Superstrong Catalyst-free Polycrystalline Diamond Compact Through High Temperature and High Pressure

Diamond is the hardest naturally occurring material, but single-crystal diamond is brittle due to catastrophic cleavage fracture. Polycrystalline diamond compact (PDC) materials, synthesized under high pressure and high temperature , are widely used in oil & gas drilling, mining, and cutting applications because of their exceptional hardness, thermal conductivity, and wear resistance. However, conventional PDCs rely on metallic catalysts such as cobalt, which reduce hardness, introduce thermal instability, and cause microcracking and chipping under severe drilling conditions. These limitations shorten tool life and restrict broader industrial applications.

In our research, we focus on synthesizing an ultra-strong, catalyst-free PDC material using innovative ultra-high pressure and ultra-high temperature technology. The resulting material exhibits unprecedented wear resistance and thermal stability, breaking all existing industry records for PDC cutters. Its hardness exceeds that of conventional PDCs to a large extent. In addition, the optical properties of PCD have also improved.

This breakthrough not only provides a powerful solution for the oil and gas industry, but also opens new frontiers for scientific research and industrial applications requiring extreme hardness and durability. For instance, PCD is an optical material with photothermal properties that will signifcantly improve the output limit and performance of high-power lasers.