Abstract: Bearing assemblies, bearing components and related methods are provided for heavy load applications. In one embodiment, a bearing assembly includes a first bearing apparatus having a base member and a first plurality of polycrystalline diamond compacts (PDCs) on a first surface of the base member, the first plurality of PDCs defining a first collective bearing surface. A second bearing apparatus is configured to engage and slide over the first collective bearing surface. the second bearing apparatus may include a second plurality of PDCs defining a second collective bearing surface. The collective bearing surfaces may be configured to be substantially planar or substantially arcuate. Such bearing assemblies may be implemented in, for example, bridges, roadways, buildings, railways and other structures and machines that may require heavy load bearing support.

Abstract: Embodiments of the invention are directed to bearing assemblies configured to effectively provide heat dissipation for bearing elements, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed about an axis. Each superhard bearing element of the plurality of superhard bearing elements has a superhard table including a superhard surface. The bearing assembly includes a support ring structure coupled to the plurality of superhard bearing elements. One or more of the superhard bearing elements includes a superhard table, which may improve heat transfer from such superhard bearing elements.

Abstract: Rotary drill bits may include on or more cutting element assemblies which include a cutter and a mounting system. In one embodiment, the mounting system includes a housing, a first bearing component disposed within the housing, and a second bearing component associated with the cutting element. In certain embodiments, the bearing components may comprise a table of superhard material bonded with a substrate. In one or more embodiments, the bearing components may include bearing surfaces that are arcuate. For example, the bearing surfaces may be substantially spherical (a portion of a sphere). The bearing components may be arranged to act as a radial bearing as well as a thrust bearing for the cutting element, enabling the cutting element to rotate about a longitudinal axis of the cutter, relative to the housing, while also enabling the longitudinal axis of the cutter to be displaced (change angles) relative to the housing.

Abstract: Methods of screening a polycrystalline diamond element for suitability for electrical discharge machining (“EDM”). The method includes providing a PCD element including a plurality of bonded diamond grains, determining at least one characteristic of the PCD table correlated to electrical conductivity of the PCD element, and EDM the PCD element if the value of the at least one characteristic correlates to an electrical conductivity above a threshold value.

Abstract: Embodiments of the invention are directed to bearing assemblies configured to effectively provide heat dissipation for bearing elements, bearing apparatuses including such bearing assemblies, and methods of operating such bearing assemblies and apparatuses. In an embodiment, a bearing assembly includes a plurality of superhard bearing elements distributed about an axis. Each superhard bearing element of the plurality of superhard bearing elements has a superhard table including a superhard surface. The bearing assembly includes a support ring structure coupled to the plurality of superhard bearing elements. One or more of the superhard bearing elements includes a superhard table, which may improve heat transfer from such superhard bearing elements.

Abstract: A polycrystalline diamond compact useful for wear, cutting, drilling, drawing and like applications is provided with a first diamond region remote from the working surface which has a metallic catalyzing material and a second diamond region adjacent to or including the working surface containing a non-metallic catalyst and the method of making such a compact is provided. This compact is particularly useful in high temperature operations, such as hard rock drilling because of the improved thermal stability at the working surface.

Abstract: A traction control device and the method of making the same wherein the device has contact surfaces, typically formed from polycrystalline diamond compacts inserted into a base, and where the inserts, and in some embodiments the base, are machined or cut to induce profiles for enhanced gripping and improved wear characteristics.

Abstract: A superhard compact having an improved superabrasive-substrate interface region design for use in drilling bits, cutting tools and wire dies and the like. This compact is designed to provide an interface design to manipulate residual stresses to enhance the working the strength of the compact. The compact is provided with a network on interface features that share common walls to form cavities.

Abstract: A new drill insert product and the method of making the same are provided. This invention makes use of a multi-metal region bonded to the top (cutting) surface of a superabrasive layer to improve drill life, decrease the propensity for delamination and to avoid crack initiation sites in the drill insert product. This invention makes use of an inner can top composed essentially of niobium, which, under the compression pressure of an ultra high pressure press, bonds to a molybdenum disk, thereby providing improved tensile strength, abrasion resistance, bonding strength, as well as improved control over the cutting surface flatness. By using the inner can top, this invention improves process efficiency, while reducing manufacturing complexity and waste.

Abstract: A cutting element, insert or compact, is provided for use with drills used in the drilling and boring of subterranean formations or in machining of metal, composites or woodworking. This new insert besides having a superabrasive layer on the surface of a substrate, also may have one or more superabrasive core element sections incorporated in the substrate to provide improved internal residual stress characteristics. By so manipulating residual stresses, this invention provides cutting elements, which are more fracture resistant thereby providing improved work life. Also, by providing additional superabrasive material in the substrate, this invention improves the cutting efficiency of the compact after the compact has undergone significant wear. Another embodiment of this invention employs one or more carbide core regions within a superabrasive region, which covers the majority of the outer surface of the insert.

Abstract: A cutting element insert is provided for use with drills used in the drilling and boring through of subterranean formations. This new insert has a modified diamond surface shape having ridges, facets and/or other discontinuities on the cutting surface topography, formed on or about an otherwise non-planar shape, such as spherical, hemispherical, conical or the like. This modified diamond layer shape provides increased cutting stress at the diamond/rock interface, thereby causing the rock to fail with less over all drilling energy being required, while simultaneously introducing little additional stresses to the cutter or insert.

Abstract: A cutting element, insert or compact, is provided for use with drills used in the drilling and boring of subterranean formations. This new insert, in its preferred embodiment, has a “hoop” region of polycrystalline diamond extending around the periphery of the compact to reduce the residual stresses inherent in thick diamond regions of cutters. This compact has improved wear and durability characteristics because it avoids failures due to stresses, delaminations and fractures caused by the differences in thermal expansion coefficient between the diamond and the substrate during sintering. Moreover, this invention may provide multiple polycrystalline diamond edges as the PDC wears. This exposure of multiple polycrystalline diamond edges slows the rate of wear flat surface development and reduces the weight on the bit required for acceptable drill penetration rates.

Abstract: Polycrystalline diamond cutter (PDC) designs which substantially improve the penetration rate of fixed cutter drill bits while simultaneously reducing the wear on the bit during drilling operations are disclosed. The designs are based upon the observation that: 1) the wear pattern of a PDC is roughly a conic section and is parallel to bit rotation, and 2) the cutting surface is perpendicular to the rotation of the bit. The inventive PDC designs provide cutting action both perpendicular and parallel to the direction of bit rotation.

Abstract: A cutting element is provided for use with drill used in the drilling and boring through subterranean formations. This new cutter has improved wear characteristics while maximizing the manufacturability and cost effectiveness of the cutter. This invention accomplishes these objectives by incorporating a single chamfer of increased size. This chamfer is introduced on the periphery of the abrasive cutting face of the cutter. This chamfer has been found to reduce the tensile stress within the cutter, which tensile stress is primarily responsible for spalling and delamination of the abrasive layer of the cutter.

Abstract: An improved surface finish for non-planar drill inserts or cutting elements is provided for use on inserts used in the drilling and boring of subterranean rock formations. This new surface finish provides an insert with improved wear characteristics, a decrease in heat generation, a decrease in frictional work loss, and a minimization of failure inducting surface cracks. This invention accomplishes these objectives by a process of polishing the cutting or contact surface of the insert to a very high degree of smoothness.

Abstract: A composite body cutting instrument formed of a polycrystalline diamond layer sintered to a carbide substrate with a carbide/diamond transition layer. The transition layer is made by creating carbide projections perpendicular to the plane of the carbide substrate face in a random or nonlinear orientation. The transition layer manipulates residual stress caused by both thermal expansion and compressibility differences between the two materials and thus increases attachment strength between the diamond and carbide substrate by adjusting the pattern, density, height and width of the projections.

Abstract: A compact cutter for drilling or cutting material, such as rock, is formed from a substrate of tungsten carbide, or other hard substance, bonded to a polycrystalline layer which includes an upper, generally planar cutting surface. The corner formed by the cutting surface and the sides of the polycrystalline layer is rounded by honing to remove cracks and other irregularities and to eliminate the need for chamfering the corner.

Abstract: A cutting implement formed from a substrate of carbide, or other hard substance, bonded to a polycrystalline layer which serves as the cutting portion of the implement. The interface between the substrate and polycrystalline layer is defined by surface topography with radially spaced-apart protuberances and depressions forming smooth transitional surfaces.

Abstract: This patent covers the concept of putting a previously sintered carbide tool or part back through the sintering process. This resintering, heals stress related microcracks which, when allowed to progress, could ultimately be a cause of the failure for the object. This produces a longer life, better quality cemented carbide tool to be used for cyclically applying pressure and/or heat.

Abstract: An abrasive compact with a substantially solid body is provided from a mass of abrasive particles which are bonded together on a particle-to-particle basis. A network of interstices is formed within the body by removing the metallic second phase by-product of a solvent catalyst sintering aid. The network of interstices is filled with the carbide by product of a non-catalyst sintering aid forking a solid body. A substrate is bonded to some of the particles and to some of the carbide filling the network of interstices.