Abstract: A multi-layer polycrystalline superabrasive PCD or PCBN blank for attachment to a working tool is disclosed. The blank comprises an abrasive layer of PCD or PCBN and a substrate layer of cobalt containing cemented tungsten carbide. In between the abrasive and substrate layers is a metal mesh stabilizer layer sintered by HPHT to the abrasive and substrate layers. The apertures of the mesh layer contain PCD or PCBN which, along with the mesh are sintered to the support and substrate layers and cobalt present in the substrate layer is infiltrated through the mesh layer into the abrasive layer as a binder. The metal mesh layer provides stability to the abrasive and substrate layers which have different stress and thermal expansion properties.

Abstract: A multi-layer polycrystalline superabrasive PCD or PCBN blank for attachment to a working tool is disclosed. The blank comprises an abrasive layer of PCD or PCBN and a substrate layer of cobalt containing cemented tungsten carbide. In between the abrasive and substrate layers is a metal mesh stabilizer layer sintered by HPHT to the abrasive and substrate layers. The apertures of the mesh layer contain PCD or PCBN which, along with the mesh are sintered to the support and substrate layers and cobalt present in the substrate layer is infiltrated through the mesh layer into the abrasive layer as a binder. The metal mesh layer provides stability to the abrasive and substrate layers which have different stress and thermal expansion properties.

Abstract: A polycrystalline superabrasive composite tool can be produced using high pressure high temperature processes allowing for increased thermal resistance, wear resistance and toughness of abrasive tools, and additionally allowing for increased effective thickness of abrasive tools. A polycrystalline superabrasive compact can include a support substrate and a superabrasive polycrystalline layer having a diffusion bridge embedded therein that includes a carbide former. Additionally, a working layer can be attached adjacent to the superabrasive polycrystalline layer and opposite the support substrate to form a drill bit sandwich segment. The diffusion bridge matrix of the present invention allows for a new welding phase at each interface between the superabrasive polycrystalline layer and support substrate and between the polycrystalline layer and the metal working layer, thus eliminating delamination failure at the interfaces.

Abstract: A new industrial thermally stable polycrystalline diamond (TSP) is disclosed and described as a replacement of natural as well as synthetic diamond grit in concrete cutting, grinding, polishing, and surface-set grinding or core bit drilling applications. Conventional diamond is too strong and brittle for self-sharpening and polishing and has a lower thermal stability inferior to the industrial standard for high temperature tool segment bonding. TSP grits can be tailor-made having unique properties as well as an engineered shape of grits over naturally or synthetically produced diamond grits. The TSP grits have a high thermal stability of up to 1200° C. and are self-sharpening. Further, economical production of coarse TSP grit size up to 1-2 mm from 50/60 mesh size in almost any preferred shape such as blocky, round, hexagonal, thin elongated, spherical, needle like, and any desirable tailor-made shaped etc can be realized.

Abstract: A weldable ultrahard insert can include an ultrahard working layer and a weldable metal layer metallically bonded with the working layer. The ultrahard working layer can be any ultrahard material such as PCD, PCBN, metal carbide, ceramic, diamond, or the like. The weldable ultrahard inserts can be formed by charging a reaction vessel with ultrahard materials, including precursors thereof, and placing a weldable metal layer in the reaction vessel with an optional intermediate layer. The assembly can be subjected to a pressure and a temperature sufficient to metallically bond the weldable metal layer to the ultrahard material. The weldable layer is formed as part of the insert in situ which facilitates subsequent welding of the insert to a tool substrate without risking damage to the ultrahard material.

Abstract: A polycrystalline superabrasive composite tool can be produced using high pressure high temperature processes allowing for increased thermal resistance, wear resistance and toughness of abrasive tools, and additionally allowing for increased effective thickness of abrasive tools. A polycrystalline superabrasive compact can include a support substrate and a superabrasive polycrystalline layer having a diffusion bridge embedded therein that includes a carbide former. Additionally, a working layer can be attached adjacent to the superabrasive polycrystalline layer and opposite the support substrate to form a drill bit sandwich segment. The diffusion bridge matrix of the present invention allows for a new welding phase at each interface between the superabrasive polycrystalline layer and support substrate and between the polycrystalline layer and the metal working layer, thus eliminating delamination failure at the interfaces.

Abstract: A self-grown monopoly compact grit and high pressure, high temperature process for preparing the same. The high pressure, high temperature sintered/synthesized monopoly compact grit is used in various industrial tools such as saw blades, grinding wheels, cutting tools and drill bits. Further, the monopoly compact grit of the present invention is produced from a seed of a mono-crystal of diamond or cubic boron nitride surrounded by either a self-grown crystal layer or an integrally bonded poly-crystalline sintered compact layer. The self-grown crystal layer is a new grown crystal structure where the seed crystal grows into a new phase through a normal diamond or cubic boron nitride synthesis process in the presence of a catalyst metal solvent.

Abstract: A self-grown monopoly compact grit and high pressure, high temperature process for preparing the same. The high pressure, high temperature sintered/synthesized monopoly compact grit is used in various industrial tools such as saw blades, grinding wheels, cutting tools and drill bits. Further, the monopoly compact grit of the present invention is produced from a seed of a mono-crystal of diamond or cubic boron nitride surrounded by either a self-grown crystal layer or an integrally bonded poly-crystalline sintered compact layer. The self-grown crystal layer is a new grown crystal structure where the seed crystal grows into a new phase through a normal diamond or cubic boron nitride synthesis process in the presence of a catalyst metal solvent.

Abstract: A new PCD/PCBN tool and method for making the same involve the use of an intermediate layer of polycrystalline material between a substrate and an outer working layer. The intermediate layer is formulated to limit or prevent the amount of cobalt or other binders which may infiltrate the outer working layer and accelerate deterioration under high throughput conditions. In accordance with one aspect of the invention, the substrate is corrugate or rounded projections to both reduce stress and to decrease infiltration of cobalt through the polycrystalline structures. In accordance with another aspect of the invention, the bonding medium and/or binder agents in the intermediate layer may be selected to decrease mobility of cobalt and the like.

Abstract: Finely divided silicon carbide materials, particularly powders, whiskers and short fibers, are provided with a titanium nitride surface coating by the process of (i) placing a low carbon diffusivity layer atop the silicon carbon, (ii) placing a titanium metal coating atop the low carbon diffusivity layer, and (iii) nitriding the titanium metal.

Abstract: Finely divided silicon carbide materials, particularly powders, whiskers and short fibers, are provided with a titanium nitride surface coating by the process of (i) placing a low carbon diffusivity layer atop the silicon carbide, (ii) placing a titanium metal coating atop the low carbon diffusivity layer, and (iii) nitriding the titanium metal.