Polycrystalline Abrasive Compacts

Abstract

A method of manufacturing polycrystalline abrasive elements consisting of micron, sub-micron or nano-sized ultrahard abrasives dispersed in micron, sub-micron or nano-sized matrix materials. A plurality of ultrahard abrasive particles having vitreophilic surfaces are coated with a matrix precursor material in a refined colloidal process and then treated to render them suitable for sintering. The matrix precursor material can be converted to an oxide, nitride, carbide, oxynitride, oxycarbide, or carbonitride, or an elemental form thereof. The coated ultrahard abrasive particles are consolidated and sintered at a pressure and temperature at which they are crystallographically or thermodynamically stable.

We claim: 
     
         1 . A polycrystalline ultrahard abrasive material comprising ultrahard abrasive particles in a matrix material, the matrix having an average matrix or binder thickness of less than 0.5 μm and a standard deviation of 0.5 μm or less. 
     
     
         2 . A polycrystalline ultrahard abrasive material according to  claim 1 , wherein the average matrix or binder thickness has a standard deviation in the range between 0.1 μm and 0.5 μm. 
     
     
         3 . A polycrystalline ultrahard abrasive material according to  claim 2 , wherein the average matrix or binder thickness has a standard deviation in the range between 0.1 μm and 0.45 μm. 
     
     
         4 . A polycrystalline ultrahard abrasive material according to  claim 1 , wherein the average matrix or binder thickness is in the range between 0.1 and 0.5 μm. 
     
     
         5 . A polycrystalline ultrahard abrasive material comprising ultrahard abrasive particles in a matrix, the ultrahard abrasive particles having an average grain size of greater than 0.01 μm, and the matrix having an average matrix or binder thickness of more than 0.5 μm and a standard deviation of less than 0.4 μm. 
     
     
         6 . A polycrystalline ultrahard abrasive material according to  claim 5 , wherein the average matrix or binder thickness has a standard deviation of less than 0.35 μm. 
     
     
         7 . A polycrystalline ultrahard abrasive material according to  claim 5 , wherein the ultrahard abrasive particles are selected from the group comprising diamond, cubic boron nitride, silicon carbide, silicon nitride, boron carbide and boron suboxide (B 6 O), or combinations thereof. 
     
     
         8 . A polycrystalline ultrahard abrasive material according to  claim 7 , wherein the ultrahard abrasive particles are diamond or cubic boron nitride, or combinations thereof.