Abstract: A thin layer of carbide containing an ultra-hard component, such as diamond, is applied to a formed compact for a drilling tool. The compact is then subjected to a high-temperature, high-pressure process to bond it to the added layer. This process allows the use of an underlying substrate which has a lower binder content than previously possible. The compact provides superior cutting ability, as even if the diamond-enhanced layer wears through, the carbide can provide enhanced hardness.

Abstract: An apparatus and method for monitoring and reporting downhole bit failure. Sensors are located on a sub assembly (which is removable from the drill bit) and send data to neural net or other adaptive filter. The neural net uses past sensor readings to predict future sensor readings. The value predicted for the sensors is subtracted from the actual value to produce a prediction error. Increases in prediction error are used to indicate bit failure. The results of this are transmitted to the operator by varying the pressure in the drilling mud flow.