高压物理学报

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

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

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

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

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%

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%

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°

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°

Parameters of granite		VTL test
110 HSD	182		20	100	1.0	1	Wet

Parameters of granite		VTL test
110 HSD	182		20	100	1.0	1	Wet

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

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

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

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

梯度结构对PDC齿综合性能的影响

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

高压物理学报 | 高压下的碳材料 2026,40(9): 090109-1-090109-13

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高压物理学报 |高压下的碳材料 2026 , 40 (9) : 090109-1 -090109-13

梯度结构对PDC齿综合性能的影响

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

作者信息

浙江大学能源工程学院, 浙江杭州　310027

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

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

Role of Gradient Structure in the Integrated Performance of PDC Cutters

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

Affiliations

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

出版时间: 2026-09-05 doi: 10.11858/gywlxb.20251233

文章导航

摘要

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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。

关键词

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

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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.

Key words

polycrystalline diamond compact (PDC) / gradient structure / impact performance / wear resistance / thermal stability / high pressure sintering

引用本文

高俊, 张治财, 侯志强, 王超, 李好, 杨易侃, 杨娇, 方锐, 唐垚, 王海阔. 梯度结构对PDC齿综合性能的影响. 高压物理学报, 2026 , 40 (9) : 090109-1 -090109-13 . DOI: 10.11858/gywlxb.20251233

Jun GAO, Zhicai ZHANG, Zhiqiang HOU, Chao WANG, Hao LI, Yikan YANG, Jiao YANG, Rui FANG, Yao TANG, Haikuo WANG. Role of Gradient Structure in the Integrated Performance of PDC Cutters[J]. Chinese Journal of High Pressure Physics, 2026 , 40 (9) : 090109-1 -090109-13 . DOI: 10.11858/gywlxb.20251233

正文

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随着全球碳氢资源需求持续增长及中浅层油气资源储备的快速消耗，矿产资源的勘探活动正不断向深层和超深层领域推进^[1–3]。聚晶金刚石复合片（polycrystalline diamond compact, PDC）凭借其高硬度和优异的破岩效率，已成为中浅层油气钻井作业中的关键工具^[4–7]。传统的PDC齿通常在高压高温（high pressure and high temperature, HPHT）条件下（5.0～7.7 GPa、1 400～1 700 ℃）制备，在含钴硬质合金基体上烧结金刚石微粉，利用熔融钴催化剂渗透至金刚石层，促进金刚石-金刚石（D-D）键合，从而烧结成致密的整体结构^{[5, 8–9]}。

在深层井/超深井钻探过程中，高硬耐磨岩层（如花岗岩、燧石和石英岩）会显著加剧PDC齿的磨损失效^[10]；此外，多种岩层交替出现，使PDC齿承受更严峻的冲击与磨粒磨损的耦合作用^[11–12]。在动态冲击与磨损载荷下，金刚石层与硬质合金基体之间显著的热膨胀系数差异^[13–14]以及钴元素聚集引发的应力集中，容易导致PDC齿出现剥落或断裂现象，降低钻孔效率，缩短使用寿命^{[1, 9, 15]}。因此，为降低深层/超深层钻探成本，提升作业效率，开发兼具高耐磨、高热稳定性和良好冲击韧性的PDC齿尤为重要^[16–17]。

近期研究表明，提高PDC齿的合成压力^{[5, 18]}、设计多层梯度结构^{[2, 4]}以及优化材料设计^[19–22]等措施是突破其性能瓶颈的有效途径。在高于传统PDC齿烧结压力条件下（高于8.0 GPa）合成PDC材料，理论上可促进更广泛、更牢固的D-D键合，抑制金属催化剂的迁移与聚集，从而获得结构更致密、力学性能更优的PDC复合材料。尽管超过8.0 GPa的高压合成技术具有显著潜力，但目前针对在该极端条件下制备全尺寸、具备工业应用价值的PDC（如广泛使用的1613型号）的报道仍较为有限，理论前景与实际规模化生产之间的衔接仍有待进一步探索。

本研究采用正交试验法优化实验设计并确定PDC齿的最佳合成配方，在高温、高压烧结（8.5 GPa、1 750 ℃）条件下，制备具有梯度结构的新型PDC齿材料，并对其性能进行系统检测与评估。通过将梯度结构在工作层中构建合理的双峰金刚石粒径分布，系统研究梯度结构在高压环境下对PDC齿的微观结构、力学性能及热性能的影响，以期实现PDC齿综合性能的显著提升，为开发适用于深层/超深层钻井苛刻环境的下一代超硬复合材料提供理论依据与技术路线。

1 实　验

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1.1 PDC的制备

PDC制备的原料选用D₁（4～6 μm）、D₂（8～12 μm）和D₃（15～22 μm）3种不同粒径的金刚石微粉，纯度均高于99%，由河南联合精密材料股份有限公司提供；钴（Co）粉作为烧结助剂，纯度高于99.9%，购自厦门金鹭特种合金有限公司；基体采用钴的质量分数为13%的WC-Co硬质合金，由株洲精钻硬质合金有限公司生产。首先，利用乙醇对金刚石微粉和钴粉进行超声处理30 min；然后于70 ℃干燥12 h，在球磨机中以400 r/min的速率球磨5 h。将混合粉末置于真空环境中，先从室温升温至200 ℃保温3 h，再升温至450 ℃进行H₂还原处理2 h。随后，将混合粉末装入金属杯并与硬质合金基体组装，置于六面顶压机装置（GY650）中进行高压烧结；升压速率为100 MPa/s，升温速率与降温速率均为25 ℃/s，保温5 min，腔体温度降至常温后保压2 min。接着进行降压处理，首先以100 MPa/s的降压速率降压至5.5 GPa，保压60 s；然后以50 MPa/s的速率降压至常压。实验制备过程与组装结构分别如图1(a)和图1(b)所示。本研究重点考察不同金刚石微粉及钴粉质量分数在高温、高压烧结（8.5 GPa，1750 ℃）条件下对PDC性能的影响。采用L9(3⁴)正交试验设计，以金刚石微粉粒径（D₁、D₂和D₃）和Co为影响因素，其质量分数各设3个水平，其中粒径为D₁的金刚石微粉的质量分数

$w_{D_1} $

由粒径为D₂和D₃的金刚石微粉

$w_{D_2} $

、

$w_{D_3} $

共同决定，并满足

$w_{D_1}+w_{D_2}+w_{D_3} $

=100%，具体因素水平如表1所示。以PDC在立式车床（vertical turning lathe, VTL）实验中磨损失效时的车磨次数N（pass）作为评价指标，具体试验结果如表2和表3所示，其中，R和K_i（i=1, 2, 3）为极差分析法的核心统计量，R代表极值，K_i代表第i水平下的总和。

依据上述正交试验所得最优配方，制备了2种结构的PDC齿样品：一种为均匀混合型PDC齿（H-PDC），金刚石层中，粒径为D₁、D₂和D₃的金刚石微粉的质量分数分别为10%、15% 和75%，Co的质量为金刚石微粉总质量的3%；另一种为具有梯度结构的PDC齿（G-PDC），其表面工作层由粒径为D₂（质量分数为80%）和D₁（质量分数为20%）的金刚石微粉构成，过渡层组成则与H-PDC的聚晶金刚石层（PCD layer）保持一致（见图1(c)），梯度结构设计参照文献[2]。所有样品均经研磨和抛光处理，最终制成尺寸为

$\varnothing $

16 mm×13 mm（1613型）的PDC齿材料，具体参数如表4所示。实验极差分析表明，各因素影响主次顺序由大到小依次为w_Co、

$w_{D_2} $

、

$w_{D_1} $

，据此确定最优配方为：钴粉质量占金刚石微粉总质量的3%，粒径为D₃、D₂和D₁的金刚石微粉的质量分数分别为75%、15%和10%。

1.2 材料表征

采用型号为Bruker D8 Advance的X射线衍射仪（X-ray diffractometer, XRD）对原料及PDC齿进行物相分析，扫描范围为30°～100°。利用ZEISS Gemini 300型扫描电子显微镜（scanning electron microscope, SEM）观察其微观形貌，并结合能谱仪（energy dispersive spectrometer, EDS）表征元素分布及含量。利用拉曼光谱仪（Horiba LabRAM HR Evolution）在1 000～1 600 cm⁻¹范围内对PDC齿的截面位置进行扫描，以评估其残余应力。采用热膨胀仪（PCY-G，湘潭湘仪）在空气气氛下测试样品的热稳定性，测试温度范围为30～1 000 ℃，升温速率为10 ℃/min。

1.3 VTL检测

采用立式车床（VTL，SVT125，齐重数控装备）对PDC齿样品的耐磨性能进行评估。PDC刀具对花岗岩工件由外径至内径进行径向磨削，单次磨削行程（1 pass）长度约为283 m。通过测量磨损区域的面积（S）、长度（a）及高度（h）对磨损程度进行量化表征，具体实验测试与相关工艺参数如图2和表5所示。

1.4 冲击实验

采用重力落锤冲击试验机（LCS150，郑州豪泰机械）对PDC齿样品进行冲击韧性测试，图3为实验装置结构示意图。样品固定于专用夹具中，与合金钢冲击垫块（洛氏硬度为HRC61～HRC63）呈15°夹角。初始冲击能量设定为30 J，若样品可连续承受10次冲击而未发生失效，则冲击能量以10 J为梯度逐级增加，并重复上述过程，直至样品发生冲击失效。记录导致样品破裂的冲击能量及相应的冲击次数。

2 结果与讨论

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2.1 相组成分析

图4给出了原料及PDC齿样品的XRD谱，金刚石微粉与钴粉均为高纯相，与标准PDF卡片吻合。在混合粉末的XRD谱中可识别出金刚石、钴以及碳化钨（WC）的衍射峰，其中WC来源于球磨过程中硬质合金磨球的磨损；钴的衍射强度显著低于WC与金刚石，其特征峰会被强衍射峰掩盖。经高温高压烧结的PDC齿样品，其PCD层的衍射峰出现明显右移，该现象归因于金刚石层与硬质合金基体之间热膨胀系数的显著差异：在PDC齿冷却过程中，基体的收缩程度大于金刚石层，使其受到均匀的压缩应变，导致金刚石晶面间距减小，最终在PCD层中呈现残余压应力。

进一步对PDC不同位置处的残余应力进行拉曼测试，残余应力（σ_h）^[9]表示为

(1)

$ {\sigma }_{\text{h}}=1\;000({\gamma }_{0}-\gamma )/2.88 $

式中：γ₀为金刚石无应力下的拉曼位移（1 332 cm⁻¹）；γ为测量的拉曼位移，cm⁻¹。式(1)中，σ_h<0表示压应力，σ_h>0表示拉应力。图5和表6的实验结果表明，PDC截面位置的拉曼光谱显示出蓝移现象，进一步证实金刚石层中存在残余压应力。值得注意的是，G-PDC工作层的压应力更大，而过渡层的压应力小于H-PDC的同一位置。这种残余应力状态主要源于金刚石、碳化钨基底（WC-Co）与烧结助剂之间的热失配；均匀分布且较高的Co含量进一步增强了G-PDC工作层的压应力。此外，烧结过程中细晶粒与粗晶粒金刚石颗粒之间的体积收缩差异也对残余应力状态产生影响，粗晶粒之间的相互约束能力较弱，有更多的空间可以通过晶界的微量滑移或调整来释放部分应力，因而过渡层的残余压应力比工作层的残余压应力小，PCD层整体呈现压缩应力，有利于提高PDC的抗冲击性能^[19]。

2.2 微观形貌分析

图6展示了PDC齿的PCD层原料的微观形貌、粒度分布及元素组成。可见，金刚石粉末表面洁净、晶形完整、棱角清晰，边缘缺陷较少，颗粒尺寸分布窄，平均粒径与标称范围一致，晶粒尺寸较均匀。亚微米级钴粉（尺寸约为580 nm）因比表面积大且具有磁性，呈现团聚倾向，团聚体的尺寸约为4 μm，需球磨处理等工艺来改善其在混合粉末中的分散状态。EDS检测（图6(f)）显示，混合粉末位置2的W元素含量较高，与2.1节XRD中检测出WC物相的结果相互印证，证实了硬质合金磨球因磨损产生WC颗粒，并分散附着于金刚石表面。

对H-PDC和G-PDC截面位置的微观形貌、粒径分布及元素分布进行表征，结果如图7所示。2种PDC的金刚石颗粒均烧结致密，未观察到明显的裂纹或孔隙。H-PDC与G-PDC在组织结构和晶粒尺寸分布方面存在明显差异，G-PDC在工作层与过渡层之间呈现出清晰的界面，与初始材料设计的梯度组成一致。高压烧结工艺有效抑制了金刚石晶粒的异常长大；同时，高压作用使部分颗粒发生破碎，进一步细化了晶粒。为探究梯度结构在高温高压环境下对元素迁移行为的影响，对样品不同区域的元素分布及含量进行检测。黑色区域代表金刚石，亮白色的晶界区域则对应Co和WC，钴烧结助剂在高温高压驱动下发生熔化和迁移，优先富集于晶界区域，填充金刚石颗粒间的孔隙，提升PCD层的致密度，催化金刚石与金刚石之间形成强D-D键。值得注意的是，若晶界处的钴含量过高，易形成局部钴池，成为潜在失效源，降低PDC的使用寿命。较小的金刚石颗粒往往更易溶解于液态钴，然后重新沉淀D-D键合的金刚石^[23]。G-PDC工作层在材料设计中并没有额外添加钴，但经高温高压烧结，钴含量高于其过渡层，也显著高于H-PDC中对应区域的钴含量。这归因于其G-PDC的工作层采用更细的金刚石颗粒，有助于提高烧结致密度，高比面积造成晶界数量众多，毛细作用增强，钴含量随之增多，形成众多狭窄的钴迁移通道；同时，高比表面积的细晶结构增强钴的均匀分布能力，使得钴元素在更广泛的晶界区域内分散，从而在宏观上表现为整体钴含量较高；但在微观尺度上，单个晶粒界面的钴浓度相对较低。

2.3 脱钴检测

为模拟PDC材料在实际钻井极端工况下的服役行为，在性能测试前，需要对样品进行脱钴处理^[24–25]，PDC的脱钴深度均大于1 mm。PDC脱钴后的截面形貌如图8所示。

从实验结果可清晰识别出3个区域：浅色部分为PCD脱钴层，黑色区域为硬质合金基体，介于两者之间的区域为未脱钴的PCD层。进一步对脱钴区域进行微观结构表征，G-PDC脱钴层中的钴含量相对较高，检测结果与2.2节未进行脱Co的位置一致（图7）；钴在晶界处均匀分布，单个金刚石晶粒周围的钴含量较H-PDC的钴含量更少。从工作层到过渡层再到基体，构成了钴浓度梯度。

2.4 耐磨性能检测

为评估复合片在极端工况下的耐磨性能，对脱钴后的PDC进行了车磨花岗岩实验，以模拟其在超深井坚硬地层中的磨削环境。通过测量磨损参数（S、a、h）表征其耐磨性能。PDC样品的磨损参数均随车磨次数增加而逐渐上升，如图9和图10所示。

H-PDC的耐磨寿命为800 passes，显著优于正交试验中其他配方样品；G-PDC在整个测试过程中未出现磨损失效迹象，仅表现为磨损参数的均匀增长，其寿命高达920 passes。以H-PDC为例，其磨损过程可分为4个阶段：初始磨损阶段（小于320 passes），因初始接触面积有限，磨损率较高；稳定磨损阶段（400～480 passes）：磨损参数均匀上升，磨损速率最低；快速磨损阶段（480～780 passes），磨损高度h超过脱钴深度，致使材料耐磨性显著降低，同时H-PDC中钴的局部聚集加剧了磨损行为；失效阶段（大于等于800 passes），钴富集区域出现大颗粒金刚石脱落^[26]，导致局部剥落，参数h急剧上升。值得注意的是，在800 passes时，G-PDC的磨损参数S、h和a分别较H-PDC降低23.81%、28.39%和1.50%。G-PDC的磨损过程以初始磨损区和稳定磨损区为主，表现出更小的磨损参数与更长的耐磨寿命。G-PDC耐磨性能的显著提升得益于其双层梯度结构设计：工作层细晶粒的金刚石具有高比表面积，在高温高压烧结过程中促进颗粒塑性流动与重排，形成高度致密的烧结体，具备优异的表面完整性与耐磨性；同时，该结构中钴分布更均匀，有效避免钴池形成，提升了整体硬度与强度，从而赋予其卓越的耐磨性能^[27]。

2.5 冲击性能检测

采用重力落锤冲击试验评估PDC齿的冲击韧性，以模拟钻探过程中遭遇地层突变或钻井液冲击等引起的瞬时高能载荷作用，进而量化其抗断裂及抗裂纹扩展能力。结果显示，G-PDC的平均冲击能量（

$ \overline{E} $

）为740.0 J，较H-PDC提升约107%；其冲击能量标准差（σ）为82.05 J，较H-PDC降低约46.87%（表7）。以上数据表明，G-PDC不仅具备优异的冲击韧性，同时具有更高的冲击稳定性，实现了PDC的冲击韧性与耐磨性的同步提升。

为深入探究PDC齿冲击性能的差异机制，对冲击实验后的样品断裂面进行了微观结构表征，结果如图11所示。H-PDC与G-PDC在断裂形貌上表现出较大区别。H-PDC的SEM图像显示，其断面不规则，存在因金刚石颗粒剥落形成的凹凸区域，晶界处可见明显的D-D键合及亮白色Co-W氧化物，并伴有脱钴处理留下的孔隙。此外，部分晶界区域出现钴元素聚集现象。G-PDC的断裂面则同时呈现穿晶断裂（transgranular fracture, TF）与沿晶断裂（intergranular fracture, IF）特征。由于其过渡层中的粗晶金刚石比例较高，扩展中的微裂纹在遇到大尺寸晶粒时会发生偏转，沿晶界分支或绕行至能量较低的路径。这一过程使裂纹扩展路径由直线转变为曲折形态，从而显著增加断裂能消耗，缓解裂纹尖端的应力集中，降低发生灾难性脆性断裂的风险。此类混合断裂模式有效提高了材料的裂纹扩展能量阈值，进而增强整体冲击抗力^{[9, 28]}。

G-PDC抗冲击性能的提升源于多因素的协同作用，该冲击试验主要受径向残余应力的影响，而径向残余应力主要来源于界面处的热残余应力，集中在界面的径向位置，而中心受到的影响较小^{[23, 29]}，且PCD层中的残余压应力有利于延迟裂纹的形成，抑制冲击载荷的破坏行为，从而提高冲击韧性^[30]；粒径和钴含量梯度结构设计有助于提升PDC齿的冲击韧性。过渡层中的钴含量较高（见图7），但钴分布均匀，未出现明显聚集，有利于构建良好的钴过渡梯度，提升硬质合金与金刚石层的界面强度^[31]。因此，所设计的梯度结构有效增强了层间界面的结合强度，对PDC材料的冲击韧性与稳定性的整体提升具有重要的促进作用。

2.6 热稳定性测试

为模拟井下钻探过程中因切削岩石产生的局部高温环境，对PDC齿样品进行了热膨胀分析以评估其热稳定性。图12展示了热膨胀（ΔL）和热膨胀系数（α）随温度（T）的变化规律。

本研究依据热膨胀曲线（ΔL-T和α-T）切线交点所对应的温度作为热稳定性的关键评价指标^[32]，并取2组样品的平均值作为最终结果。在该临界温度以下，热膨胀系数与热膨胀均呈现缓慢而均匀的上升趋势；一旦超过该温度，则出现急剧加速增长。这一突变主要源于碳化钨、金刚石与钴三者具有不同的热膨胀系数，所产生的热应力诱发微裂纹，最终导致金刚石层的剥落或断裂。对于未脱钴的PCD层，G-PDC的热稳定温度较H-PDC提高约30 ℃。经脱钴处理后，2种PDC的热稳定温度均提升约55 ℃，且G-PDC仍比H-PDC高出近15 ℃。在临界温度点，G-PDC的热膨胀为219.5 μm，较H-PDC降低10.59%，其热膨胀系数也相应下降8.07%。这些结果充分表明，双层梯度结构设计有助于提高复合片的热失效阈值。EDS结果（图7和图8）进一步表明：工作层晶界处实现更均匀的钴分布，梯度结构有效降低了过渡层中的钴含量，构建钴梯度浓度，从而改善了金刚石层和硬质合金界面的热失配问题。实验结果表明，钴含量的合理控制有助于降低PDC热膨胀率，进而提升热稳定性。

3 结　论

收起

通过正交试验对PDC齿配方进行了设计与优化，在1750 ℃和8.5 GPa的高温高压条件下，成功制备了具有“细晶工作层/粗晶过渡层”梯度结构的PDC齿（G-PDC），系统评价了其微观结构、耐磨性、冲击韧性及热稳定性，并与均匀结构的PDC齿（H-PDC）进行对比，得到以下主要结论。

(1) 高压烧结结合梯度结构设计有效细化了金刚石晶粒，促进了钴黏结剂的均匀分布，抑制了钴池形成，增强了D-D键合及层间界面结合，并在PCD层中引入了更高的残余压应力。

(2) G-PDC展现出优异的综合力学性能：其耐磨寿命达920 passes，较H-PDC（800 passes）显著提升；平均冲击韧性为740 J，比H-PDC提高约107%，且其冲击能的标准差降低46.87%，具备更优的冲击稳定性。

(3) 梯度结构有效缓解了因热失配引发的内应力集中，使G-PDC在脱钴前后的热稳定温度均高于H-PDC，热稳定温度保持约30 ℃的优势，同时热膨胀与热膨胀系数分别降低了10.59%与8.07%。

本研究证实，在高温高压烧结环境下选择“梯度结构”设计可突破传统PDC齿的性能瓶颈，实现耐磨性、冲击韧性及热稳定性的同步提升，为适用于深层/超深层钻探的下一代超硬复合材料开发提供了新的设计思路与实验依据。

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2026年第40卷第9期

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文章信息

doi: 10.11858/gywlxb.20251233

接收时间：2025-10-21
首发时间：2026-11-05
出版时间：2026-09-05

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收稿日期：2025-10-21
修回日期：2025-12-08
录用日期：2026-06-11

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作者信息

浙江大学能源工程学院, 浙江杭州　310027

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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

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2种不同金属材料的力学参数

科 Family	属数 Number of genus	种数 Number of species	占总种数比例 Percentage of total species (%)	属 Genus	种数 Number of species	占总种数比例 Percentage of total species (%)
鹅膏菌科Amanitaceae	2	11	5.26	鹅膏菌属 Amanita	10	4.78
小菇科 Mycenaceae	2	12	5.74	丝盖伞属 Inocybe	5	2.39
多孔菌科 Polyporaceae	8	14	6.70	蜡蘑属 Laccaria	5	2.39
红菇科 Russulaceae	3	23	11.00	小皮伞属 Marasmius	6	2.87
				小菇属 Mycena	11	5.26
				光柄菇属 Pluteus	5	2.39
				红菇属 Russula	17	8.13
				栓菌属 Trametes	5	2.39

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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

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

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

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

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

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

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

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

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

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