Abstract: In an embodiment, a polycrystalline diamond table includes a plurality of bonded diamond grains and a plurality of interstitial regions defined by the plurality of bonded diamond grains. The polycrystalline diamond table may be at least partially leached such that at least a portion of at least one interstitial constituent has been removed from at least a portion of the plurality of interstitial regions by exposure to a leaching agent. The leaching agent may include a mixture having a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4, and water in a concentration of about 50 weight % to about 85 weight %. Various other materials, articles, and methods are also disclosed.

Abstract: Method of processing a polycrystalline diamond element may include laser ablating at least a portion of a polycrystalline diamond element to form a laser-shaped surface and exposing at least a portion of the laser-shaped surface to a leaching solution to define a leached polycrystalline diamond volume and an unleached polycrystalline diamond volume.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”), methods of fabricating PDCs, and applications for such PDCs. In an embodiment, a method includes providing an at least partially leached polycrystalline diamond (“PCD”) body. A residual amount of acid may remain in and/or on the at least partially leached PCD body. The method further includes removing and/or neutralizing at least some of the residual amount of acid from the at least partially leached PCD body and/or a substrate to which the at least partially leached PCD body is attached.

Abstract: A polycrystalline diamond element includes a polycrystalline diamond table having a body of bonded diamond particles with interstitial regions. A first volume of the body includes an interstitial material and a second volume of the body has a lower concentration of interstitial material within the interstitial regions than the first volume. The polycrystalline diamond element includes an element face and a peripheral surface. The first volume is adjacent to a central portion of the element face and the second volume is adjacent to the peripheral surface. A method of processing a polycrystalline diamond element includes forming a concave region in the polycrystalline diamond element, exposing at least a portion of the concave region to a leaching solution, and removing at least a portion of the polycrystalline diamond element that was exposed to the leaching solution from the polycrystalline diamond element.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”), methods of fabricating PDCs, and applications for such PDCs. In an embodiment, a method includes providing an at least partially leached polycrystalline diamond (“PCD”) body. A residual amount of acid may remain in and/or on the at least partially leached PCD body. The method further includes removing and/or neutralizing at least some of the residual amount of acid from the at least partially leached PCD body and/or a substrate to which the at least partially leached PCD body is attached.

Abstract: In an embodiment, a polycrystalline diamond table includes a plurality of bonded diamond grains and a plurality of interstitial regions defined by the plurality of bonded diamond grains. The polycrystalline diamond table may be at least partially leached such that at least a portion of at least one interstitial constituent has been removed from at least a portion of the plurality of interstitial regions by exposure to a leaching agent. The leaching agent may include a mixture having a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4, and water in a concentration of about 50 weight % to about 85 weight %. Various other materials, articles, and methods are also disclosed.

Abstract: In an embodiment, a polycrystalline diamond table includes a plurality of bonded diamond grains and a plurality of interstitial regions defined by the plurality of bonded diamond grains. The polycrystalline diamond table may be at least partially leached such that at least a portion of at least one interstitial constituent has been removed from at least a portion of the plurality of interstitial regions by exposure to a leaching agent. The leaching agent may include a mixture having a ratio of weight % hydrofluoric acid to weight % nitric acid of about 1.0 to about 2.4, and water in a concentration of about 50 weight % to about 85 weight %. Various other materials, articles, and methods are also disclosed.

Abstract: A polycrystalline diamond element includes a polycrystalline diamond table having a body of bonded diamond particles with interstitial regions. A first volume of the body includes an interstitial material and a second volume of the body has a lower concentration of interstitial material within the interstitial regions than the first volume. The polycrystalline diamond element includes an element face and a peripheral surface. The first volume is adjacent to a central portion of the element face and the second volume is adjacent to the peripheral surface. A method of processing a polycrystalline diamond element includes forming a concave region in the polycrystalline diamond element, exposing at least a portion of the concave region to a leaching solution, and removing at least a portion of the polycrystalline diamond material that was exposed to the leaching solution from the polycrystalline diamond element.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”), methods of fabricating PDCs, and applications for such PDCs. In an embodiment, a method includes providing an at least partially leached polycrystalline diamond (“PCD”) body. A residual amount of acid may remain in and/or on the at least partially leached PCD body. The method further includes removing and/or neutralizing at least some of the residual amount of acid from the at least partially leached PCD body and/or a substrate to which the at least partially leached PCD body is attached.

Abstract: In an embodiment, a method of fabricating a leached polycrystalline diamond (“PCD”) body is disclosed. The PCD body includes bonded diamond grains defining interstitial regions at least a portion of which include at least one interstitial constituent disposed therein. The method includes leaching the PCD body with a leaching agent to remove at least a portion of the at least one interstitial constituent therefrom. The leaching agent includes a mixture having hydrofluoric acid in a first concentration of about 10 weight % to about 50 weight %, nitric acid in a second concentration of about 5 weight % to about 25 weight %, and water in a third concentration of about 25 weight % to about 85 weight %. Further embodiments relate to different leaching methods and different leaching agent compositions.

Abstract: Embodiments of the invention relate to methods of modeling leaching behavior of a polycrystalline diamond (“PCD”) material used in leached polycrystalline diamond compacts (“PDCs”) and methods of monitoring leaching of a PCD material. In an embodiment, a method of modeling leaching behavior is disclosed. A PCD table is provided, which includes a plurality of bonded diamond grains defining a plurality of interstitial regions in which a metallic material is disposed. The PCD table is leached with a leaching agent to at least partially remove the metallic material from the PCD table. A leach depth of the PCD table is determined. A concentration of at least one constituent of the leaching agent is also determined. The leach depth is correlated with the concentration of the at least one metal to generate the model of leaching behavior.

Abstract: Embodiments of the invention relate to methods of modeling leaching behavior of a polycrystalline diamond (“PCD”) material used in leached polycrystalline diamond compacts (“PDCs”) and methods of monitoring leaching of a PCD material. In an embodiment, a method of modeling leaching behavior is disclosed. A PCD table is provided, which includes a plurality of bonded diamond grains defining a plurality of interstitial regions in which a metallic material is disposed. The PCD table is leached with a leaching agent to at least partially remove the metallic material from the PCD table. A leach depth of the PCD table is determined. A concentration of at least one constituent of the leaching agent is also determined. The leach depth is correlated with the concentration of the at least one metal to generate the model of leaching behavior.

Abstract: Embodiments of the invention relate to methods of fabricating polycrystalline diamond compacts (“PDCs”) and applications for such PDCs. In an embodiment, a method of fabricating a PDC includes providing a polycrystalline diamond (“PCD”) table in which a catalyst is disposed throughout, leaching the PCD table with a gaseous leaching agent to remove catalyst from the PCD table and bonding the at least partially leached PCD table to a substrate to form a PDC.

Abstract: Embodiments disclosed herein relate to methods for measuring at least one pore characteristic of a polycrystalline diamond (“PCD”) element via porosimetry and, for example, using the measurement to adjust one or more process parameters for fabricating a PCD element and/or for quality control on such a PCD element. In an embodiment, a method for characterizing a PCD element is disclosed. The method includes providing a PCD element that includes a plurality of bonded diamond grains defining a plurality of pores therebetween. The method further includes conducting porosimetry on the PCD element to measure at least one pore characteristic of the plurality of pores of the PCD element. In an embodiment, the method additionally includes adjusting the one or more process parameters for fabricating the PCD element at least partially based on the measured at least one pore characteristic.

Abstract: Embodiments of the invention relate to methods of fabricating polycrystalline diamond compacts (“PDCs”) and applications for such PDCs. In an embodiment, a method of fabricating a PDC includes providing a polycrystalline diamond (“PCD”) table in which a catalyst is disposed throughout, leaching the PCD table with a gaseous leaching agent to remove catalyst from the PCD table and bonding the at least partially leached PCD table to a substrate to form a PDC.