Abstract: Methods of forming a cutting element include sintering diamond particles at a temperature of at least about 1400° C. under a pressure of at least about 10 GPa in the absence of a metal solvent catalyst so as to form a polycrystalline diamond compact (PDC), providing a barrier material over at least a portion of the PDC, providing a carbide material and a metal binder comprising at least one transition metal element over the barrier material and the PDC, and performing a second sintering process comprising sintering the carbide material, the metal binder, the barrier material, and the PDC at a temperature of at least about 1400° C. under a pressure of at least about 5 GPa to form the cutting element. At least a portion of the PDC proximate an exposed exterior surface of the PDC may be at least substantially free of the metal binder.

Abstract: A method of making a cutting element for use on an earth-boring tool may include forming the cutting element including a cutting table formed from a superabrasive polycrystalline material. The method may further include polishing a cutting surface of the cutting table by pulsing a laser onto the cutting surface of the cutting table. The cutting element may include a superabrasive polycrystalline cutting table including a cutting surface substantially free of micro-anomalies in the superabrasive material.

Abstract: A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the inter-bonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

Abstract: A cutter element for an earth-boring tool, comprising a polycrystalline diamond (PCD) volume joined at an interface boundary to a cemented carbide substrate. The PCD volume includes a rake face opposite the interface boundary, an edge of the rake face being suitable as a cutting edge of the cutter element. The PCD volume comprises a plurality of strata directly joined to each other at inter-strata boundaries, in which each of a first plurality of the strata comprises PCD material having a first diamond content; each of a second plurality of the strata comprises PCD material having a second diamond content; the second diamond content being greater than the first diamond content; and the strata of the first and second pluralities disposed in an alternating arrangement with respect to each other.

Abstract: A cutting element for downhole drilling and related earth-boring tool for downhole drilling. The cutting element may include a substrate and a polycrystalline diamond material affixed to the substrate at an interface. The polycrystalline diamond material may include a raised cutting surface having at least two cutting edges, and first transition surfaces between the at least two cutting edges of the raised cutting surface and a side surface of the cutting element. The first transition surfaces may include multiple planar surfaces.

Abstract: A cutter element for an earth-boring tool, comprising a polycrystalline diamond (PCD) volume joined at an interface boundary to a cemented carbide substrate. The PCD volume includes a rake face opposite the interface boundary, an edge of the rake face being suitable as a cutting edge of the cutter element. The PCD volume comprises a plurality of strata directly joined to each other at inter-strata boundaries, in which each of a first plurality of the strata comprises PCD material having a first diamond content; each of a second plurality of the strata comprises PCD material having a second diamond content; the second diamond content being greater than the first diamond content; and the strata of the first and second pluralities disposed in an alternating arrangement with respect to each other.

Abstract: Bearings for earth-boring tools may include a first bearing member including a first bearing pad having a first contact surface and a second bearing member including a second bearing pad having a second contact surface in sliding contact with at least a portion of the first contact surface. At least one of the first bearing member and the second bearing member may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed. Another substrate may be attached to the portion of the first substrate, the portion of the first substrate interposed between the polycrystalline table and the other substrate.

Abstract: A cutting element for an earth-boring tool includes a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline, superabrasive material includes a first transition surface extending from an outer peripheral edge of the polycrystalline, superabrasive material and in a first direction oblique to a center longitudinal axis of the substrate and a curved, stress-reduction feature located on at least the first transition surface. Additionally, the stress-reduction feature may include an undulating edge formed in at least the first transition surface and a waveform extending from the undulating edge formed in at least the first transition surface toward the center longitudinal axis of the cutting element.

Abstract: A cutting element for an earth-boring tool includes a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline, superabrasive material includes a curved, stress-reduction feature located at least on the first transition surface. The cutting element includes at least one recess defined in the curved, stress-reduction feature of the polycrystalline, superabrasive material. The at least one recess includes sidewalls intersecting with a front surface of the stress-reduction feature of the polycrystalline, superabrasive material and extending to a base wall within the polycrystalline, superabrasive material. The curved, stress-reduction feature includes an undulating edge formed proximate a peripheral edge of the polycrystalline, superabrasive material and a waveform extending from the undulating edge toward the center longitudinal axis of the cutting element.

Abstract: A cutting element for an earth-boring tool includes a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline, superabrasive material includes a first transition surface extending from an outer peripheral edge of the polycrystalline, superabrasive material and in a first direction oblique to a center longitudinal axis of the substrate and a curved, stress-reduction feature located on at least the first transition surface. Additionally, the stress-reduction feature may include an undulating edge formed in at least the first transition surface and a waveform extending from the undulating edge formed in at least the first transition surface toward the center longitudinal axis of the cutting element.

Abstract: A cutting element for an earth-boring tool includes a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline, superabrasive material includes a curved, stress-reduction feature located at least on the first transition surface. The cutting element includes at least one recess defined in the curved, stress-reduction feature of the polycrystalline, superabrasive material. The at least one recess includes sidewalls intersecting with a front surface of the stress-reduction feature of the polycrystalline, superabrasive material and extending to a base wall within the polycrystalline, superabrasive material. The curved, stress-reduction feature includes an undulating edge formed proximate a peripheral edge of the polycrystalline, superabrasive material and a waveform extending from the undulating edge toward the center longitudinal axis of the cutting element.

Abstract: An earth-boring tool comprises a bit body and first and second depth of cut control (“DOCC”) features mounted thereon. The first and second DOCC features comprise a first rubbing surface having a first surface area and a second rubbing surface having a second surface area, respectively, for contacting a subterranean formation. The second surface area is different from the first surface area such that the first and second DOCC features distribute a load attributable to applied weight on bit over the first and second rubbing surfaces at different rates. Methods of forming an earth-boring tool include selecting first and second DOCC features having different rates of engagement with the subterranean formation and mounting the first and second DOCC features on a bit body.

Abstract: A hardfacing material includes a metal matrix material and particles of crushed polycrystalline diamond material embedded within the metal matrix material. An earth-boring tool includes a body comprising particles of fragmented polycrystalline diamond material embedded within a metal matrix material. The particles of fragmented polycrystalline diamond material include a plurality of inter-bonded diamond grains. A method includes forming an earth-boring tool including a metal matrix material and particles of crushed polycrystalline diamond material.

Abstract: Cutting elements include a volume of superabrasive material. The volume of superabrasive material comprises a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. An earth-boring tool may comprise a bit body and at least one cutting element attached to the bit body. Methods of forming cutting elements comprise forming a volume of superabrasive material comprising forming a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. Methods of forming earth-boring tools comprise forming a cutting element and attaching the cutting element to an earth-boring tool.

Abstract: Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

Abstract: A cutting element for use in a drilling bit and/or a milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer.

Abstract: Methods of evaluating prototype cutting elements for earth-boring tools may involve generating first and second sets of virtual representations of cutting elements from first and second sets of used cutting elements. First and second sets of measures of damage corresponding to damage for each of the first and second sets set of virtual representations of cutting elements may be determined. A best-performing set of cutting elements from the first and second sets of used cutting elements according to the first and second sets of measures of damage may be identified by performing a statistical analysis.

Abstract: Methods of forming cutting elements may involve providing a thermally stable polycrystalline table and a substrate portion located adjacent to the thermally stable polycrystalline table in a mold. A metal material may be provided over the substrate portion on a side of the substrate portion opposing the thermally stable polycrystalline table in the mold, the metal material exhibiting a melting temperature of less than 1,320° C. A mixture of particles may be distributed on the metal material in the mold. The mold and its contents may be exposed to a temperature less than 1,320° C. and pressure may be applied to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and to at least partially melt the metal material to flow, infiltrate the substrate portion, and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween.

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: An earth-boring tool comprises a bit body and first and second depth of cut control (“DOCC”) features mounted thereon. The first and second DOCC features comprise a first rubbing surface having a first surface area and a second rubbing surface having a second surface area, respectively, for contacting a subterranean formation. The second surface area is different from the first surface area such that the first and second DOCC features distribute a load attributable to applied weight on bit over the first and second rubbing surfaces at different rates. Methods of forming an earth-boring tool include selecting first and second DOCC features having different rates of engagement with the subterranean formation and mounting the first and second DOCC features on a bit body.