Role of Gradient Structure in the Integrated Performance of PDC Cutters

GAO Jun; ZHANG Zhicai; HOU Zhiqiang; WANG Chao; LI Hao; YANG Yikan; YANG Jiao; FANG Rui; TANG Yao; WANG Haikuo

doi:10.11858/gywlxb.20251233

Volume 40 Issue 9

Sep 2026

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Article Contents

Chinese Journal of High Pressure Physics > 2026 > 40(9): 090109.

GAO Jun, ZHANG Zhicai, HOU Zhiqiang, WANG Chao, LI Hao, YANG Yikan, YANG Jiao, FANG Rui, TANG Yao, WANG Haikuo. Role of Gradient Structure in the Integrated Performance of PDC Cutters[J]. Chinese Journal of High Pressure Physics, 2026, 40(9): 090109. doi: 10.11858/gywlxb.20251233

Citation:

GAO Jun, ZHANG Zhicai, HOU Zhiqiang, WANG Chao, LI Hao, YANG Yikan, YANG Jiao, FANG Rui, TANG Yao, WANG Haikuo. Role of Gradient Structure in the Integrated Performance of PDC Cutters[J]. Chinese Journal of High Pressure Physics, 2026, 40(9): 090109. doi: 10.11858/gywlxb.20251233

Citation:

GAO Jun, ZHANG Zhicai, HOU Zhiqiang, WANG Chao, LI Hao, YANG Yikan, YANG Jiao, FANG Rui, TANG Yao, WANG Haikuo. Role of Gradient Structure in the Integrated Performance of PDC Cutters[J]. Chinese Journal of High Pressure Physics, 2026, 40(9): 090109. doi: 10.11858/gywlxb.20251233

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Role of Gradient Structure in the Integrated Performance of PDC Cutters

doi: 10.11858/gywlxb.20251233

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

Received Date: 21 Oct 2025
Rev Recd Date: 08 Dec 2025
Accepted Date: 11 Jun 2026

Available Online: 11 Dec 2025

Issue Publish Date: 05 Sep 2026

Abstract

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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References(32)

References

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