Patent ID: 9297211
Filing Date: 2016-03-29
CPC Classification: B22F,B24D,C22C,E21B

Claim Text:
1. A polycrystalline diamond construction comprising: a sintered diamond body comprising a matrix phase of intercrystalline bonded together diamond crystals extending throughout the body and a plurality of interstitial regions disposed among the matrix phase, the diamond body comprising only a catalyst metal material disposed within the interstitial regions, the diamond body comprising a working surface positioned along an outside portion of the body, wherein the content of the catalyst metal material within the diamond body increases in a gradual manner moving away from the working surface; and a metallic substrate attached to the diamond body along an interface disposed therebetween; wherein the diamond body includes a catalyst metal rich zone adjacent the substrate, and the substrate includes a catalyst metal depleted zone adjacent the diamond body, wherein the catalyst metal content at a point in the body positioned at least about 100 microns from the interface and adjacent the catalyst metal rich zone is at least about 3 percent by weight greater than the catalyst metal content at a point in the catalyst metal depleted zone that includes the interface, wherein the catalyst metal content in the diamond body working surface is in the range of from 2 to 8 percent by weight, wherein the metal depleted zone has an axial thickness of greater than about 1.25 mm and the metal content within the metal depleted zone changes less than about 4 percent by weight per millimeter moving axially along the substrate, and wherein the catalyst metal content within the catalyst metal depleted zone increases in a gradual manner moving axially away from the diamond body.