Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material.

Abstract: A support structure (40) for a PCD element (10) comprises a support (42) into which a PCD element (10) is locatable and a sealing element (48) for location in the support structure (40) and configured to protect a non-leached portion of a PCD element (10) during a leaching process. The support (42) is formed from or coated with a polyketone based plastics material.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A PCD insert comprises a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A support structure (40) for a PCD element comprises a support (42) into which a plurality of PCD elements are locatable, and a plurality of sealing elements (48) for location in the support structure. Each sealing element (48) is configured to protect a non-leached portion of an associated PCD element during a leaching process, said support being formed from or coated with a polyketone based plastics material. A plurality of support structures (42) may be stacked on top of each other and a central support rod (52) is locatable in a central aperture (50) extending though the stack of support structures (42). A handle (54) may be attached to the central support rod (52) for ease of transporting the assembled support structure.

Abstract: A support structure (40) for a PCD element (10) comprises a support (42) into which a PCD element (10) is locatable and a sealing element (48) for location in the support structure (40) and configured to protect a non-leached portion of a PCD element (10) during a leaching process. The support (42) is formed from or coated with a polyketone based plastics material.

Abstract: A superhard polycrystalline construction comprises a body of polycrystalline superhard material having a first region and a second region adjacent to and bonded to the first region by intergrowth of grains of superhard material. The first region comprises a plurality of alternating strata or layers, each having a thickness in the range of around 5 to 300 microns. One or more strata or layers in the second region have a thickness greater than the thicknesses of the individual strata or layers in the first region. The alternating layers or strata in the first region comprise first layers or strata alternating with second layers or strata, the first layers or strata being in a state of residual compressive stress and the second layers or strata being in a state of residual tensile stress.

Abstract: A superhard polycrystalline construction comprises a body of polycrystal-line superhard material formed of a mass of superhard grains exhibiting inter- granular bonding and defining a plurality of interstitial regions therebetween, the superhard grains having an associated mean free path, and a non- superhard phase at least partially filling a plurality of the interstitial regions and having an associated mean free path. The median of the mean free path associated with the non-superhard phase divided by (Q3-Q1) for the non-superhard phase is greater than or equal to 0.83 where Q1 is the first quartile and Q3 is the third quartile and the median of the mean free path associated with the superhard grains divided by (Q3-Q1) for the superhard grains is less than 0.47.

Abstract: A PCD body comprises a skeletal mass of inter-bonded diamond grains defining interstices between them. At least some of the interstices contain a filler material comprising a metal catalyst material for diamond, the filler material containing Ti, W and an additional element M selected from the group consisting of V, Y, Nb, Hf, Mo, Ta, Zr Cr, Zr and the rare earth elements. The content of Ti within the filler material is at least 0.1 weight % and at most 20 weight %. The content of M within the filler material is at least 0.1 weight % and at most 20 weight %, and the content of W within the filler material is at least 5 weight % and at most 50 weight % of the filler material.

Abstract: A method of processing a polycrystalline diamond (PCD) material having a non-diamond phase comprising a diamond catalyst/solvent material comprises leaching an amount of the diamond catalyst/solvent from the PCD material by exposing at least a portion of the PCD material to a leaching mixture. The leaching mixture comprises hydrochloric acid and one or more additional mineral acids, the molar concentration of the hydrochloric acid being greater than the molar concentration of the one or more additional mineral acids in the leaching mixture.

Abstract: A method of producing a composite diamond compact comprising a polycrystalline diamond (PCD) compact bonded to a cemented carbide substrate is provided. The method includes the steps of: providing a PCD table, preferably a PCD table with diamond-to-diamond bonding and a porous microstructure in which the pores are empty of second phase material bringing together the PCD table and a cemented carbide substrate in the presence of a bonding agent to form an unbonded assembly; subjecting the unbonded assembly to an initial compaction at a pressure of at least 4.5 GPa and a temperature below the melting point of the bonding agent for a period of at least 150 seconds; and thereafter subjecting the unbonded assembly to a temperature above the melting point of the bonding agent and a pressure of at least 4.5 GPa for a time sufficient for the bonding agent to become molten and bond the PCD table to the substrate to form a composite diamond compact.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or ail of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A method of producing a composite diamond compact comprising a polycrystalline diamond (PCD) compact bonded to a cemented carbide substrate is provided. The method includes the steps of: providing a PCD table, preferably a PCD table with diamond-to-diamond bonding and a porous microstructure in which the pores are empty of second phase material bringing together the PCD table and a cemented carbide substrate in the presence of a bonding agent to form an unbonded assembly; subjecting the unbonded assembly to an initial compaction at a pressure of at least 4.5 GPa and a temperature below the melting point of the bonding agent for a period of at least 150 seconds; and thereafter subjecting the unbonded assembly to a temperature above the melting point of the bonding agent and a pressure of at least 4.5 GPa for a time sufficient for the bonding agent to become molten and bond the PCD table to the substrate to form a composite diamond compact.

Abstract: The invention is for a polycrystalline diamond material comprising a first phase of bonded diamond particles and a second phase interspersed through the first phase. The second phase contains vanadium in the form of the metal or vanadium carbide or vanadium tungsten carbide or two or more of these forms and may be present in the polycrystalline diamond material in the range 1 to 8 percent by mass of the material.