Abstract: The present invention relates to a composite material having non-planar geometries and edge-shaving surfaces comprising a CVD diamond coating applied to a composite substrate made from a ceramic material and a preferably unreacted carbide-forming material of various configurations and for a variety of applications.

Abstract: The present invention relates to a composite material and the method of making same, which comprises a CVD diamond coating applied to a composite substrate of ceramic material and an unreacted carbide-forming material of various configurations and for a variety of applications. One example of the composite material is a composite of SiC and free silicon metal known as Reaction-Bonded Silicon Carbide. Several examples of applications of the invention include: 1) heads or disks for conditioning polishing pads, including pads used in Chemical-Mechanical-Planarization, 2) cutting and dressing tool inserts and tips, 3) heat spreaders for electronic devices, and 4) wear components including mechanical seals and pump seals.

Abstract: Multilayer CVD diamond films are provided, wherein grain boundaries of the diamond layers are interrupted by renucleating and growing diamond on new nucleation sites comprised of metal. These nucleation sites are positioned on the interface between diamond layers. Methods for producing these multilayer CVD diamond films are also provided wherein the diamond growth on a substrate is interrupted by the deposition of metals which provide new nucleation sites. Diamond growth is then reinitiated.

Abstract: Chemical vapor deposition of diamond with <100> orientation and (100) growth facets is performed at an increased growth rate and affords cubic diamond crystals when a gas mixture comprising hydrogen, a hydrocarbon such as methane and specific minor amounts of oxygen and an inert gas, preferably predominantly nitrogen, is employed.

Abstract: Graphite substrate holders for employment in apparatus for chemical vapor deposition of diamond decrease the tendency of the formed diamond sheets to crack or shatter upon separation from the substrates. Said holders and the substrates therein preferably have rounded edges, to suppress crack formation at sharp corners. The holders are preferably coated, at least in part, with a tie-layer and a hydride-forming metal such as niobium. Also, certain maximum distances between the edges of the holder and substrates are preferably maintained in order to prevent contact of diamond with a heated filament employed for thermal activation.

Abstract: The present invention provides a method for forming uniform CVD diamond coatings on a substrate wherein diamond is deposited on a plurality of substrates which are rotated in unison during the coating process to provide for more uniform radial growth. An advantageous substrate is a wire which can be coated with a layer of CVD diamond for making components in water-jet cutting apparatus, wire-drawing dies, or other tubular articles when the wire is separated from the resulting diamond tube. Identical tubes with higher uniformity in wall thickness are among the products which can be obtained. In addition, tubes having a uniform particle size distribution along their wall thickness which supports columnar diamond growth are also provided.

Abstract: Chemical vapor deposition method for producing a diamond film substantially free of thermal stress-induced cracks in which diamond growth occurs on both sides of a thin substrate so that two diamond coatings with identical opposing tensile forces are formed on each side of the substrate at a thickness greater than the thickness of the thin substrate.

Abstract: The present invention is directed to rotary drill bits and blanks which retain polycrystalline diamond or CBN compacts, but which do not suffer from disadvantages attendant by prior drill designs. The inventive rotary drill bit has a slot within the head thereof which slot has brazed therein with a brazing alloy preferably having a liquidus greater than 700.degree. C. an unsupported thermally-stable polycrystalline diamond or CBN compact. The drill bit is made in another aspect of the invention by forming a slot in the head of the rotary drill and then brazing an unsupported thermally-stable polycrystalline diamond or CBN compact therein with a brazing alloy preferably having a liquidus greater than 7000.degree. C. For present purposes, polycrystalline diamond and CBN compacts are termed "thermally stable" by being able to withstand a temperature of 1200.degree. C. in a vacuum without any significant structural degradation of the compact occurring.

Abstract: A chemical vapor deposition method for producing a flat diamond film substantially free of cracks by forming the diamond film on the surface of a substrate having a convex growth surface wherein the radius of curvature is matched with the tensile stress within the diamond coating produced to compensate for distortion when the film is separated from the substrate.

Abstract: Multi-layer coated diamond abrasive particles which exhibit good retention in abrasive tools and are simpler to manufacture are provided, wherein the coating comprises a single homogenous, carbide forming metal primary layer, preferably of chromium, and at least one non-carbide forming secondary layer, preferably of nickel, iron, cobalt, or alloys thereof. The primary layer is preferably applied so as to chemically bond to the surface of the diamond abrasive particles without sintering following deposition by using chemical vapor deposition or packed salt bath deposition.

Abstract: Multi-layer coated diamond abrasive particles having improved wear performance in abrasive tools are provided, wherein the coating comprises a single homogenous, carbide forming metal primary layer, preferably of chromium, and at least one non-carbide forming secondary layer applied by electroless deposition, preferably comprised of nickel/phosphorus or cobalt/phosphorus.

Abstract: Multigrain abrasive compacts and processes for making the same are provided which comprise fine granules of cubic boron nitride or diamond bound by a sintered matrix derived from a coating on the granules. The coating comprises one or more layers of an active coating material which chemically bonds to the underlying surface. These compacts are obtained by coating fine granules of cubic boron nitride or diamond with the active coating material and sintering the coated particles with or without a powdered metal or alloy. The compacts can be obtained utilizing a short sintering step with relatively low pressures and temperatures. In certain embodiments, the use of high pressure, high temperature equipment can be voided. These compacts have improved breakdown characteristics due to the nature of the coated particles incorporated therein. The process provided is well suited for the use of diamond powder obtained from chemical vapor deposition processes.

Abstract: Multigrain abrasive particles and articles made therefrom are provided wherein the particles comprise fine granules of cubic boron nitride or diamond bound by a sintered matrix of one or more layers of active coating material that is chemically bonded to the underlying surface. These particles are obtained by sintering the coated granules under relatively mild conditions in comparison to those necessary to form monocrystalline abrasive particles of a similar size. In certain embodiments, the use of high pressure, high temperature equipment can be avoided. The particles have improved breakdown characteristics which can be controlled through a selection of the coating thickness, the type of coating and the size of the fine granules to be bonded. The process is well suited for the use of diamond powder produced from chemical vapor deposition processes.

Abstract: Disclosed is a mining pick of the type having a shank and head with the head having an integrally bonded cutting tip, the cutting tip having a metallic substrate which is bonded to the head and also bonded to a superabrasive material cutting surface, wherein a thin section of the superabrasive material is bonded to the metallic substrate such that at least one edge of the thin dimension of the superabrasive material is oriented such that the digging action of the mining pick is that of a slicing or cutting action, rather than a crushing or pawing action.

Abstract: An oversize compact blank having a surface and edges that establish it as oversized is provided. A chip breaker pattern is formed on the compact blank surface. Preferred means for forming the chip breaker pattern include use of a laser, a plunge EDM apparatus, or by ultrasonic abrading. Thereafter, the edges of the patterned oversized compact blank are finished to reduce the size of the blank. When pluge EDM apparatus fitted with a patterned plunger is used, the compact blank must be electrically conductive.

Abstract: Abrasive particles and articles made from cubic boron nitride derived from coated hexagonal boron nitride which is substantially free of oxides and volatile contaminants. Polycrystalline CBN is prepared from HBN by removing oxide from the surface of HBN particles to form HBN particles having a substantially oxide-free surface. The HBN particles having a substantially oxide-free surface are coated with an agent which is capable of preventing re-oxidation of the surface of the HBN particles to form coated HBN particles in a substantially oxide-free state. The coated HBN particles in a substantially oxide-free state are then converted to a polycrystalline CBN by direct conversion of HBN to CBN. Coating agents include metals, metal carbides, metal nitrides and metal borides. A preferred coating agent is titanium carbide.

Abstract: Disclosed is a brazed implement comprising a thermally-stable polycrystalline diamond compact, e.g. a compact of self-bonded diamond particles having a network of inter-connected empty pores dispersed throughout the compact, bonded to another of said compact or bonded to a cemented carbide support by a brazing filler metal disposed therebetween. The brazing metal comprises an alloy having a liquidus above about 700.degree. C. and containing an effective amount of chromium. Translational shear strengths exceed about 50 kpsi even upon furnace cycling of the brazed implements and often exceed 90 kpsi. The method for fabricating the brazed implement also is disclosed.

Abstract: Disclosed is a brazed implement comprising a thermally-stable polycrystalline diamond compact, e.g. a compact of self-bonded diamond particles having a network of inter-connected empty pores dispersed throughout the compact, bonded to another of said compact or bonded to a cemented carbide support by a brazing filler metal disposed therebetween. The brazing metal comprises an alloy having a liquidus above about 700.degree. C. and containing an effective amount of chromium. Translational shear strengths exceed about 50 kpsi even upon furnace cycling of the brazed implements and often exceed 90 kpsi. The method for fabricating the brazed implement also is disclosed.