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, thereby providing 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.

Abstract: Prosthetic joints, components for prosthetic joints, superhard bearing and articulation surfaces, diamond bearing and articulation surfaces, substrate surface topographical features, materials for making joints, bearing and articulation surfaces, and methods for manufacturing and finishing the same, and related information are disclosed, including a prosthetic hip joint having sintered polycrystalline diamond articulation.

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, or insert, is provided for use with drills used in the drilling and boring of subterranean formations. This new insert has improved wear characteristics while maximizing the manufacturability and cost effectiveness of the insert. This invention accomplishes these objectives by employing a superabrasive diamond layer of increased depth and by making use of diamond layer surface shape that is generally convex.

Abstract: A cutting element for use in drilling subterranean formations. The cutting element includes a superabrasive table mounted to a supporting substrate. The superabrasive table includes a two-dimensional cutting face having a cutting edge along at least a portion of its periphery, and a first surface extending forwardly and inwardly from a location radially interior of the cutting edge at a first angle of orientation with respect to the longitudinal axis of the cutting element. The cutting face also includes at least a second surface located between the first surface and the cutting edge and oriented at a different, greater angle to the longitudinal axis than the angle of orientation of the first surface.

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: An earth-boring bit has a bit body and at least one cantilevered bearing shaft depending inwardly and downwardly from the bit body. A cutter is mounted for rotation on the bearing shaft and includes a plurality of cutting elements. At least one of the cutting elements has a generally cylindrical body formed of hard metal with a convex cutting end. A plurality of substantially recesses are formed on the cutting end of the body. The recesses are configured such that a line parallel to the longitudinal axis of the body may extend from any point of each of the recess without touching any other point on the same recess. This enables the cutting element body and the recess to be formed simultaneously by conventional powder metallurgical techniques. A layer of super-hard material is formed on the cutting end of the body and overlays the recesses formed thereon.

Abstract: A cutting element for use in drilling subterranean formations. The cutting element includes a superabrasive table between about 0.070 inch and 0.150 inch thickness, mounted to a supporting substrate. The superabrasive table includes a two-dimensional cutting face having a cutting edge along at least a portion of its periphery, and a rake land extending forwardly and inwardly from the cutting edge at an angle of between about 10.degree. and 80.degree. to the longitudinal axis of the cutting element for a width, measured along the surface of the rake land, of not less than about 0.050 inch. The interface between the superabrasive volume and the substrate, taken to the rear of the cutting edge, is located no less than about 0.015 inch to the rear of the cutting edge.

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 manufacturing method and a drill bit composite insert for performing mechanical actions that require high wear and impact resistance are provided. The composite insert has improved interface strength and improved residual stress distribution. These improved features are achieved by chemically and mechanically attaching the layer of abrasion and corrosion resistant polycrystalline material to the substrate that ordinarily is tungsten carbide. The chemical bond is formed during high pressure and high temperature sintering. Mechanically, the abrasion and corrosion resistant layer is attached to the substrate by means of irregularities on the substrate's top surface. These irregularities are designed to distribute stress and minimize the number of features that would lead to crack formation and subsequent failure of the insert.

Abstract: An earth-boring bit has a bit body and at least one cantilevered bearing shaft depending inwardly and downwardly from the bit body. A cutter is mounted for rotation on the bearing shaft and includes a plurality of cutting elements. At least one of the cutting elements has a generally cylindrical body formed of hard metal with a convex cutting end. A plurality of substantially linear, parallel lands are formed on the cutting end of the body. The lands have arcuate top surfaces and define grooves between the land having arcuate bottom surfaces. A layer of super-hard material is formed on the cutting end of the body and engages the lands and grooves formed thereon.

Abstract: A cutting element for use in drilling subterranean formations. The cutting element includes a superabrasive table between about 0.070 inch and 0.150 inch thickness, mounted to a supporting substrate. The superabrasive table includes a two-dimensional cutting face having a cutting edge along at least a portion of its periphery, and a rake land extending forwardly and inwardly from the cutting edge at an angle of between about 10.degree. and 80.degree. to the longitudinal axis of the cutting element for a width, measured along the surface of the rake land, of not less than about 0.050 inch. The interface between the superabrasive volume and the substrate, taken to the rear of the cutting edge, is located no less than about 0.015 inch to the rear of the cutting edge.

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.