梯度结构对PDC齿综合性能的影响

高俊; 张治财; 侯志强; 王超; 李好; 杨易侃; 杨娇; 方锐; 唐垚; 王海阔

doi:10.11858/gywlxb.20251233

梯度结构对PDC齿综合性能的影响

doi: 10.11858/gywlxb.20251233

浙江大学能源工程学院, 浙江杭州　310027

基金项目: 国家自然科学基金（52073254）

详细信息

作者简介:
高　俊（1996－），男，博士研究生，主要从事超硬材料制备研究. E-mail：12327111@zju.edu.cn

通讯作者:
王海阔（1984－），男，博士，研究员，主要从事超硬材料和纳米块体材料的合成、表征与应用研究. E-mail：haikuo.wang@zju.edu.cn

中图分类号: O521.2; TQ164; TG58; TG74
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出版历程
- 收稿日期: 2025-10-21
- 修回日期: 2025-12-08
- 录用日期: 2026-06-11
- 网络出版日期: 2025-12-11

Role of Gradient Structure in the Integrated Performance of PDC Cutters

College of Energy Engineering, Zhejiang University, Hangzhou 310027, Zhejiang, China

摘要

摘要: 针对深层/超深层油气勘探对高性能聚晶金刚石复合片（polycrystalline diamond compact, PDC）齿的迫切需求，通过正交试验法优化PDC齿的合成配方，在高温高压（8.5 GPa、1 750 ℃）烧结条件下，成功制备出传统均匀混合型PDC齿（H-PDC）以及具有“细晶工作层/粗晶过渡层”的梯度结构型PDC齿（G-PDC）。梯度结构有助于促进钴烧结助剂的均匀分布，抑制钴的聚集，增强层间的界面结合，并产生较高的残余压应力。G-PDC工作层中钴的质量分数为9.16%，经酸浸脱钴后，钴的质量分数降低至2.49%。性能测试表明：G-PDC的耐磨寿命达到920 车磨次数（passes），优于H-PDC（800 passes）；G-PDC的平均冲击能为740.0 J，较H-PDC提升约107%；同时，梯度结构缓解了PDC齿的热失配问题，使热稳定温度提高约30 ℃。实验结果表明，高压烧结与梯度结构设计的协同作用会显著提升PDC齿的耐磨性、冲击韧性及热稳定性。本研究为面向极端工况的下一代超硬复合材料开发提供了可行路径。
- 聚晶金刚石复合片 /
- 梯度结构 /
- 冲击性能 /
- 耐磨性能 /
- 热稳定性 /
- 高压烧结
Abstract: Addressing the urgent demand for high-performance polycrystalline diamond compact (PDC) cutters in deep/ultra-deep oil and gas exploration, this work optimized the PDC synthesis formulation through orthogonal experimental design. Under high pressure conditions (8.5 GPa and 1 750 ℃), we successfully fabricated both conventional homogeneous mixed PDC cutter (H-PDC) and gradient-structured PDC cutter (G-PDC) featuring a “fine-grained work layer/coarse-grained transition layer” structure. Microstructural characterization reveals that the gradient structure facilitates uniform distribution of cobalt binder, suppresses cobalt aggregation, enhances interlayer interfacial bonding, and generates higher residual compressive stress. The cobalt mass fraction in the G-PDC work layer is 9.16%. After acid leaching for cobalt removal, the cobalt mass fraction decreased to 2.49%. Performance evaluations demonstrate that G-PDC achieves a wear resistance lifespan of 920 passes, superior to H-PDC (800 passes). The average impact toughness of G-PDC reaches 740.0 J, representing approximately 107% improvement over H-PDC. Furthermore, the gradient structure alleviates thermal expansion mismatch, increasing the thermal stability temperature by about 30 ℃. This research confirms that combining high pressure synthesis technology with gradient structural design can synergistically enhance the wear resistance, impact toughness, and thermal stability of PDC cutters, providing a viable pathway for developing next-generation superhard composites for extreme conditions.
- polycrystalline diamond compact (PDC) /
- gradient structure /
- impact performance /
- wear resistance /
- thermal stability /
- high pressure sintering

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图 1 (a) PDC齿的制备流程，(b) 高压组装结构示意图，(c) PDC齿的结构示意图

Figure 1. (a) Pocess of preparing PDC cutters; (b) schematic diagram of high-pressure assembly; (c) schematic diagrams of the PDC cutters

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图 2 (a) 车磨花岗岩的参数，(b) PDC齿车磨花岗岩示意图，(c) PDC磨损位置的定量化表征

Figure 2. (a) Parameters for grinding granite; (b) schematic diagram of the PDC cutter grinding the granite; (c) quantitative characterization of PDC cutter wear morphology

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图 3 重力落锤冲击实验示意图

Figure 3. Schematic diagram of the drop hammer impact test

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图 4 原料及PDC齿的XRD谱：(a) 原料，(b) WC基体，(c) 混料，(d) 金刚石层和基体

Figure 4. XRD patterns of the raw materials and PDC cutter: (a) raw materials; (b) WC matrix; (c) mixed powders; (d) PCD layer and the matrix of PDC

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图 5 (a) PDC齿截面的拉曼测试位置，(b) 不同位置的拉曼光谱，(c) 拉曼特征峰的高斯拟合曲线

Figure 5. (a) Raman test positions of PDC cutters section; (b) Raman spectra at different positions; (c) Gaussian fitting curves of the Raman characteristic peak positions

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图 6 PCD层原料的SEM图像及粒径分布：(a) D₁，(b) D₂，(c) D₃，(d) Co，(e) 混料，(f) 混料中颗粒点扫

Figure 6. SEM images and particle size distribution of the raw PCD layer material: (a) D₁; (b) D₂; (c) D₃; (d) Co; (e) mixed materials; (f) element content of the particles in the mixed material

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图 7 PCD 层的SEM图像、元素分布及含量：(a) H-PDC 中的PCD 层，(b) G-PDC的工作层，(c) G-PDC 中的工作层与过渡层的界面位置，(d) G-PDC 中的过渡层

Figure 7. SEM images, element distribution and elemental composition of the PCD layer: (a) PCD layer in H-PDC; (b) working layer of G-PDC; (c) interface between the working layer and the transition layer in G-PDC; (d) transition layer in G-PDC

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图 8 X射线检测的 (a) H-PDC、(b) G-PDC的脱钴深度，(c) H-PDC截面脱钴的金刚石层以及(d) G-PDC截面脱钴的工作层的SEM图像及元素含量

Figure 8. X-ray characterization of Co-depleted depth in (a) H-PDC and (b) G-PDC; SEM images and element composition of (c) the Co-depleted diamond layer in the cross-section of H-PDC, and (d) Co-depleted working layer in the cross-section of G-PDC

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图 9 PDC的VTL耐磨性能检测：(a) H-PDC，(b) G-PDC

Figure 9. VTL wear resistance tests of PDC: (a) H-PDC; (b) G-PDC

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图 10 (a) PDC齿在800 passes的磨损情况以及磨损参数 (b) S、(c) h、(d) a随车磨测试的变化

Figure 10. (a) Wear condition of PDC cutter after 800 passes, and the wear parameters (b) S, (c) h, (d) a change with the number of passes

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图 11 PDC齿冲击断裂位置的SEM谱：(a)～(b) H-PDC，(c)～(d) G-PDC

Figure 11. SEM spectrum of the impact fracture location of PDC cutters: (a)–(b) H-PDC; (c)–(d) G-PDC

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图 12 未脱钴PDC齿的 (a) 热膨胀和 (b) 热膨胀系数随温度的变化，脱钴PDC的 (c) 热膨胀和 (d) 热膨胀系数随温度的变化

Figure 12. Temperature dependence of (a) thermal expansion and (b) coefficient of thermal expansion for the PDC cutter without codepletion; (c) thermal expansion and (d) coefficient of thermal expansion for the cobalt-depleted PDC cutter

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表 1 正交试验因素

Table 1. Factors of orthogonal test

Level	$w_{D_3} $/%	$w_{D_2} $/%	$w_{D_1} $/%	w_Co/%
1	75	20	5	5
2	70	15	15	3
3	65	10	25	0

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表 2 正交试验结果

Table 2. Results of orthogonal test

Test No.	Level of w_Co	Level of $w_{D_3} $	Level of $w_{D_2} $	Level of $w_{D_1} $	N/passes
1	1	1	1	1	55
2	1	2	2	2	80
3	1	3	3	3	96
4	2	1	2	3	230
5	2	2	3	1	40
6	2	3	1	2	60
7	3	1	3	2	20
8	3	2	1	3	18
9	3	3	2	1	30

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表 3 极差分析结果

Table 3. Results of the variance analysis

Factor	K₁	K₂	K₃	R	Optimal scheme
w_Co	77	110	22.667	87.333	3%
$w_{D_3} $	101.667	46	62	55.667	75%
$w_{D_2} $	44.333	113.330	52	69	15%

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表 4 PDC齿的尺寸参数

Table 4. Size of PDC cutter samples

No.	Diameter/mm	Height/mm	Thickness of PCD/mm	Chamfer of PCD
H-PDC	15.88	13.20	2.90	0.45 mm, 45°
G-PDC	15.88	13.21	2.92	0.43 mm, 44°

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表 5 花岗岩参数和VTL实验参数

Table 5. Granite parameters and VTL experimental parameters

Parameters of granite		VTL test
Hardness	Compression strength/MPa	Relief angle/(°)	Rotational speed/(r·min⁻¹)	Feed rate/ (mm·rad⁻¹)	Depth/mm	Condition
110 HSD	182	20	100	1.0	1	Wet

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表 6 测试点的拉曼频移和残余应力

Table 6. Raman shift and residual stress for the test points

Test point	Raman shift/cm⁻¹	Δγ/cm⁻¹	Residual stress/MPa
A	1 332.44	−0.44	−152.8
B	1 332.86	−0.86	−298.6
C	1 333.33	−1.33	−461.8
D	1 332.77	−0.77	−267.4

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表 7 PDC齿的冲击测试数据

Table 7. Impact test data of PDC cutters

Sample	Impact energy/J	$ \overline{E} $/J	σ/J
H-PDC	300, 210, 420, 500	357.5	154.48
G-PDC	700, 750, 850, 660	740.0	82.05

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