The novel and facile electrolysis method for removing the cobalt binder phase from large diameter polycrystalline diamond compacts

The thermal stability, wear resistance and impact toughness of polycrystalline diamond compact (PDC) are the primary determining variables in determining the performance. The cobalt binder contributes significantly to the PDC's thermal stability and wear resistance. To increase the thermal stability of the PDC, this paper used electrolysis to remove the cobalt binder from the polycrystalline diamond (PCD) layer of the PDC with a diameter of 62 mm. The optimal process parameters for cobalt removal via electrolysis were determined by examining the electrolyte concentration, the electrolytic voltage, and the electrolytic time. The cobalt removal impact was evaluated using a scanning electron microscope (SEM), an energy dispersive spectrometer (EDS), an X-ray diffraction (XRD), and thermogravimetric analysis-differential thermal analysis (TG-DTA). In addition, the abrasion ratio of the PDC samples were tested. The experimental results indicated that the optimal electrolysis parameters for cobalt removal were obtained when the concentration of cobalt sulphate was 4 g/100 mL, the electrolysis voltage was 2.5 V, and the electrolysis time was 10 h; in this case, the cobalt removal rate from the PCD layer exceeded 80%, and the cobalt removal depth was 372 μm. TG-DTA analysis revealed that the thermal stability of PDC was significantly enhanced as a result of the initial graphitization temperature of the cobalt removal sample being increased from 1071 °C to 1113 °C, but the abrasion ratio rose by more than 20%. It was discovered that electrolysis may efficiently remove the cobalt binder phase from the PCD layer, therefore improving the thermal stability and wear resistance of PDC.