Abstract: Cutting elements include a substrate, a thermally stable polycrystalline table comprising a superhard material secured to the substrate, and a layer of metal interposed between, and attaching the substrate and the thermally stable polycrystalline table. Methods of forming a cutting element include providing a thermally stable polycrystalline table in a mold, providing a layer of metal on the thermally stable polycrystalline table, distributing a mixture of particles comprising a plurality of hard particles and a plurality of particles comprising a matrix material on the layer of metal, and heating the mold while applying pressure to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and at least partially melt the layer of metal to flow and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween.

Abstract: An earth-boring tool includes a bit body, a plurality of first cutting elements, and a plurality of second cutting elements. Each of the first cutting elements includes a discontinuous phase dispersed within a continuous matrix phase. The discontinuous phase includes a plurality of particles of superabrasive material. Each of the second cutting elements includes a polycrystalline diamond compact or tungsten carbide. A method of forming an earth-boring tool includes disposing a plurality of first cutting elements on a bit body and disposing a second plurality of second cutting elements on the bit body. Another method of foaming an earth-boring tool includes forming a body having a plurality of first cutting elements and a plurality of cutting element pockets and securing each of a plurality of second cutting elements within each of the cutting element pockets.

Abstract: Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material.

Abstract: A cutting element for an earth-boring tool. The cutting element comprises a substrate base, and a volume of polycrystalline diamond material on an end of the substrate base. The volume of polycrystalline diamond material comprises a generally conical surface, an apex centered about a longitudinal axis extending through a center of the substrate base, a flat cutting surface extending from a first point at least substantially proximate the apex to a second point on the cutting element more proximate a lateral side surface of the substrate base. Another cutting element is disclosed, as are a method of manufacturing and a method of using such cutting elements.

Abstract: Cutting elements for use with earth-boring tools include a cutting table having a base surface and a substrate having a support surface. An intermediate structure and an adhesion layer extend between the base surface of the cutting table and the support surface of the substrate. Earth-boring tools include such cutting elements. Methods for fabricating cutting elements for use with earth-boring tools include forming an intermediate structure on and extending from a support surface of a substrate and adhering a cutting table comprising a superabrasive material to the support surface of the substrate.

Abstract: Geometric compensation techniques are used to improve the accuracy by which features may be located on drill bits formed using particle compaction and sintering processes. In some embodiments, a positional error to be exhibited by at least one feature in a less than fully sintered bit body upon fully sintering the bit body is predicted and the at least one feature is formed on the less than fully sintered bit body at a location at least partially determined by the predicted positional error. In other embodiments, bit bodies of earth-boring rotary drill bits are designed to include a design drilling profile and a less than fully sintered bit body is formed including a drilling profile having a shape differing from a shape of the design drilling profile. Less than fully sintered bit bodies of earth-boring rotary drill bits are formed using such methods.

Abstract: Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to form diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material.

Abstract: A reactive foil is used to assemble the components of rock bit cutters and to affix cutting elements to rock bit bodies. A small pulse of localized energy ignites the foil in a fraction of a second to deliver the necessary amount of heat energy to flow solder or braze and form a strong, true metallic joint. The reaction in the foil may be activated using optical, electrical, or thermal sources.

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, earth-boring drill bits having such cutting elements and related methods are described herein. In some embodiments, a cutting element for an earth-boring tool may include a diamond table having an indentation in a cutting face thereof and a shaped feature in a substrate at the interface between the diamond table and the substrate, the shaped feature corresponding to the indentation in the cutting face of the diamond table. In further embodiments, a cutting element for an earth-boring tool may include a sacrificial structure positioned within an indentation in a diamond table. In additional embodiments, a method of forming a cutting element may include positioning a sacrificial structure in a mold, positioning a powdered precursor material over the sacrificial structure, and pressing and sintering the powdered precursor material to form a diamond table having an indentation in a cutting face formed by the sacrificial structure.

Abstract: Earth-boring tools include a body, one or more blades projecting outwardly from the body, and cutting elements carried by the blade. The cutting elements include at least one shearing cutting element and at least one gouging cutting element. Methods of forming an earth-boring tool include mounting a shearing cutting element comprising an at least substantially planar cutting face to a body of an earth-boring tool, and mounting a gouging cutting element comprising a non-planar cutting face to the body of the earth-boring tool. The gouging cutting element may be positioned on the body of the earth-boring tool such that the gouging cutting element will gouge formation material within a kerf cut in the formation material by the shearing cutting element, or between kerfs cut in the formation material by a plurality of shearing cutting elements.

Abstract: Earth-boring tools include combinations of shearing cutting elements and gouging cutting elements on a blade of the earth-boring tools. In some embodiments, a gouging cutting element may be disposed adjacent to a shearing cutting element on a blade of an earth-boring tool. Methods of forming earth-boring tools include providing such combination of at least one shearing cutting element and at least one gouging cutting element on a blade of an earth-boring tool.

Abstract: A method for conducting nondestructive internal inspection of a rotary drill bit used for drilling subterranean formations comprises communicating ultrasonic waves into a drill bit and detecting ultrasonic waves that are reflected by at least a portion of the drill bit. In some embodiments, the waves may be directed into the drill bit from within a longitudinal bore thereof. Reflected waves also may be detected from within the bore. The methods may be used to develop threshold acceptance criteria for classifying drill bits as acceptable or unacceptable to prevent catastrophic failures of drill bits during use. Systems and apparatuses are disclosed for conducting nondestructive ultrasonic inspection of a drill bit used for drilling subterranean formations. The systems and apparatuses may comprise an ultrasonic probe configured for insertion within an internal longitudinal bore of a drill bit. Drill bits are disclosed that are configured to facilitate nondestructive ultrasonic inspection thereof.

Abstract: A cutting element comprising a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface. The cutting element further includes a superabrasive layer comprising a rear surface, an upper surface, and a side surface connected to and extending between the rear surface and upper surface, wherein the rear surface of the superabrasive layer overlies the upper surface of the substrate. The cutting element is also formed to include a jacket overlying the side surface of the substrate and abutting a portion of the rear surface of the superabrasive layer, wherein the jacket comprises a flange extending along a portion of the side surface of the superabrasive layer.

Abstract: Earth-boring tools comprise a shank comprising a distal connector including a set of threads thereon and a bit body comprising a shank connector, also comprising at least one set of threads thereon. The set of threads on the distal connector and the at least one set of threads on the shank connector are at least substantially bound together. Methods of forming such earth-boring tools are also disclosed, as well as methods of securing a bit body of an earth-boring tool to a shank.

Abstract: Methods of forming polycrystalline diamond elements include forming a polycrystalline diamond compact comprising a cavity in a surface thereof. A catalyst is at least substantially removed from the polycrystalline diamond compact, and the polycrystalline diamond compact is secured to a supporting substrate. Cutting elements include a diamond table formed with a cavity in a back side surface thereof and a supporting substrate secured to the back side surface of the diamond table. Earth-boring tools comprise a bit body carrying one or more cutting elements including a diamond table, a supporting substrate and an adhesion layer comprising a superhard material between and bonding the cutting table and the supporting substrate.

Abstract: Methods of forming cutting element pockets in earth-boring tools may include forming a first recess and a second recess. A filler material is disposed in the second recess to the form at least a portion of a back surface of the pocket. Methods of forming cutting element pockets in earth-boring tools may include orienting a rotating cutter generally parallel to a longitudinal axis of a cutting element pocket to be formed in a body of an earth-boring tool and machining the cutting element pocket in the earth-boring tool. Methods of forming earth-boring tools include forming a body comprising at least one blade and forming at least one cutting element pocket in the at least one blade.

Abstract: A cutting element for use in a drill bit for drilling subterranean formations includes a cutting body having a substrate including a rear surface, an upper surface, and a peripheral side surface extending between the rear surface and the upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve surrounding the peripheral side surface of the cutting body and comprising a superabrasive layer bonded to an external surface of the sleeve.

Abstract: A cutting element for use in a drilling bit and/or 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 including 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: Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles.