Abstract: A super hard polycrystalline construction is disclosed as comprising a first region comprising a body of thermally stable polycrystalline diamond material comprising a plurality of intergrown grains of diamond material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface. The interface comprises at least a portion having an uneven topology, and the third region comprises a diamond composite material including a first phase comprising a plurality of non-intergrown super hard grains, said super hard grains comprising diamond grains; and a matrix material. The superhard material and matrix material of the third region form a diamond composite material which is more acid resistant than polycrystalline diamond material having a binder-catalyst phase comprising cobalt, and/or more acid resistant than cemented tungsten carbide material.

Abstract: A polycrystalline super hard construction has a first region having a body of thermally stable polycrystalline super hard material having a plurality of intergrown grains of super hard material; a second region forming a substrate having a hard phase and a binder phase; and a third region interposed between the first and second regions. The third region includes a composite material having a first phase comprising a plurality of non-intergrown grains of super hard material, and a matrix material. A fourth region interposed between the second and third region has a major proportion having one or more components of the binder material of the second region, and one or more reaction products between the binder material of the second region and one or more components of the third region.

Abstract: A polycrystalline super hard construction is disclosed having a first region comprising a body of thermally stable polycrystalline super hard material having an exposed surface forming a working surface, and a peripheral side edge, the polycrystalline super hard material comprising a plurality of grains of super hard material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface, the interface comprising a portion having an uneven topology and a substantially planar portion, the third region comprising a composite material including a first phase comprising a plurality of non-intergrown diamond grains, and a matrix material.

Abstract: A superhard construction comprises a substrate comprising a peripheral surface, an interface surface and a longitudinal axis and a super hard material layer formed over the substrate and having an exposed outer surface forming a working surface, a peripheral surface extending therefrom and an interface surface. One of the interface surface of the substrate or the interface surface of the super hard material layer comprises one or more projections arranged to project from the interface surface, the height of the one or more projections being between around 0.2 mm to around 1.0 mm measured from the lowest point on the interface surface from which the one or more projections extend.

Abstract: A superhard polycrystalline construction comprises a body of polycrystalline superhard material formed of a mass of superhard grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween, and a non-superhard phase at least partially filling a plurality of the interstitial regions and having an associated shape factor of greater than around 0.65 and a substrate bonded to the body of superhard material along an interface, the substrate having a region adjacent the interface comprising hinder material in an amount at least 5% less than the remainder of the substrate.

Abstract: A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers, each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a polycrystalline diamond structure.

Abstract: A superhard construction comprises a substrate comprising a peripheral surface, an interface surface and a longitudinal axis and a super hard material layer formed over the substrate and having an exposed outer surface forming a working surface, a peripheral surface extending therefrom and an interface surface. One of the interface surface of the substrate or the interface surface of the super hard material layer comprises one or more projections arranged to project from the interface surface, the height of the one or more projections being between around 0.2 mm to around 1.0 mm measured from the lowest point on the interface surface from which the one or more projections extend.

Abstract: A polycrystalline super hard construction has a first region comprising a body of thermally stable polycrystalline super hard material having an exposed surface forming a working surface, and a peripheral side edge, said polycrystalline super hard material comprising a plurality of intergrown grains of super hard material; a second region forming a substrate to the first region, the second region comprising a hard phase and a binder phase; and a third region interposed between the first and second regions, the third region extending across a surface of the second region along an interface. The third region comprises a composite material having a first phase comprising a plurality of non-intergrown grains of super hard material, and a matrix material.

Abstract: A super hard polycrystalline construction is disclosed as comprising a first region comprising a body of thermally stable polycrystalline diamond material comprising a plurality of intergrown grains of diamond material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface. The interface comprises at least a portion having an uneven topology, and the third region comprises a diamond composite material including a first phase comprising a plurality of non-intergrown super hard grains, said super hard grains comprising diamond grains; and a matrix material. The superhard material and matrix material of the third region form a diamond composite material which is more acid resistant than polycrystalline diamond material having a binder-catalyst phase comprising cobalt, and/or more acid resistant than cemented tungsten carbide material.

Abstract: A polycrystalline super hard construction is disclosed having a first region comprising a body of thermally stable polycrystalline super hard material having an exposed surface forming a working surface, and a peripheral side edge, the polycrystalline super hard material comprising a plurality of grains of super hard material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface, the interface comprising a portion having an uneven topology and a substantially planar portion, the third region comprising a composite material including a first phase comprising a plurality of non-intergrown diamond grains, and a matrix material.

Abstract: A super hard polycrystalline construction has a first region comprising a body of thermally stable polycrystalline super hard material having an exposed surface forming a working surface, and a peripheral side edge, said polycrystalline super hard material comprising a plurality of intergrown grains of super hard material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface, the interface comprising at least a portion having an uneven topology, the third region comprising a composite material having a first phase comprising a plurality of non-intergrown grains of super hard material, and a matrix material, the third region having a wear resistance at least three times less than sintered polycrystalline diamond material having the same average grain size of diamond grains as the super hard grains in the third region.

Abstract: A polycrystalline diamond construction comprising a body of polycrystalline diamond material is formed of a mass of diamond grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween, and a non-diamond phase at least partially filling a plurality of the interstitial regions to form non-diamond phase pools, the non-diamond phase pools each having an individual cross-sectional area. The percentage of non-diamond phase in the total area of a cross-section of the body of polycrystalline diamond material and the mean of the individual cross-sectional areas of the non-diamond phase pools in the image analysed using an image analysis technique at a selected magnification is less than 0.7, or less than 0.340 microns squared, or between around 0.005 to 0.340 microns squared depending on the percentage of non-diamond phase in the total area of the cross-section of the polycrystalline diamond construction.

Abstract: A PCD structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains; the first region comprising a plurality of alternating strata or layers, each stratum or layer having a thickness in the range of around 5 to 300 microns. The second region comprises a plurality of strata or layers, one or more strata or layers in the second region having 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 polycrystalline superhard material, comprising 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 being greater than or equal to 0.50, 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 being less than 0.60. The body of polycrystalline superhard material has a first surface having a surface topology comprising one or more indentations therein and/or projections therefrom. There is also disclosed a method of forming such a construction.

Abstract: A polycrystalline superhard construction comprises a body of polycrystalline superhard material, and a substrate of hard material bonded thereto along an interface. The body of polycrystalline superhard material comprises a first region abutting the substrate along the interface and a second region bonded to the first region. The second region defines a rake face, a cutting edge, a chamfer and at least a part of a flank face, the cutting edge being defined by an edge of the flank face joined to the chamfer, the chamfer extending between the cutting edge and the rake face. The height of the chamfer in a plane parallel to the plane through which the longitudinal axis of the polycrystalline superhard construction extends is less than the thickness of the second region. The first region comprises a material having coarser grains than the second region. There is also disclosed a method of making the same.

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 superhard polycrystalline construction comprises a body of polycrystalline superhard material formed of a mass of superhard grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween, and a non-superhard phase at least partially filling a plurality of the interstitial regions and having an associated shape factor of greater than around 0.65 and a substrate bonded to the body of superhard material along an interface, the substrate having a region adjacent the interface comprising binder material in an amount at least 5% less than the remainder of the substrate.

Abstract: A super hard polycrystalline construction comprises a body of polycrystalline super hard material, said body having an exposed working surface. The body of polycrystalline super hard material comprises a first region adjacent the working surface and a second region adjacent the first region; the first region being more thermally stable than the second region; and a plurality of apertures or channels, one or more of said apertures or channels extending from the exposed working surface of the body into the second region.

Abstract: A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers, each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a polycrystalline diamond structure.

Abstract: A cutter comprises a superhard construction, the cutter having a cutting edge defined by a rake face, and a flank extending therefrom. The cutter also has first and second regions, the first region abutting the second region along a boundary, the first region having a different material composition from the second region. At least the second region comprises superhard material, the material of the first region has a different coefficient of thermal expansion (CTE) from the material of the second region. The second region extends around the peripheral edge of the first region defined by the boundary to form a collar therearound, the first region and/or the second region extending to and/or forming at least a part of the rake face.