Abstract: A tool for removing material includes a body, an ultrahard insert, and a matrix. The body has a forward portion, an opposing rear portion, and a longitudinal axis therebetween. The ultrahard insert includes an ultrahard material, and the ultrahard insert is mounted to and contacts the body proximate the forward portion. The matrix contacts the body and the ultrahard insert. The matrix is mechanically interlocked with the body and at least a portion of the matrix is positioned circumferentially around at least a portion of the forward portion of the body.

Abstract: Cutting elements include a carbonate diamond-bonded body that is sintered under HPHT conditions in the presence of a carbonate material, where the body includes a matrix phase of intercrystalline bonded diamond with interstitial regions including the carbonate material, where the diamond-bonded body is sintered without a substrate. A matrix casting is formed and mechanically coupled to the body after the body is sintered, and a portion of the body surface is exposed along a surface of the matrix casting. The exposed body surface is thereafter intentionally treated to induce a compressive residual surface stress that is greater than a remaining portion of the body. The compressive residual surface stress is less than about 500 MPa, and from about 100 to 500 MPa, and a remaining region the body may have a residual stress of less than about 300 MPa, and less than about 100 MPa.

Abstract: A cutting element includes a substrate that is axially symmetric about a central axis. The substrate has a radius perpendicular to the central axis and that extends from the central axis to an outer surface of the substrate. A super-hard material is coupled to the substrate, and the central axis passes through the super-hard material. The super-hard material has an external surface defining at least one ridge protruding from a remainder of the external surface. A central point on the central axis is offset from the external surface of the super-hard material by a distance equal to the radius of the substrate. A distance measured from the external surface of the super-hard material to the central point is greatest at a position between 25° and 45° from the central axis of the substrate.

Abstract: A method of forming a polycrystalline diamond body includes mixing a sintering agent with diamond powder to form a premixed layer, the sintering agent including at least one alkaline earth metal carbonate; forming an infiltration layer adjacent to the premixed layer, the infiltration layer including an infiltrant material including at least one alkaline earth metal carbonate; and subjecting the premixed layer and the infiltration layer to high pressure high temperature conditions.

Abstract: Luminescent diamond is made by subjecting a volume of diamond grains to high-pressure/high-temperature conditions with or without a catalyst or pressure transfer media to cause the grains to undergo plastic deformation to produce nitrogen vacancy defects, increasing the luminescent activity/intensity of the resulting diamond material. The consolidated diamond material may be further treated to further increase luminescent activity/intensity including reducing the consolidated diamond material to diamond particles, heat treatment in vacuum, and/or air heat treatment. The resulting luminescent diamond particles display a level of luminescence intensity greater than that of conventional luminescent nanodiamond, and may be functionalized for use in biological applications.

Abstract: A drilling tool having a body, at least one blade extending from the body, and a first cutting element attached to the at least one blade. The first cutting element includes a cutting face at an opposite axial end from a base, a side surface extending from the base to the cutting face, an edge formed at the intersection between the cutting face and the side surface, and an elongated protrusion formed at the cutting face and extending between opposite sides of the edge. The elongated protrusion has a geometry including a border extending around a concave surface, a face chamfer formed around the border, and sloped surfaces extending between the border and the edge. An edge chamfer is between the face chamfer and the edge.

Abstract: A cutting element has a cutting face at an opposite axial end from a base, a side surface extending from the base to the cutting face, an edge formed at the intersection between the cutting face and the side surface, and an elongated protrusion formed at the cutting face and extending between opposite sides of the edge, wherein the elongated protrusion has a geometry including a border extending around a concave surface and sloped surfaces extending between the border and the edge, and wherein the concave surface has a major axis dimension measured between opposite sides of the border and a minor axis dimension measured perpendicularly to the major axis dimension and ranging from 50 percent to 99 percent of the major axis dimension.

Abstract: A cutting device for use in a drill bit has a body including an ultrahard material. The body has a top surface, a front surface, and at least one lateral surface adjacent the top surface. The lateral surface is oriented at a surface angle relative to the top surface between 30 and 150 degrees. One or more locking features are located on the lateral surface.

Abstract: A cutting element may include a body, a concave cutting face formed at a first end of the body, the cutting face including one or more cutting ridges adjacent a cutting tip that are raised above the concavity of the cutting face and having a length that is at least about 10% of a diameter of the cutting face. An edge is formed around a perimeter of the cutting face, and the edge has an edge angle defined between a tangent of the cutting face and a cylindrical side surface of the body, the edge angle being acute at the cutting tip and varying around the perimeter of the cutting face.

Abstract: A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high-temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material.

Abstract: Luminescent diamond is made by subjecting a volume of diamond grains to high-pressure/high-temperature conditions with or without a catalyst to cause the grains to undergo plastic deformation to produce nitrogen vacancy defects in the diamond grains, increasing the luminescent activity/intensity of the resulting diamond material. The consolidated diamond material may be further treated to further increase luminescent activity/intensity, which treatment may comprise reducing the consolidated diamond material to diamond particles, heat treatment in vacuum, and air heat treatment, which reducing process further increases luminescent activity/intensity. The resulting luminescent diamond particles display a level of luminescence intensity greater than that of conventional luminescent nanodiamond, and may be functionalized for use in biological applications.

Abstract: A tool for removing material includes a body, an ultrahard insert, and a matrix. The body has a forward portion, an opposing rear portion, and a longitudinal axis therebetween. The ultrahard insert includes an ultrahard material, and the ultrahard insert is mounted to and contacts the body proximate the forward portion. The matrix contacts the body and the ultrahard insert. The matrix is mechanically interlocked with the body and at least a portion of the matrix is positioned circumferentially around at least a portion of the forward portion of the body.

Abstract: A cutting element has an intercrystalline-bonded diamond body that includes an inner region and an outer surface that includes a working surface of the cutting element. The outer surface is treated, after formation of the intercrystalline-bonded diamond by high-pressure/high-temperature process, to have a level of surface compressive stress that is greater than a compressive stress of the inner region.

Abstract: A cutting element has a cutting face at an opposite axial end from a base, a side surface extending from the base to the cutting face, an edge formed at the intersection between the cutting face and the side surface, and an elongated protrusion formed at the cutting face and extending between opposite sides of the edge, wherein the elongated protrusion has a geometry including a border extending around a concave surface and sloped surfaces extending between the border and the edge, and wherein the concave surface has a major axis dimension measured between opposite sides of the border and a minor axis dimension measured perpendicularly to the major axis dimension and ranging from 50 percent to 99 percent of the major axis dimension.

Abstract: Cutting elements include a carbonate diamond-bonded body that is sintered under HPHT conditions in the presence of a carbonate material, where the body includes a matrix phase of intercrystalline bonded diamond with interstitial regions including the carbonate material, where the diamond-bonded body is sintered without a substrate. A matrix casting is formed and mechanically coupled to the body after the body is sintered, and a portion of the body surface is exposed along a surface of the matrix casting. The exposed body surface is thereafter intentionally treated to induce a compressive residual surface stress that is greater than a remaining portion of the body. The compressive residual surface stress is less than about 500 MPa, and from about 100 to 500 MPa, and a remaining region the body may have a residual stress of less than about 300 MPa, and less than about 100 MPa.

Abstract: A cutting bit includes a body, a plurality of blades, and at least one ultrahard insert cast directly into at least one of the plurality of blades. The ultrahard insert is positioned with a rear face directly contacting the blade.

Abstract: Cutting elements include a diamond-bonded body attached with a substrate. The substrate has a coercivity of greater than about 200 Oe, and has a magnetic saturation of from about 73 to 90. The diamond-bonded body has a compressive stress at the surface of greater than about 0.9 GPa after heat treatment, and greater than about 1.2 GPa prior to heat treatment.

Abstract: A cutting element has an ultrahard layer on a substrate, the ultrahard layer having a non-planar working surface. The non-planar working surface is formed from a first region and a second region, where the first region encompasses at least a cutting edge or tip of the cutting element and has a differing composition than the second region.

Abstract: The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance.

Abstract: A cutting element may be formed by sintering together a plurality of metal carbide grains and a metal binder to form a substrate, forming at least one binder gradient in the substrate, and mounting an abrasive layer to the substrate at an interface. The concentration of metal binder material may decrease along at least one direction to form the at least one binder gradient.