Abstract: A drill bit for drilling a borehole in earth formations may include a bit body having a bit axis and a bit face; a plurality of blades extending radially along the bit face; and a plurality of cutting elements disposed on the plurality of blades, the plurality of cutting elements comprising: at least one cutter comprising a substrate and a diamond table having a substantially planar cutting face; and at least two non-planar cutting elements comprising a substrate and a diamond layer having a non-planar cutting end, wherein in a rotated view of the plurality of cutting elements into a single plane, the at least one cutter is located a radial position from the bit axis that is intermediate the radial positions of the at least two non-planar cutting elements.

Abstract: A cutting element has a port extending through at least a portion of the cutting element body. A cutting face of the cutting element includes an ultrahard material. The port is configured to provide fluid communication therethrough and to direct focused energy from a focused energy source through the cutting element toward a formation proximate the cutting face.

Abstract: A cutting element has a port extending through at least a portion of the cutting element body. A cutting face of the cutting element includes an ultrahard material. The port is configured to provide fluid communication therethrough and to direct focused energy from a focused energy source through the cutting element toward a formation proximate the cutting face.

Abstract: A drill bit for drilling a borehole in earth formations may include a bit body having a bit axis and a bit face; a plurality of blades extending radially along the bit face; and a plurality of cutting elements disposed on the plurality of blades, the plurality of cutting elements comprising: at least one cutter comprising a substrate and a diamond table having a substantially planar cutting face; and at least two non-planar cutting elements comprising a substrate and a diamond layer having a non-planar cutting end, wherein in a rotated view of the plurality of cutting elements into a single plane, the at least one cutter is located a radial position from the bit axis that is intermediate the radial positions of the at least two non-planar cutting elements.

Abstract: Methods and systems of attaching a thermally stable polycrystalline diamond (TSP) material layer to a substrate. The methods include placing a braze material between the TSP material layer and the substrate, pressing at least one of the TSP material layer and substrate against the other of the TSP material layer and the substrate, heating the braze material to a temperature of at least 800° C., and cooling the braze forming a bond attaching the TSP material layer to the substrate.

Abstract: An insert for a drill bit that includes diamond particles disposed in a matrix material, wherein the diamond particles have a contiguity of 15% or less is disclosed. A method of forming a diamond-impregnated cutting structure, that includes loading a plurality of substantially uniformly coated diamond particles into a mold cavity, pre-compacting the substantially uniformly coated diamond particles using a cold-press cycle, and heating the compacted, substantially uniformly coated diamond particles with a matrix material to form the diamond impregnated cutting structure is also disclosed.

Abstract: Polycrystalline diamond composites comprise a polycrystalline diamond body having a plurality of ultra-hard discrete regions dispersed within a polycrystalline diamond second region. The plurality of discrete regions has an density different from of the polycrystalline diamond second region. A metallic substrate can be joined to the body. The discrete regions can be relatively more thermal stable than, have a higher diamond density than, and/or may comprise a binder material that is different from the polycrystalline diamond second region. Polycrystalline diamond composites can be formed by combining already sintered granules with diamond grains to form a mixture, and subjecting the mixture to high pressure/high temperature conditions, wherein the granules form the plurality of discrete regions, or can be made by forming a plurality of unsintered granules, combining them with diamond grains to form a mixture, and then subjecting the mixture to first and second high pressure/high temperature conditions.

Abstract: A lubricant for a drill bit that includes from about 0.1 to about 10 weight percent of at least one nanomaterial, from about 5 to 40 weight percent of a thickener, and a basestock is disclosed.

Abstract: A carbide composite that includes carbide particles having an average particle size of less than about 100 nanometers and a metallic binder disposed around the carbide particles is disclosed. The carbide composite may also include carbide particles having an average particle size ranging from 3 to 10 microns.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and to a bit incorporating such cutting element. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: High energy sheer cutting elements and bits incorporating the same are provided. The cutting elements have at least a portion of their cutting layers which will be exposed to high temperatures during drilling formed from a PCBN material capable of operating at temperatures of at least 1000° C.

Abstract: A roller cone drill bit for drilling earth formations includes a bit body having at least one roller cone rotably attached to the bit body and a plurality of cutting elements disposed on the at least one roller cone in a plurality of rows arranged circumferentially around the at least one roller cone, wherein at least one cutting element in the gage row, the heel row, or a surface of the at least one roller cone bounded by the gage and heel rows comprises thermally stable polycrystalline diamond or a thermally stable polycrystalline diamond composite. The at least one cutting element may be a TSD insert or a TSD composite insert and may be formed by brazing, sintering, or bonding by other technologies known in the art a thermally stable polycrystalline diamond table to a substrate. The interface between the diamond table and the substrate may be non-planar.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.

Abstract: Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided.

Abstract: A cutting element is provided including a substrate and a TSP material layer over the substrate. The TSP material layer includes at least a property having a value that varies through the layer.

Abstract: A drill bit having a bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade, at least one cutter disposed in the at least one cutter pocket, hardfacing applied to at least a selected portion of the drill bit is shown and described. The hardfacing includes a first hardfacing layer disposed on the selected portion of the drill bit, a second hardfacing layer disposed on the first hardfacing layer, wherein the first hardfacing layer has a hardness different than a hardness of the second hardfacing layer.

Abstract: A polycrystalline diamond compact cutter that includes a thermally stable polycrystalline diamond layer, a carbide substrate, and a polycrystalline cubic boron nitride layer interposed between the thermally stable polycrystalline diamond layer and the carbide substrate is disclosed. A method of forming a polycrystalline diamond compact cutter that includes the steps of providing a carbide substrate, disposing a polycrystalline cubic boron nitride layer on the carbide substrate, disposing a polycrystalline diamond layer on the polycrystalline cubic boron nitride layer, and treating at least a portion of the polycrystalline diamond layer to form a thermally stable polycrystalline diamond layer is also disclosed.

Abstract: An insert for a drill bit that includes diamond particles disposed in a matrix material, wherein the diamond particles have a contiguity of 15% or less is disclosed. A method of forming a diamond-impregnated cutting structure, that includes loading a plurality of substantially uniformly coated diamond particles into a mold cavity, pre-compacting the substantially uniformly coated diamond particles using a cold-press cycle, and heating the compacted, substantially uniformly coated diamond particles with a matrix material to form the diamond impregnated cutting structure is also disclosed.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and a method of forming the same. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: Cutting elements are provided having multiple diameter sections. Also provided are bits incorporating such cutting elements.