Abstract: A cutting element for use in a drilling bit and/or a milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer.

Abstract: Methods of forming cutting elements may involve providing a thermally stable polycrystalline table and a substrate portion located adjacent to the thermally stable polycrystalline table in a mold. A metal material may be provided over the substrate portion on a side of the substrate portion opposing the thermally stable polycrystalline table in the mold, the metal material exhibiting a melting temperature of less than 1,320° C. A mixture of particles may be distributed on the metal material in the mold. The mold and its contents may be exposed to a temperature less than 1,320° C. and pressure may be applied to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and to at least partially melt the metal material to flow, infiltrate the substrate portion, and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween.

Abstract: A polycrystalline super hard construction has a body of PCD material and a plurality of interstitial regions between inter-bonded diamond grains forming the PCD material. The body also has a first region substantially free of a solvent/catalyzing material which extends a depth from a working surface into the body of PCD material. A second region remote from the working surface includes solvent/catalyzing material in a plurality of the interstitial regions. A chamfer extends between the working surface and a peripheral side surface of the body of PCD material. The chamfer has a height which is the length along a plane perpendicular to the plane along which the working surface extends between the point of intersection of the chamfer with the working surface and the point of intersection of the chamfer and the peripheral side surface of the body of PCD material. The depth of the first region is greater than the height of the chamfer.

Abstract: A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed.

Abstract: Methods of forming a polycrystalline table may involve disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles may be partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate may be removed from the brown polycrystalline table and catalyst material may be removed from the brown polycrystalline table. The brown polycrystalline table may then be fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate may include a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table may include a plurality of interbonded grains of a superabrasive material.

Abstract: A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed.

Abstract: An earth-boring drilling tool comprises a cutting element. The cutting element comprises a substrate, a diamond table, and at least one sensing element formed from a doped diamond material disposed at least partially within the diamond table. A method for determining an at-bit measurement for an earth-boring drill bit comprises receiving an electrical signal generated within a doped diamond material disposed within a diamond table of a cutting element of the earth-boring drill bit, and correlating the electrical signal with at least one parameter during a drilling operation.

Abstract: Cutting elements include a substrate, a thermally stable polycrystalline table comprising a superhard material secured to the substrate, and a layer of metal interposed between, and attaching the substrate and the thermally stable polycrystalline table. Methods of forming a cutting element include providing a thermally stable polycrystalline table in a mold, providing a layer of metal on the thermally stable polycrystalline table, distributing a mixture of particles comprising a plurality of hard particles and a plurality of particles comprising a matrix material on the layer of metal, and heating the mold while applying pressure to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and at least partially melt the layer of metal to flow and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween.

Abstract: Polycrystalline elements include a substrate and a polycrystalline table attached to an end of the substrate. The polycrystalline table includes a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability, the at least a second region being interposed between the substrate and the first region. Methods of forming a polycrystalline element involve attaching a polycrystalline table including a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability to an end of a substrate, the at least a second region being interposed between the first region and the substrate. Catalyst material is removed from at least the first region of the polycrystalline table.

Abstract: Polycrystalline compact tables for cutting elements include regions of grains of super hard material. One region of grains (“first grains”) and another region of grains (“second grains”) have different properties, such as different average grain sizes, different super hard material volume densities, or both. The region of first grains and the region of second grains adjoin one another at grain interfaces that may include a curved portion in a vertical cross-section of the table. In some embodiments, discrete regions of the first grains may be vertically disposed between discrete regions of the second grains. As such, the tables have ordered grain regions of different properties that may inhibit delamination and crack propagation through the table when used in conjunction with a cutting element. Methods of forming the tables include forming the regions and subjecting the grains to a high-pressure, high-temperature process to sinter the grains.

Abstract: A cutting element for an earth-boring tool includes a volume of superabrasive material having a cutting face and a shaped feature on the cutting face. The shaped feature may include at least one of a recess extending into the volume of superabrasive material from the cutting face and a protrusion extending outward from the cutting face. A first portion of the cutting face may have a first surface roughness, and a second portion of the cutting face may have a second surface roughness greater than the first surface roughness of the first portion of the cutting face. The volume of superabrasive material may be disposed on a substrate. Methods of forming cutting elements may include forming one or more shaped features in a cutting face of the cutting elements. Earth-boring tools may include such cutting elements.

Abstract: A cutting element for an earth-boring tool includes a volume of superabrasive material on a substrate. The cutting element has an elongated shape in a lateral dimension parallel to a front cutting face of the cutting element, and has a maximum lateral width in a first direction parallel to the front cutting face of the cutting element and a maximum lateral length in a second perpendicular direction parallel to the front cutting face of the cutting element. The maximum lateral length is significantly greater than the maximum lateral width. An earth-boring tool includes one or more such cutting elements mounted to a body of the earth-boring tool. A method of forming such an earth-boring tool includes selecting at least one such cutting element and mounting the cutting element to a body of an earth-boring tool.

Abstract: A cutting element comprises a supporting substrate, and a polycrystalline compact attached to an end of the supporting substrate. The polycrystalline compact comprises a region adjacent the end of the supporting substrate, and another region at least substantially laterally circumscribing the region and having lesser permeability than the region. A method of forming a cutting element, and an earth-boring tool are also described.

Abstract: An earth-boring drilling tool comprises a cutting element. The cutting element comprises a substrate, a diamond table, and at least one sensing element formed from a doped diamond material disposed at least partially within the diamond table. A method for determining an at-bit measurement for an earth-boring drill bit comprises receiving an electrical signal generated within a doped diamond material disposed within a diamond table of a cutting element of the earth-boring drill bit, and correlating the electrical signal with at least one parameter during a drilling operation.

Abstract: Cutting elements for an earth-boring tool include a substrate base and a cutting tip. The cutting tip may include a first generally conical surface, a second, opposite generally conical surface, a first flank surface extending between the first and second generally conical surfaces, and a second, opposite flank surface. The cutting tip may include a central axis that is not co-linear with a longitudinal axis of the substrate base. The cutting tip may include a surface defining a longitudinal end thereof that is relatively more narrow in a central region thereof than in a radially outer region thereof. Earth-boring tools include a body and a plurality of such cutting elements attached thereto, at least one cutting element oriented to initially engage a formation with the first or second generally conical surface thereof. Methods of drilling a formation use such cutting elements and earth-boring tools.

Abstract: A cutting element for an earth-boring drilling tool comprises a cutting body having a cutting surface thereon, and a sensor coupled with the cutting surface, the sensor configured to determine resistivity of a contacting formation. An earth-boring drilling tool comprises a bit body and an instrumented cutting element coupled with the bit body. The cutting element includes a cutting body having a cutting surface thereon, and at least one sensor located proximate the cutting surface. The at least one sensor is oriented and configured to determine resistivity of a contacting formation. A method of determining resistivity of a subterranean formation during a drilling operation comprises energizing a sensor of an instrumented cutting element of a drill bit, sensing a return signal flowing on or through the subterranean formation through the instrumented cutting element, and determining a resistivity of the subterranean formation based, at least in part, on the return signal.

Abstract: A method of forming a cutting element for an earth-boring tool includes forming a table of superabrasive material over a substrate in an HTHP environment such that the table of superabrasive material is bonded to the substrate. The table of superabrasive material and the substrate form a cutting element. The method includes removing the cutting element from the HTHP environment, ascertaining predictable residual stresses within the table of superabrasive material, and marking the cutting element with at least one mark. The at least one mark provides indication of a region of the table of superabrasive material having a maximum or minimum residual stress therein. An additional method includes obtaining such a marked cutting element and affixing the cutting element on an earth-boring tool in a preferential orientation as indicated at least partially by the mark.

Abstract: Polycrystalline compacts include non-catalytic nanoparticles in interstitial spaces between interbonded grains of hard material in a polycrystalline hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming polycrystalline compacts include sintering hard particles and non-catalytic nanoparticles to form a polycrystalline material. Methods of forming cutting elements include infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of non-catalytic nanoparticles.

Abstract: A cutting element for use in a drilling bit and/or a milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer.

Abstract: A downhole tool comprises a mechanical joint, and a diamond-like coating over at least a portion of a surface of at least one component of the mechanical joint, the diamond-like coating having a thickness greater than 10 micrometers. Methods of manufacturing a mechanical joint of a downhole tool comprise disposing a diamond-like coating on at least a portion of a surface of a component of the mechanical joint of the downhole tool to a thickness of at least 10 microns and at a temperature less than about 200° C.