INVESTIGATION OF THE CHARACTERISTICS OF THE DIAMOND LAYER AND THE INTERFACE OF TWO-LAYER DIAMOND-CARBIDE PLATES
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-06-20 |
| Journal | IZVESTIYA VYSSHIKH UCHEBNYKH ZAVEDENIY KHIMIYA KHIMICHESKAYA TEKHNOLOGIYA |
| Authors | V.M. Prokhorov, Sergey A. Perfilov, Andrey A. Pozdnyakov, Elizaveta V. Illich-Svitych, Alexander Fedotkin |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Diamond-Carbide Plate Characteristics
Section titled âTechnical Documentation & Analysis: Diamond-Carbide Plate CharacteristicsâThis document analyzes the research on two-layer diamond-carbide plates (ATP/PDC cutters) manufactured via High-Pressure/High-Temperature (HPHT) synthesis, focusing on the diamond layer properties and interface characteristics. This analysis highlights how 6CCVDâs advanced Microwave Plasma Chemical Vapor Deposition (MPCVD) diamond materials offer superior performance and customization capabilities for engineers working in superhard materials and drilling applications.
Executive Summary
Section titled âExecutive Summaryâ- Application Focus: The research investigates Polycrystalline Diamond Compact (PDC) cutters, critical components in modern drill bits, synthesized using HPHT technology (5.0-5.7 GPa, ~1500 °C).
- Key Findings: Significant variation in mechanical properties (Hardness HIT: 44 GPa to 74 GPa; Elastic Modulus E*: 1430 GPa to 1560 GPa) was observed between two batches, linked to differences in structure and metal content (Cobalt infiltration).
- Interface Criticality: Confocal optical profilometry confirmed the interface layer thickness (25-75 ”m) and revealed microdefects (pores), emphasizing the interfaceâs role in overall cutter strength and stability.
- Structural Correlation: A direct relationship was established between the microstructure (grain size, metal content) and the resulting physical and mechanical properties (hardness, elasticity, density).
- 6CCVD Value Proposition: While HPHT relies on metal binders (Co) leading to thermal instability and property variation, 6CCVD specializes in high-purity, binderless MPCVD PCD and SCD, offering superior thermal stability and precise control over material properties for next-generation drilling and high-power applications.
- Customization Advantage: 6CCVD provides custom-sized PCD plates up to 125 mm and offers advanced metalization services, enabling researchers to move beyond standard HPHT dimensions (e.g., 13.44 mm diameter).
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the analysis of the two batches of diamond-carbide plates (ATP/PDC cutters).
| Parameter | Sample 1 Value | Sample 2 Value | Unit | Context |
|---|---|---|---|---|
| Synthesis Pressure | 5.0 | 5.7 | GPa | HPHT process range |
| Synthesis Temperature | ~1500 | ~1500 | °C | HPHT process temperature |
| PDC Diameter (Nominal) | 13.44 (1308 size) | 13.44 (1308 size) | mm | Standard cutter size |
| Diamond Grain Size | 10-15 | 10-15 | ”m | Characteristic particle size |
| Interface Thickness (Optical) | 44-75 | 50-70 | ”m | Measured via Olympus BX-51M |
| Interface Thickness (Profilometry) | 25-49 | 25-49 | ”m | Measured via S Neox Profilometer |
| Hardness (HIT) | 44 ± 20 | 74 ± 36 | GPa | Measured via NanoScan-4D |
| Elastic Modulus (E)* | 1430 ± 850 | 1560 ± 570 | GPa | Measured via NanoScan-4D |
| Density (Ï) | 3.769 | 3.542 | g/cmÂł | Sample 1 higher density suggests higher metal content |
| Longitudinal Wave Speed (VL) | 16.0 | 18.0 | km/s | Measured via laser ultrasound |
| Shear Wave Speed (VT) | 9.6 | 10.5 | km/s | Measured via laser ultrasound |
| Youngâs Modulus (E) | 840 | 970 | GPa | Calculated elastic constant |
| Bulk Modulus (K) | 500 | 630 | GPa | Calculated elastic constant |
Key Methodologies
Section titled âKey MethodologiesâThe research utilized a combination of destructive and non-destructive testing methods to characterize the HPHT-synthesized PDC cutters:
- Synthesis: PDC plates were manufactured using a GY850 multi-punch press with a 135 cm³ working volume high-pressure chamber, operating at 5.0-5.7 GPa and ~1500 °C.
- Sample Preparation: Sintered plates were mechanically processed to required dimensions (ATP cutter), then cut into vertical sections (4 mm thick) using an Arta 423 PRO electro-erosion machine.
- Surface Finishing: Cut sections were polished and ground using a Struers TegraPol-11 system for subsequent optical and profilometric analysis.
- Microstructural Analysis (Optical): An Olympus BX-51M optical microscope was used to determine diamond grain size (10-15 ”m) and measure the interface thickness (44-75 ”m).
- Mechanical Testing (Nanoindentation): Hardness (HIT) and Elastic Modulus (E*) were measured using a âNanoScan-4Dâ nanohardness tester with a Berkovich pyramidal indenter, applying a maximum load of 0.05 N.
- Elastic Constant Determination (Ultrasonic): Elastic constants (E, K, G, Ï) were determined using an ultrasonic laser defectoscope (UDL-2M) via laser excitation of longitudinal (VL) and shear (VT) elastic waves.
- Interface Profilometry: Three-dimensional images of the diamond-carbide interface were obtained using confocal optical profilometry (S Neox) to determine interface thickness (25-49 ”m) and detect defects (pores).
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research highlights the challenges inherent in HPHT PDC manufacturing, specifically the variability in properties and the reliance on metal binders (Cobalt) which compromise thermal stability. 6CCVDâs MPCVD technology provides advanced, high-purity diamond solutions that directly address these limitations for high-performance applications.
Applicable Materials
Section titled âApplicable MaterialsâTo replicate or extend this research, particularly for applications requiring higher thermal stability or specific electronic/optical properties, 6CCVD recommends the following MPCVD materials:
| 6CCVD Material | Description & Advantage over HPHT PDC | Relevant Application Extension |
|---|---|---|
| High-Purity Polycrystalline Diamond (PCD) | Binderless, high-density MPCVD PCD. Eliminates the Cobalt binder found in HPHT PDC, drastically improving thermal stability (up to 1200 °C vs. ~750 °C for Co-PDC). | High-speed drilling, dry machining, high-temperature wear parts. |
| Optical Grade Single Crystal Diamond (SCD) | SCD layers (0.1 ”m to 500 ”m) for ultimate purity and structural perfection (Ra < 1 nm). Ideal for high-power laser windows or quantum applications. | High-precision cutting tools, thermal management, quantum sensing. |
| Boron-Doped Diamond (BDD) | Highly conductive PCD or SCD films. Can be used as a functional layer or as a substrate material for electrochemical applications. | Electrodes, sensors, high-frequency electronics. |
Customization Potential
Section titled âCustomization PotentialâThe paper studied standard 13.44 mm diameter cutters. 6CCVDâs manufacturing capabilities allow researchers and engineers to scale up or customize dimensions far beyond these limitations:
- Large Area PCD: 6CCVD offers Polycrystalline Diamond plates/wafers up to 125 mm in diameter, enabling the production of larger, custom-shaped cutters or wear parts.
- Custom Thickness Control: We provide precise control over diamond layer thickness: SCD and PCD layers from 0.1 ”m up to 500 ”m. Substrates can be provided up to 10 mm thick.
- Advanced Polishing: We guarantee ultra-low roughness, critical for the advanced profilometry techniques used in the paper: Ra < 1 nm (SCD) and Ra < 5 nm (Inch-size PCD).
- Tailored Metalization: The interface analysis in the paper is crucial. 6CCVD offers in-house metalization services (Au, Pt, Pd, Ti, W, Cu) for creating custom, high-strength interfaces or electrical contacts, allowing for precise control over bonding layers, unlike the uncontrolled Co infiltration in HPHT.
Engineering Support
Section titled âEngineering SupportâThe observed variability in hardness (44 GPa to 74 GPa) and density (3.769 g/cmÂł vs. 3.542 g/cmÂł) between the two HPHT batches underscores the need for precise material engineering.
- Material Selection Expertise: 6CCVDâs in-house PhD team specializes in correlating diamond microstructure (grain size, purity, interface chemistry) with resulting mechanical and thermal properties. We can assist clients in selecting the optimal MPCVD recipe (e.g., grain size, deposition rate) for similar PDC Cutter and Superhard Wear Part projects.
- Global Logistics: We ensure reliable delivery of custom diamond materials worldwide, with DDU (Delivered Duty Unpaid) as the default shipping method and DDP (Delivered Duty Paid) available upon request.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
The article presents the results of a study of a number of characteristics of double-layer diamond-carbide plates (ATP) manufactured at the NRC «Kurchatov Institute» - TISNCM. ATP is the cutting element of a drill bit and consists of a layer of Polycrystalline Diamond Compact (PDC) deposited on a substrate of a superhard tungsten carbide alloy with a cobalt bond. The ATPs were manufactured using high-pressure technology (5-5.7 GPa) and high temperatures (~ 1500 °C) using an installation based on a GY850 multi-punch press with a high-pressure chamber with a working volume of 135 cm3. By mechanical processing, the sintered ATP was adjusted to the required dimensions of the drilling tool cutter (ATP cutter). One sample was taken from two batches of ATP cutters manufactured under different technological conditions. Comprehensive studies were carried out on vertical sections of the ATP cutter and the cut diamond layer. For the diamond layer, the size of diamond grains and the presence of diamond layer leaching were determined by optical method. The hardness and modulus of elasticity in various areas of the diamond layer were measured using instrumental indentation on a âNanoScan-4Dâ nanohardness tester with a Berkovich pyramidal indenter. The elastic constants of the diamond layer were determined by ultrasound using laser excitation of elastic waves in the sample. Three-dimensional images of the interface between a diamond layer and a hard alloy substrate have been obtained by confocal optical profilometry. The images allowed us to determine the thickness of the interface and detect defects in the interface. A relationship has been established between the structure and a number of properties of ATP samples. For citation: Prokhorov V.M., Perfilov S.A., Pozdnyakov A.A., Illich-Svitych E.V., Fedotkin A.P. Investigation of the characteristics of the diamond layer and the interface of two-layer diamond-carbide plates. ChemChemTech [Izv. Vyssh. Uchebn. Zaved. Khim. Khim. Tekhnol.]. 2025. V. 68. N 9. P. 28-34. DOI: 10.6060/ivkkt.20256809.7y.