period of about two hours to about sixty hours, depending upon the size of the body comprising the hard material. After leaching the hard material, the interstitial spaces between the inter-bonded grains within the hard material may be at least substantially free of catalyst material used to catalyze formation of intergranular bonds between the grains in the hard polycrystalline material. In some embodiments, leaching may be selectively applied to specific regions of the polycrystalline table 202, and not to other regions. For example, in some embodiments, a mask may be applied to a region of the polycrystalline table 202, and only the unmasked regions may be leached.

(29) Other methods of removing catalyst material are described in U.S. Pat. Application Pub. 2011/0258936, published Oct. 27, 2011, and titled Methods of Forming Polycrystalline Compacts, the disclosure of which is incorporated herein in its entirety by this reference.

(30) The catalyst 104 may be substantially removed from a volume of the polycrystalline table 202 to a substantially uniform depth from surfaces 210, 212 (FIG. 2) of the polycrystalline table 202. In such embodiments, an interface may be formed between a volume of the polycrystalline table 202 from which catalyst 104 has been leached and a volume of the polycrystalline table 202 from which catalyst 104 has not been leached. In some embodiments, the catalyst 104 may be substantially removed from within 1.0 mm, within 0.7 mm, within 0.5 mm, within 0.25 mm, within 0.1 mm, or even within 0.01 mm of the surfaces 210, 212.

(31) After the catalyst 104 has been substantially removed from at least a portion of the polycrystalline table 202, a portion of the hard material 103 may be removed from the polycrystalline table 202. For example, a volume of leached hard polycrystalline material may be removed from the polycrystalline table 202 to improve cutting performance of the polycrystalline compact 200. In some embodiments, removal may include polishing or smoothing of one or more surfaces 210, 212 (FIG. 2) of the polycrystalline table 202, such as by methods described in U.S. Pat. No. 6,145,608, issued Nov. 14, 2000, and titled Superhard Cutting Structure Having Reduced Surface Roughness and Bit for Subterranean Drilling so Equipped; U.S. Pat. No. 5,653,300, issued Aug. 5, 1997, and titled Modified Superhard Cutting Elements Having Reduced Surface Roughness Method of Modifying, Drill Bits Equipped with Such Cutting Elements, and Methods of Drilling Therewith; and U.S. Pat. No. 5,447,208, issued Sep. 5, 1995, and titled Superhard Cutting Element Having Reduced Surface Roughness and Method of Modifying; the disclosure of each of which is incorporated herein in its entirety by this reference.

(32) For example, surfaces 210, 212 may be polished to have a surface finish with irregularities or roughness (measured vertically from the surface) less than about 10 in. (about 0.254 m) RMS (root mean square). In further embodiments, the polycrystalline table 202 may have a surface roughness less than about 2 in. (about 0.0508 m) RMS. In yet further embodiments, the polycrystalline table 202 may have a surface roughness less than about 0.5 in. (about 0.0127 m) RMS, approaching a true mirror finish. The foregoing surface roughness measurements of the polycrystalline table 202 may be measured using a calibrated HOMMEL America Model T 4000 diamond stylus profilometer contacting the surface of the polycrystalline table 202.

(33) In some embodiments, portions of the hard material 103 may be removed from the polycrystalline table 202 to form shaped surfaces on the polycrystalline compact 200. For example, the polycrystalline table 202 may be machined or otherwise shaped to form non-planar surfaces, such as described in U.S. Patent Publication 2012/0103698, published May 3, 2012, and titled Cutting Elements, Earth-boring Tools Incorporating Such Cutting Elements, and Methods of Forming Such Cutting elements; U.S. Patent Publication 2013/0068534, published Mar. 21, 2013, and titled Cutting Elements for Earth-boring Tools, Earth-boring Tools Including Such Cutting Elements and Related Methods; U.S. Patent Publication 2013/0068537, published Mar. 21, 2013, and titled Cutting Elements for Earth-boring Tools, Earth-boring Tools Including Such Cutting Elements and Related Methods; U.S. Patent Publication 2013/0068538, published Mar. 21, 2013, and titled Cutting Elements for Earth-boring Tools, Earth-boring Tools Including Such Cutting Elements, and Related Methods; the entire disclosure of each of which are incorporated herein in their entirety by this reference.

(34) In some embodiments, one or more recesses may be formed that extend into a surface of the polycrystalline table 202. For example, FIG. 5 illustrates a perspective view of a polycrystalline compact 300, which may be formed as described above with respect to the polycrystalline compact 200 shown in FIG. 2.

(35) The polycrystalline compact 300 may be formed as illustrated in FIGS. 6 through 8. FIG. 6 illustrates a partially formed polycrystalline compact 301 having a polycrystalline table 302 and a substrate 306. The polycrystalline table 302 may be at least partially leached to substantially remove catalyst material from interstitial spaces between polycrystalline material. That is, substantially all the catalyst may be removed from a leached portion 304 of the polycrystalline table 302, and catalyst may remain in an unleached portion 308 of the polycrystalline table 302.

(36) FIG. 7 illustrates a partially formed polycrystalline compact 303 having recesses 314 (see also FIG. 5) formed in the polycrystalline table 302 after leaching the catalyst from a portion of the polycrystalline table 302. For example, the recesses 314 are formed in a front cutting face 310. Thus, the front cutting face 310 includes one or more non-planar surfaces. The front cutting face 310 may be polished after leaching, as previously described. A chamfer surface 316 (see also FIG. 5) may be formed after leaching, such as by exposing the polycrystalline table 302 to an energy beam (e.g., a beam of electromagnetic radiation, such as a laser), as described in U.S. Patent Publication 2009/0114628, published May 7, 2009, and titled Methods and Apparatuses for Forming Cutting Elements Having a Chamfered Edge for Earth-boring Tools, the disclosure of which is incorporated herein in its entirety by this reference. A chamfer 318 may also be formed on the substrate 306 on an end opposite the polycrystalline table 302.

(37) FIG. 8 illustrates a partially formed polycrystalline compact 305 having a masking material 320 covering a portion of the polycrystalline table 302 and/or the substrate 306. The masking material 320 may be an impermeable material, such as a wax, an epoxy, etc. The partially formed polycrystalline compact 305 may then be leached again to remove additional catalyst material. The masking material 320 may limit or prevent leaching over areas of the partially formed polycrystalline compact 305 covered by the masking material 320. Thus, in the subsequent leaching, removal of the catalyst material may be limited to selected areas, such as those areas over which polycrystalline material has been removed. For example, subsequent leaching may be performed to remove catalyst material from a volume beneath the recesses 314. The masking material 320 may be removed after leaching is complete.

(38) Substantial removal of the catalyst 104 (FIG. 3) from at least a portion of the polycrystalline table 202, 302 before polishing or shaping the polycrystalline table 202, 302 may limit or prevent damage during subsequent processing. For example, polishing or shaping the polycrystalline table 202, 302 may locally heat the material of the polycrystalline table 202, 302 (e.g., individual grains of the hard material 103 (FIG. 3)) to temperatures at which damage may occur. It is well known that high temperatures can cause damage to unleached polycrystalline diamond material, such as due to differences in the coefficients of thermal expansion of the polycrystalline diamond material itself and the catalyst, as well as back-graphitization of the diamond to carbon. By removing at least a portion of the catalyst before polishing or shaping, the localized heating of unleached polycrystalline material can be avoided. Thus, polycrystalline compacts 200, 300 formed from diamond as described herein may exhibit improved service life and/or lower rates of manufacturing defects in comparison with conventional polycrystalline diamond compacts.

(39) FIG. 9 is a simplified cross-section of a polycrystalline compact 400 including a polycrystalline table 402 and a substrate 406. The polycrystalline table 402 includes a leached portion 410 and unleached portion 412. The leached portion 410 may be adjacent exposed surfaces of the polycrystalline table 402. Thus, the exposed surfaces of the polycrystalline table 402 may be processed as described herein (e.g., polished, shaped, etc.). For example, a surface 420 may be polished or a chamfer 422 may be formed. An interface 424 between the leached portion 410 and the unleached portion 412 of the polycrystalline table 402 may be referred to as a leach boundary, and the distance between the interface 424 and the exposed surface may be referred to as the leach depth d. The leach depth d may be, for example, from about 0.01 mm to about 1.0 mm, such as about 0.1 mm to about 0.5 mm. The leach depth d may be at least as large as a depth of material expected to experience a temperature higher than a selected threshold temperature (e.g., 500 C., 700 C., 900 C., etc.) during subsequent processing. After polishing, shaping, or otherwise processing the leached portion 410, the polycrystalline table 402 may be further leached. For example, catalyst material may subsequently be removed from the unleached portion 412 of the polycrystalline table 402.

(40) An earth-boring tool may be formed by securing a polycrystalline cutting element formed as described herein to a bit body. As a non-limiting example, FIG. 10 illustrates a fixed-cutter type earth-boring rotary drill bit 500 that includes a plurality of cutting elements 502, each of which includes a polycrystalline compact comprising polycrystalline hard material 504 on an optional substrate 506. The cutting elements 502 may be any of the polycrystalline compacts 200, 300, 400 previously described herein. The earth-boring rotary drill bit 500 includes a bit body 508, and the cutting elements 502 are bonded to the bit body 508. The cutting elements 502 may be brazed or otherwise secured within pockets formed in the outer surface of the bit body 508.

(41) Additional non-limiting example embodiments of the disclosure are described below.

Embodiment 1

(42) A method of forming a polycrystalline compact, comprising subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The method further comprises substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.

Embodiment 2

(43) The method of Embodiment 1, wherein substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact comprises acid-leaching the catalyst material from the interstitial spaces in the at least a portion of the polycrystalline material.

Embodiment 3

(44) The method of Embodiment 1 or Embodiment 2, wherein substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material comprises forming an interface between a first volume of polycrystalline material and a second volume of polycrystalline material, the first volume of polycrystalline material having a first concentration of the catalyst material and the second volume of polycrystalline material having a second, substantially higher concentration of the catalyst material.

Embodiment 4

(45) The method of Embodiment 3, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises removing a portion of the first volume of polycrystalline material from the at least partially leached polycrystalline compact.

Embodiment 5

(46) The method of any of Embodiments 1 through 4, further comprising substantially removing the catalyst material from the interstitial spaces in an additional portion of the polycrystalline material having substantial catalyst material therein after removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.

Embodiment 6

(47) The method of any of Embodiments 1 through 5, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises polishing at least one surface of the at least partially leached polycrystalline compact.

Embodiment 7

(48) The method of Embodiment 6, wherein polishing at least one surface of the at least partially leached polycrystalline compact comprises polishing at least a portion of the polycrystalline material from which the catalyst material has been substantially removed to form a surface having a surface roughness less than about 10 in. root mean square (RMS).

Embodiment 8

(49) The method of any of Embodiments 1 through 7, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming one or more non-planar areas on a front cutting face on the at least partially leached polycrystalline compact.

Embodiment 9

(50) The method of any of Embodiments 1 through 8, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming a recess extending into the polycrystalline material.

Embodiment 10

(51) The method of any of Embodiments 1 through 9, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises exposing the polycrystalline material to electromagnetic radiation to remove at least a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.

Embodiment 11

(52) The method of Embodiment 10, wherein exposing the polycrystalline material to electromagnetic radiation to remove at least a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises exposing the polycrystalline material to laser irradiation.

Embodiment 12

(53) The method of any of Embodiments 1 through 11, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming a chamfer adjacent a front cutting surface of the at least partially leached polycrystalline compact.

Embodiment 13

(54) The method of any of Embodiments 1 through 12, wherein subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions comprises forming a polycrystalline compact comprising polycrystalline material bonded to a substrate.

Embodiment 14

(55) The method of any of Embodiments 1 through 13, wherein subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions comprises subjecting a plurality of grains of diamond interspersed with the catalyst material to high-temperature and high-pressure conditions to form polycrystalline diamond.

Embodiment 15

(56) A method of forming an earth-boring tool, comprising forming a polycrystalline cutting element and securing the polycrystalline cutting element to a bit body. The polycrystalline cutting element is formed by subjecting a plurality of grains of hard material interspersed with a catalyst material to high-temperature and high-pressure conditions to form a polycrystalline material having intergranular bonds and interstitial spaces between adjacent grains of the hard material. The catalyst material is disposed in at least some of the interstitial spaces in the polycrystalline material. The method further comprises substantially removing the catalyst material from the interstitial spaces in at least a portion of the polycrystalline material to form an at least partially leached polycrystalline compact and removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact.

Embodiment 16

(57) The method of Embodiment 15, further comprising substantially removing an additional portion of the catalyst material from the interstitial spaces in the polycrystalline material having substantial catalyst material therein after removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact and before securing the polycrystalline cutting element to the bit body.

Embodiment 17

(58) The method of Embodiment 15 or Embodiment 16, wherein forming a polycrystalline cutting element comprises forming the polycrystalline material on a substrate.

Embodiment 18

(59) The method of any of Embodiments 15 through 17, wherein removing a portion of the polycrystalline material from which the catalyst material has been substantially removed from the at least partially leached polycrystalline compact comprises forming a front cutting face comprising one or more non-planar surfaces on the at least partially leached polycrystalline compact.

Embodiment 19

(60) A method of forming a polycrystalline diamond compact, comprising subjecting a plurality of diamond grains and a metal catalyst material to high-temperature and high-pressure conditions to form a diamond table having intergranular bonds and interstitial spaces between adjacent diamond grains. The metal catalyst material is disposed in at least some of the interstitial spaces in the diamond table. The method further comprises leaching the catalyst material from the interstitial spaces in a first portion of the diamond table to form a partially leached diamond table; mechanically removing a portion of the diamond grains from the first portion of the partially leached diamond table; and leaching the catalyst material from the interstitial spaces in a second portion of the diamond table.

Embodiment 20

(61) The method of Embodiment 19, wherein mechanically removing a portion of the diamond grains from the first portion of the partially leached diamond table comprises polishing at least one surface of the diamond table.

(62) While the present invention has been described herein with respect to certain illustrated embodiments, those of ordinary skill in the art will recognize and appreciate that it is not so limited. Rather, many additions, deletions, and modifications to the illustrated embodiments may be made without departing from the scope of the invention as hereinafter claimed, including legal equivalents thereof. In addition, features from one embodiment may be combined with features of another embodiment while still being encompassed within the scope of the invention as contemplated by the inventors. Further, embodiments of the disclosure have utility with different and various types and configurations of cutting elements, drill bits, and other tools.