US4944772A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fabrication of supported polycrystalline abrasive compacts
Assignee: General Electric Co
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Filing: 1988-11-30
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Granted: 1990-07-31
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Expires: 2008-11-30
Abstract
Abstract Disclosed is a process for fabricating a supported polycrystalline diamond or CBN bi-layer compact which comprises forming a sintered polycrystalline or CBN compact which preferably is a thermally-stable compact. A cemented carbide support is separately formed. The compact and the support then are mated with a layer of diamond or CBN crystals having the largest dimension of between about 30 and 500 micrometers interposed therebetween. A source of catalyst/sintering aid material is provided in association with the layer of interposed crystals. The entire assembly then is subjected to HP/HT conditions and for a time adequate for converting the diamond or CBN crystals into a polycrystalline diamond or CBN layer and for producing the bi-layer supported compact of the present invention.
Inventors
- 👤 Hyun S. Cho
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 12:00
CPC Classifications
B; B24; B24D; B24D3/00; B24D3/02; B24D3/04; B24D3/06; C; C01; C01B; C01B32/00; C01B32/25; B01; B01J; B01J3/00; B01J3/06; B01J3/062; B22; B22F; B22F7/00; B22F7/06; B23; B23B; B23B27/00; B23B27/14; B23B27/148; B24D3/10; C04; C04B; C04B35/00; C04B35/515; C04B35/58; C04B35/583; C04B35/5831; C04B37/00; C04B37/001; B01J2203/00; B01J2203/06; B01J2203/0605; B01J2203/062; B01J2203/0645; B01J2203/065; B01J2203/0655; B01J2203/066; B01J2203/0675; B01J2203/0685; C04B2235/00; C04B2235/65; C04B2235/656; C04B2235/6567; C04B2235/70; C04B2235/74; C04B2235/78; C04B2235/786; C04B2237/00; C04B2237/30; C04B2237/32; C04B2237/36; C04B2237/361; C04B2237/363; C04B2237/38; C04B2237/385; C04B2237/40; C04B2237/405; C04B2237/408; C04B2237/50; C04B2237/52; C04B2237/525
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
129 words
A process for fabricating a supported polycrystalline diamond or CBN bi-layer compact which comprises: (a) forming a sintered polycrystalline diamond or CBN compact having a surface; (b) separately forming a cemented carbide support having a support surface; (c) mating said compact and said support at their respective surfaces with a layer of diamond or CBN crystals having a largest dimension of between about 30 and 500 micrometers interposed between said surfaces; (d) providing a source of catalyst/sintering aid material in association with said layer of crystals; (e) subjecting said mated compact and support to HP/HT conditions and for a time adequate for converting said diamond or CBN crystals into a polycrystalline diamond or CBN layer and for providing a support polycrystalline bi-layer compact comprising at least two polycrystalline layers.
Claim 2
Dependent Claim
129 words
A process for fabricating a supported polycrystalline diamond or CBN bi-layer compact which comprises: (a) forming a sintered polycrystalline diamond or CBN compact having a surface; (b) separately forming a cemented carbide support having a support surface; (c) mating said compact and said support at their respective surfaces with a layer of diamond or CBN crystals having a largest dimension of between about 30 and 500 micrometers interposed between said surfaces; (d) providing a source of catalyst/sintering aid material in association with said layer of crystals; (e) subjecting said mated compact and support to HP/HT conditions and for a time adequate for converting said diamond or CBN crystals into a polycrystalline diamond or CBN layer and for providing a support polycrystalline bi-layer compact comprising at least two polycrystalline layers.
Claim 3
Dependent Claim
16 words
The process of claim 1 wherein said sintered compact having a surface comprises a thermally-stable compact.
Claim 4
Dependent Claim
34 words
The process of claim 1 wherein said catalyst/sintering aid material is selected from the group consisting of cobalt, nickel, iron, ruthenium, rhodium, palladium, platinum, chromium, manganese, tantalum, osmium, iridium, alloys thereof, and mixtures thereof.
Claim 5
Dependent Claim
15 words
The process of claim 1 wherein said layer interposed between said surfaces comprises diamond crystals.
Claim 6
Dependent Claim
69 words
The process of claim 1 wherein said cemented carbide support is selected from the group consisting of cemented tungsten carbide, titanium carbide, tungsten-molybdenum carbide, and tantalum carbide, wherein the metal bond material for the carbide is selected from the group consisting of cobalt, nickel, iron, and mixtures thereof, an elemental metal which forms a stable nitride or boride, and a metal alloy which forms a stable nitride or boride.
Claim 7
Dependent Claim
28 words
The process of claim 1 wherein said HP/HT conditions comprise a temperature ranging from between about 1000° and 2000° C. and a pressure in excess of 40 kbars.
Claim 8
Dependent Claim
19 words
The process of claim 1 wherein said catalyst/sintering aid material source is in admixture with said layer of crystals.
Claim 9
Dependent Claim
18 words
The process of claim 1 wherein said catalyst/sintering aid material source is placed adjacent said layer of crystals.
Claim 10
Dependent Claim
17 words
The process of claim 1 wherein said compact having a surface comprises a direct converted CBN compact.
Claim 11
Dependent Claim
87 words
The process of claim 1 wherein said compact having a surface is a thermally-stable compact or direct converted CBN compact; said catalyst/sintering aid material is selected from the group consisting of cobalt, nickel, and iron; said cemented carbide support is selected from the group consisting of cemented tungsten carbide, titanium carbide, tungsten-molybdenum carbide, and tantalum carbide, wherein the metal bond comprises cobalt; and said HP/HT conditions comprise a temperature ranging from between about 1000° and 1500° C. and a pressure of between about 40 and 60 kbars.
Claim 12
Dependent Claim
30 words
The process of claim 1 wherein said cemented carbide support comprises an annular cemented carbide support and said sintered polycrystalline diamond or CBN compact having a surface is interposed therewith.
Claim 13
Dependent Claim
25 words
The process of claim 1 wherein said cemented carbide support is cylindrical and said sintered polycrystalline diamond or CBN compact having a surface is cylindrical.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-07-30 | 1994-01-29 | 1994-07-31 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-07-30 | 1998-01-29 | 1998-07-31 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-07-30 | 2002-01-29 | 2002-07-31 | $7700.00 | Window Closed / Lapsed |