Abstract: A device, system and method for nondestructively obtaining qualitative and/or quantitative information relating to the material properties of a region in a diamond body comprises directing x-rays onto the body. The body can comprise sintered or unsintered diamond. The body can ultimately be in the form of a cutting element used with a subterranean drill bit. The x-rays penetrate the body and cause a target element within the desired region including the same to emit x-ray fluorescence. The emitted x-ray fluorescence is received and information relating to content, location, and/or distribution of the target element in the region within the body is determined therefrom. The measured region can extend axially or radially from a surface of the body, and the target elements are nondiamond materials that can be constituents of a substrate attached to the body, or of a container used during HPHT sintering of the body.

Abstract: A method for manufacturing an ultrahard compact includes assembling a mass of ultrahard material with a mass of substrate material such that the mass of ultrahard material extends radially outward a greater extent than the substrate material to compensate for a difference in the radial shrinkage of the ultrahard material compared to the substrate material during a sintering process. The method may further includes subjecting the assembled compact to a high pressure high temperature process mat results in the forming of an ultrahard compact including an ultrahard layer integrally bonded with a substrate.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body. The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

Abstract: A cutting element is provided including a substrate having a periphery and an interface surface. An ultra hard material layer is formed over the substrate and interfaces with the interface surface. The interface surface also includes a plurality of spaced apart projections formed inwardly and spaced apart from the periphery and arranged around an annular path, such that each projection includes a convex upper surface defining the projection as viewed in plan view. Each upper surface continuously and smoothly curves in the same direction when viewed along a plane through a diameter of the substrate. Bits incorporating such cutting elements are also provided.

Abstract: Methods for nondestructively measuring a characteristic within an ultra-hard polycrystalline construction comprises projecting a beam of energy from an emitter onto the construction. The energy is directed to a target region within the ultra-hard polycrystalline construction and passes through the construction where it is received by a detector. The target region can be within a diamond body of the construction, and can relate to an interface between two or more regions within the diamond body. The energy that is received by the detector is evaluated for the purpose of determining the desired measurement characteristic. In an example embodiment, the measured characteristic can be the interface of between two or more regions and the distance from a surface of the construction to the interface. The method can be used to generate an average distance within the construction, and to provide a visual image of the same in a nondestructive manner.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals and interstitial regions disposed among the crystals. A metallic substrate is attached to the body. The body includes a first region substantially free of a catalyst material that extends a partial depth from a surface into the body, and a second region that includes the catalyst material. The body can include natural diamond grains and/or a blend of natural and synthetic diamond grains, and is treated to form the first region. Before treatment, a portion of the body to be treated is finished to an approximate final dimension so that the depth of the first region of the finished product is substantially the same as when treated. During treatment, catalyst materials as well as non-catalyst metallic materials are removed from the diamond body to provide a further enhanced degree of thermal stability.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.

Abstract: Ultrahard composite constructions comprise a plurality of first phases dispersed within a matrix second phase, wherein each can comprise an ultrahard material including PCD, PcBN, and mixtures thereof. The constructions are formed from a plurality of granules that are combined and sintered at HP/HT conditions. The granules include a core surrounded by a shell and both are formed from an ultrahard material or precursor comprising an ultrahard constituent for forming the ultrahard material. When sintered, the cores form the plurality of first phases, and the shells form at least a portion of the second phase. The ultrahard material used to form the granule core may have an amount of ultrahard constituent different from that used to form the granule shell to provide desired different properties. The ultrahard constituent in the granule core and shell can have approximately the same particle size.

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: A cutting element is provided including a substrate having a periphery and an interface surface. An ultra hard material layer is formed over the substrate and interfaces with the interface surface. The interface surface also includes a plurality of spaced apart projections formed inwardly and spaced apart from the periphery and arranged around an annular path, such that each projection includes a convex upper surface defining the projection as viewed in plan view. Each upper surface continuously and smoothly curves in the same direction when viewed along a plane through a diameter of the substrate. Bits incorporating such cutting elements are also provided.

Abstract: Ultrahard composite constructions comprise a plurality of first phases dispersed within a matrix second phase, wherein each can comprise an ultrahard material including PCD, PcBN, and mixtures thereof. The constructions are formed from a plurality of granules that are combined and sintered at HP/HT conditions. The granules include a core surrounded by a shell and both are formed from an ultrahard material or precursor comprising an ultrahard constituent for forming the ultrahard material. When sintered, the cores form the plurality of first phases, and the shells form at least a portion of the second phase. The ultrahard material used to form the granule core may have an amount of ultrahard constituent different from that used to form the granule shell to provide desired different properties. The ultrahard constituent in the granule core and shell can have approximately the same particle size.

Abstract: A method is provided for controlling the consistency of the quality of ultra hard materials formed over tungsten carbide substrates formed from different batches of tungsten carbide powder by controlling the tungsten carbide particle size distribution in each batch.

Abstract: PCD constructions include a PCD body comprising a polycrystalline matrix region, a first region that includes a replacement material positioned remote from a body surface, and a second region that is substantially free of the replacement material and that extends a depth from the body surface. The PCD construction can further include a substrate that is attached to the body. The PCD body is formed by removing a solvent catalyst material used to form the body, replacing the removed solvent catalyst material with a replacement material, and then removing the replacement material from a region of the body to thereby form the second region. The replacement material can be introduced into the PCD body during a HPHT process, and the substrate may or may not be the source of the noncatalyzing material.

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: A method for manufacturing an ultrahard compact includes assembling a mass of ultrahard material with a mass of substrate material such that the mass of ultrahard material extends radially outward a greater extent than the substrate material to compensate for a difference in the radial shrinkage of the ultrahard material compared to the substrate material during a sintering process. The method may further includes subjecting the assembled compact to a high pressure high temperature process that results in the forming of an ultrahard compact including an ultrahard layer integrally bonded with a substrate.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.

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: 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 having a non-planar substrate interface surface including a band and an ultra hard material layer over the interface surface are provided. Also provided are earth boring bits incorporating such cutting elements.