Abstract: A composite sintered material includes: a plurality of diamond grains having an average grain size of less than or equal to 10 ?m; a plurality of cubic boron nitride grains having an average grain size of less than or equal to 2 ?m; and a plurality of aluminum oxide grains having an average grain size of less than or equal to 0.5 ?m; and a remainder of a binder phase, wherein at least parts of adjacent diamond grains are bound to one another, the binder phase includes cobalt, in the composite sintered material, a content of the diamond grains is from 30 to 92 volume %, a content of the cubic boron nitride grains is from 3 to 40 volume %, a content of the aluminum oxide grains is from 2 to 15 volume %, and a content of the cobalt is from 3 to 30 volume %.

Abstract: A mixture for forming a wear resistant layer on a substrate comprises particles of a first wear resistant particle type, particles of a second wear resistant particle type and a wear resistant layer binder for binding the first and the second wear resistant particles in the wear resistant layer when the layer is formed. As well, wear resistant particle size distributions for the first and second wear resistant particle types have a first mode and a second mode. The first particle type is associated with the first mode and the second particle type is associated with the second mode. Moreover, a number of first wear resistant particles associated with the first mode is larger than a number of second wear resistant particles associated with the second mode. Further, the second mode is larger than the first mode.

Abstract: Methods of preventing or reducing cutter loss in a steel body PDC drilling tool may include applying a hardfacing layer on a surface of a PDC cutter pocket to form a covered PDC cutter pocket, the hardfacing layer comprising a metal binder and coated tungsten carbide particles; and bonding a PDC cutter into the covered PDC cutter pocket with a brazing material. Steel body PDC drilling tools may include a steel body, a PDC cutter, a PDC cutter pocket, and a hardfacing layer. Methods of preventing or reducing cutter loss in a steel body PDC drilling tool may include applying a hardfacing layer on a surface of a PDC cutter pocket of the steel body PDC drilling tool; applying a coated buffering layer on the hardfacing layer to form a coated PDC cutter pocket; and bonding the PDC cutter into the coated PDC cutter pocket with a brazing material.

Abstract: A rock drill insert made of cemented carbide having hard constituents of tungsten carbide (WC) in a binder phase including Co, wherein the cemented carbide includes 4-18 mass % Co and a balance of WC and unavoidable impurities. The cemented carbide also includes Cr in such an amount that the mass ratio Cr/Co is within the range of 0.04-0.19, and the difference between the hardness at a 0.3 mm depth at any point of the surface of the rock drill insert and the hardness of the bulk of the rock drill insert is at least 40 HV3.

Abstract: A cutting element may include a substrate, an upper surface of the substrate including a crest, the crest transitioning into a depressed region, and an ultrahard layer on the upper surface, thereby forming a non-planar interface between the ultrahard layer and the substrate. A top surface of the ultrahard layer includes a cutting crest extending along at least a portion of a diameter of the cutting element, the top surface having a portion extending laterally away from the cutting crest having a lesser height than a peak of the cutting crest.

Abstract: A cutting element has an intercrystalline-bonded diamond body that includes an inner region and an outer surface that includes a working surface of the cutting element. The outer surface is treated, after formation of the intercrystalline-bonded diamond by high-pressure/high-temperature process, to have a level of surface compressive stress that is greater than a compressive stress of the inner region.

Abstract: Embodiments disclosed herein are directed to a superabrasive compact including one or more superabrasive cutting portions or segments, rotary drill bits including one or more superabrasive compacts, and related methods (e.g., methods of fabricating and/or operating the superabrasive compacts). For example, the superabrasive compact may include polycrystalline diamond that may form at least a portion of a working surface of the superabrasive compact.

Abstract: A cutter for a cutting unit used in cutting apparatus suitable for creating tunnels or subterranean roadways. The cutter includes a disc body having an underside, an upper side arranged substantially opposite to the underside, and a radially peripheral part. A plurality of buttons for abrading rock are mounted in the radially peripheral part of the disc body and protrude outwardly therefrom to engage rock during an undercutting operation, wherein at least some of the buttons have a cutting part having a dome-shaped cutting surface.

Abstract: A conveying and conditioning roller for a harvesting machine is provided on the surface thereof with teeth in the form of toothed strips which extend over the longitudinal extent of the roller and in each case have a leading tooth flank and a trailing tooth flank as well as a tooth edge. The roller is provided with wear protection zones continuously or in partial regions, the wear resistance thereof being greater than that of the material of the base body of the roller. The base body has a tooth structure determining the shape of the teeth and tooth wear protection zones are formed on the trailing tooth flanks by a high energy radiation process, substantially maintaining the geometry of the tooth structure, roller wear protection zones being formed together thereby on the rollers, as well as a method for producing such a roller wear protection zone.

Abstract: Power transmission systems are provided that include polycrystalline diamond power transmission surfaces that are engaged with diamond solvent-catalyst power transmission surfaces. The power transmission systems may be or include gears, universal joints, or other power transmission systems or components.

Abstract: A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed.

Abstract: A method includes simulating a cutting tool drilling an earth formation by incrementally rotating the cutting tool at a plurality of time intervals, determining a true trajectory of a cutting element disposed on the cutting tool for the duration of the plurality of time intervals, and determining a dynamic work profile for the cutting element based on the true trajectory and a force acting on the cutting element at each time interval.

Abstract: An earth-boring tool includes a body, at least one blade extending axially from the body, at least one cutting element mounted at a leading face of the at least one blade and at least one hybrid ovoid mounted at an axial end of the at least one blade and rotationally trailing the at least one cutting element. The at least one hybrid ovoid includes a cylindrical base portion, a domed upper portion extending from a top of the cylindrical base portion, and an at least substantially planar cutting surface formed in at least the domed upper portion and defining a cutting edge extending angularly through an angle of at least 180°, the at least substantially planar cutting surface is configured for a shear-type cutting action, oriented substantially in the direction of intended bit rotation, and exhibits a lesser aggressiveness than the aggressiveness of the at least one cutting element.

Abstract: One aspect of the disclosure provides an iron-based hardfacing layer which includes hard or wear resistant phases resulting at least in part from dissolution of silicon and/or boron carbide particles into a liquid iron-based metal during the fabrication process. In an embodiment, the hardfacing layer is formed by a fusion welding process in which carbide particles are added to the molten weld pool. In an example, the filler metal supplied to the welding process is a mild steel. In an embodiment, the hardness as measured at the surface of the hardfacing ranges from 40 to 65 HRC. In an example, the iron-based hardfacing layer also includes tungsten carbide particles.

Abstract: An additive manufacturing method for making a metal matrix composite component includes melting a powdered mixture with an electron beam. The powdered mixture comprises powdered tungsten carbide in an amount of 45 wt % to 72 wt % of the powdered mixture and a powdered binder in an amount of 28 wt % to 55 wt % of the powdered mixture. The powdered binder comprises boron, silicon, and nickel.

Abstract: An improved diamond coated bit tip insert for a unitary bit/holder, tool, and/or pick for road milling operations that includes a body including a tip and a base subjacent to the tip. The tip of the bit tip insert includes a substrate and an overlay on an outer surface of the substrate. The base of the bit tip insert includes a tapered sidewall or a cylindrical sidewall, the tapered sidewall providing a greater concentration of force applied at an interface of the overlay and the substrate of the tip during a high pressure high temperature (HPHT) process than when using the cylindrical sidewall and the high pressure, high temperature process.

Abstract: A cutting device for cutting rock includes a disc and a plurality of cutting elements secured to the disc. The disc is supported for rotation about an axis of rotation, and the disc includes a peripheral edge extending around the axis of rotation. The plurality of cutting elements are spaced apart along the peripheral edge of the disc and positioned in a cutting plane. Each of the cutting elements includes a base portion and a cutting portion including a cutting edge, and the cutting portion has a width that is larger than a width of the base portion.

Abstract: Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure.

Abstract: A metal matrix composite tool includes a body having hard composite portion that includes reinforcing particles dispersed in a binder material. At least some of the reinforcing particles comprise a monolithic particle structure including a core having irregular outer surface features integral with the core.

Abstract: A method of forming a cutting element comprises forming a first material comprising discrete coated particles within a container. The first material is pressed to form a first green structure comprising interbonded coated particles. A second material comprising additional discrete coated particles is formed over the first green structure within the container. The second material is pressed to form a second green structure comprising additional interbonded coated particles. The first green structure and the second green structure are sintered to form a multi-layered cutting table. Additional methods of forming a cutting element, a cutting element, and an earth-boring tool are also described.

Abstract: A cutting element comprises a supporting substrate, and a cutting table attached to the supporting substrate and comprising a substantially planar apex, opposing flat surfaces extending upwardly and inwardly toward the substantially planar apex from locations proximate an interface between the cutting table and the supporting substrate, primary edge surfaces between the substantially planar apex and the opposing flat surfaces and exhibiting one or more of a radiused geometry and a chamfered geometry, opposing semi-conical surfaces intervening between the opposing flat surfaces and extending upwardly and inwardly toward the substantially planar apex from other locations proximate the interface between the cutting table and the supporting substrate, and secondary edge surfaces between the substantially planar apex and the opposing semi-conical surfaces and exhibiting one or more of another radiused geometry and another chamfered geometry.

Abstract: A downhole tool comprises a body made of a metal or metal alloy. In addition, the downhole tool comprises a coating disposed on the body. The coating includes at least 75 vol % tungsten carbide having an average grain size less than 1.0 ?m. The content of tungsten carbide in the coating with a grain size less than 0.5 ?m is between 40 and 64 vol % of the coating.

Abstract: PCD constructions as disclosed comprise a ultra-hard body attached with a metallic substrate along a substrate extending between the body and the substrate. The construction includes a protective feature or element that is configured to protect a metal rich region or zone existing in the construction from unwanted effects of corrosion or erosion. The protective element extends from the body over the interface and along a portion of the substrate and may be integral with the.

Abstract: A method for drilling out a plug includes directing a hybrid rotary cone drill bit having a plurality of rotary cones into a borehole lined with a casing. A body of the plug is drilled out using milled teeth formed in the hybrid rotary cone drill bit. A slip of the plug is drilled out using cutter inserts secured into the rotary cone where the slip contacts the casing. The drilled out plug is directed up the borehole using a drilling fluid.

Abstract: A cutting element comprises a supporting substrate exhibiting a three-dimensional, laterally elongate shape, and a cutting table of a polycrystalline hard material attached to the supporting substrate and comprising a non-planar cutting face. An earth-boring tool and method of forming an earth-boring tool are also described.

Abstract: A cladding structure and method for cladding machine components to inhibit crack propagation includes at least one set of primary bands, with each primary band being deposited adjacent to and abutting at least one other primary band, forming at least one inter-pass clad boundary, and at least one set of secondary bands deposited in a spaced configuration and oriented so as to intersect at least one inter-pass clad boundary.

Abstract: A part includes a three-dimensional porous metallic workpiece printed via an additive manufacturing process and subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.

Abstract: Aspects of the present disclosure relate to an apparatus including a drum rotatable about an axis of rotation and a support mount secured to the drum. The apparatus includes a support mount defining first and second fastener openings and first and second anchor openings. A replaceable holding block mounts to the support mount and the replaceable holding block has a front face and a rear face. The replaceable holding block defines a first fastener opening, a second fastener opening, and a tooth opening that extend through the replaceable holding block from the front face to the rear face. The first and second fastener openings of the replaceable holding block align with the first and second fastener openings of the support mount when the replaceable housing block is mounted to the block mounting surface. A tooth is secured to the replaceable holding block at the tooth opening.

Abstract: A multi-layer downhole drilling tool designed for drilling a wellbore including a plurality of formations includes a bit body and a plurality of primary blades and secondary blades with respective leading surfaces on exterior portions of the bit body. The drilling tool further includes a plurality of first layer cutting elements and second layer cutting elements located on the leading surfaces of the primary blades and secondary blades, respectively. Each second layer cutting element is under-exposed with respect to the corresponding first layer cutting element. The amount of under-exposure is selected according to each second layer cutting element having an initial critical depth of cut greater than an actual depth of cut for a first drilling distance and a critical depth of cut equal to zero at a target drilling depth.

Abstract: Embodiments of hardfacing layers in which wear resistant particles are substantially uniformly distributed in a matrix material are provided. The composition and microstructure of the matrix material and the amount, size and distribution of the wear resistant particles can be such that the hardfacing is wear resistant but still retains some toughness. The matrix material may include two components, a first component including iron, chromium and nickel and a second component including chromium and a substantial amount of carbon. The combination of the two components provides hardness and toughness to the matrix material. In embodiments of the disclosure, the wear resistant particles include tungsten. A hardfaced article, in one embodiment, may be formed by fusion welding an austenitic stainless steel filler metal to the surface of a base metal, thereby generating a weld pool; and adding a plurality of particles including tungsten carbide to the weld pool.

Abstract: Methods of making superabrasive elements may include forming a first superabrasive body, forming discrete components from the first superabrasive body, and then forming a second abrasive element from the discrete components. For example, microstructures (e.g., micro-cylinders or other geometries) may be formed from the first superabrasive element, catalyst materials may be removed from the microstructures, with the microstructures being recombined and bonded during a subsequent high-pressure, high-temperature (HPHT) process. In other embodiments, superabrasive elements may be formed to include microfeatures formed in a surface of a superabrasive body or table. For example, blind holes or slots may be formed in a surface of the element for use in attaching the superabrasive table to a substrate. The holes may be coated to provide an impermeable surface, or they may be filled with a metallic material to enhance the attachment to a substrate.

Abstract: The present invention relates to a polycrystalline diamond compact having multiple polycrystalline diamond sintered bodies and a method for producing the polycrystalline diamond compact. The method for producing the polycrystalline diamond includes: preparing first diamond powder; producing a first polycrystalline diamond sintered body having a diameter smaller than the diameter of a cemented substrate by sintering the first diamond powder under 5 to 6 GPa pressure and 1300 to 1500° C. temperature; positioning the first polycrystalline diamond sintered body in the center of the cemented substrate, and granulating second diamond powder around the first polycrystalline diamond sintered body; and sintering the second diamond powder under 5 to 6 GPa pressure and 1300 to 1500° C. temperature to form a second polycrystalline diamond sintered body. The polycrystalline diamond sintered body has uniform sintered characteristics at the center and outer edges thereof.

Abstract: A roller cone drill bit having at least one roller cone cutter, the roller cone cutter having multiple rows of cutting elements, arranged concentrically around the axis of rotation of the roller cone. One row of cutting elements is located on the heel of the roller cone. Each of the rows of cutting elements includes both cemented tungsten carbide inserts and milled teeth as cutting elements.

Abstract: A retention system is provided for use in connecting a shroud to a work tool. The retention system may have a mounting boss with a base portion, a shelf portion that overhangs opposing sides of the base portion, and a tapered depression formed within the base portion. The retention system may also have a replaceable lug insert removably disposed within the tapered depression.

Abstract: A Diamond Enhanced Insert (DEI) includes a working layer of a polycrystalline diamond material (PCD). The PCD material includes a first phase that includes a number of particles of a first material. The PCD material also includes a second phase that is adapted as a catalyst. The PCD material has a fracture toughness greater than 12.5 MPa·?m, a flexural strength of greater than 800 MPa, and a diamond frame strength of less than 400 MPa.

Abstract: A downhole tool includes a circumferential band having a plurality of axially adjacent weld beads forming a wear resistant surface along a particular axial length of the tool and at least one circumferential multi-layer coating applied axially adjacent the band on either end. The multi-layer coating includes a first layer, exhibiting a first color, applied directly onto the tool surface, and a second wear-resistant layer, exhibiting a second color different from the first color, applied directly onto the first layer. The second layer wears or is removed by a certain amount, such that the first color of the first layer is revealed to indicate the extent of wear and/or that the tool should be removed from service and refurbished by applying a new wear-resistant coating.

Abstract: An example drill bit for subterranean drilling operations includes a drill bit body with a blade. The drill bit may further include a cutting element and an alloy affixing the cutting element to the blade. The alloy may include a particulate phase, such as ceramic material or an intermetallic material, that increases the strength of the alloy without significantly affecting the melting point of the alloy.

Abstract: An improved diamond coated tip on a bit/holder for road milling operations has a broadened base that provides cutting overlap with adjacent bit/holders resulting in a micro milling type surface when utilizing a regular ? inch center-to-center drum.

Abstract: Methods of forming polycrystalline diamond include encapsulating diamond particles and a hydrocarbon substance in a canister, and subjecting the encapsulated diamond particles and hydrocarbon substance to a pressure and a temperature sufficient to form inter-granular bonds between the diamond particles. Cutting elements for use in an earth-boring tool include a polycrystalline diamond material formed by such processes. Earth-boring tools include such cutting elements.

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts including a substrate having a convexly-curved interfacial surface bonded to a polycrystalline diamond table. In an embodiment, a polycrystalline diamond compact includes a substrate including at least one side surface and a convexly-curved interfacial surface that may, in some embodiments, extend inwardly directly from the at least one side surface to form at least one peripheral edge therebetween. The polycrystalline diamond compact further includes a polycrystalline diamond table bonded to the convexly-curved interfacial surface of the substrate.

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a structure for enhancing at least one of abrasion resistance, thermal stability, or impact resistance. In an embodiment, a PDC includes a PCD table. The PCD table includes a lower region including a plurality of diamond grains exhibiting a lower average grain size and at least an upper region adjacent to the lower region and including a plurality of diamond grains exhibiting an upper average grain size. The lower average grain size may be at least two times greater than that of the upper average grain size. The PDC includes a substrate having an interfacial surface that is bonded to the lower region of the PCD table. Other embodiments are directed methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Abstract: A cutting element for an earth-boring tool includes a substrate and a volume of superabrasive material disposed on a substrate. The volume of superabrasive material has an exposed outer surface with a non-planar geometry. The cutting element is configured to be located and oriented on an earth-boring tool so as to remove subterranean earth formation material by compressing and fracturing or plastically deforming the formation material with at least a portion of the exposed outer surface of the volume of superabrasive material during use of the earth-boring tool in an earth-boring operation. The exposed outer surface of the volume of superabrasive material includes a first area having a first average surface finish roughness and a second area having a second average surface finish roughness greater than the first average surface finish roughness. Earth-boring tools carrying such cutting elements and methods of forming such earth-boring tools are also disclosed.

Abstract: Methods of forming a polycrystalline diamond compact for use in an earth-boring tool include forming a body of polycrystalline diamond material including a first material disposed in interstitial spaces between inter-bonded diamond crystals in the body, removing the first material from interstitial spaces in a portion of the body, selecting a second material promoting a higher rate of degradation of the polycrystalline diamond compact than the first material under similar elevated temperature conditions and providing the second material in interstitial spaces in the portion of the body. Methods of drilling include engaging at least one cutter with a formation and wearing a second region of polycrystalline diamond material comprising a second material faster than the first region of polycrystalline diamond material comprising a first material. Polycrystalline diamond compacts and earth-boring tools including such compacts.

Abstract: The polycrystalline diamond compact cutter includes a diamond table and a carbide substrate. Different zones of the diamond table with relative thermal stability and toughness to each other are arranged for a particular cutting efficiency and working life. A thermally stable zone has a metal formation agent removed and forms a top outer ring. A base zone bonds to the carbide substrate on the bottom surface of the diamond table. An anchor zone sets between the thermally stable zone and the base zone, and an absorbing zone extends from the top surface to the base zone. The absorbing zone is circumscribed by the thermally stable zone and the anchor zone. The weight percentage metal content of the anchor zone is less than weight percentage metal content of the base zone. The weight percentage metal content of the base zone is less than weight percentage metal content of the absorbing zone.

Abstract: A drill bit may include a matrix bit body and a plurality of cutting elements coupled to an exterior portion of the matrix bit body, wherein the matrix bit body includes matrix particles and precipitated intermetallic particles dispersed in a binder, at least some of the matrix particles having a diameter of 50 microns or greater, and at least some of the precipitated intermetallic particles having at least one dimension of 1 micron to 30 microns.

Abstract: An emergency warning light assembly has features that enable changing a color of light emitted from the assembly and changing a beam pattern and beam intensity of light emitted from the assembly.

Abstract: The Smart Reamer® Tool, Apparatus or Method is used to underream an oil or natural gas well while interlinked calipers and calibration sensors simultaneously record data relating to the geometry of the drilling operation (well diameter, diameter of the underreamed zone) and drilling fluid properties (density). Further sensors provide data on the relative position of the cutting and stabilizing blocks. Other sensors measure vibration data. All the sensors are interlinked by means of microprocessors which compare and correlate said data to automatically verify and deliver a desired wellbore diameter without the need to unnecessarily stop drilling or trip out of the hole.

Abstract: A fixed bladed drill bit has a working face that includes a plurality of blades converging at a center of the working face and diverging towards a gauge of the bit, each blade having a leading face and a trailing face, and at least one row of cutting elements disposed on at least one of the plurality of blades proximate to the leading face of the blade, where the row of cutting elements includes at least one pointed cutting element having a cutting end with a rounded apex and at least one shearing cutter. The at least one shearing cutter includes a first shearing cutter positioned proximate to a periphery of the working face.

Abstract: Drill bits with at least two roller cones of different diameters and/or utilizing different cutter pitches in order to reduce bit tracking during drilling operations are described. In particular, earth boring drill bits are provided, the bits having two or more roller cones, and optionally one or more cutter blades, the bits being arranged for reducing tracking by the roller cone teeth during operation by adjusting the teeth spacing, cone pitch angle, and/or the diameter of one or more of the cones. These configurations enable anti-tracking behavior and enhanced drilling efficiency during bit operation.

Abstract: In an embodiment, a superabrasive compact is disclosed in which a heat-absorbing material having a phase-transition temperature lower than a peak operating temperature of a superabrasive table of the superabrasive compact is positioned in the superabrasive compact. In some embodiments, the heat-absorbing material positioned between the substrate and the superabrasive table. In another embodiment, a rotary drill bit is also disclosed including a bit body and at least one cutting element including a substrate and a superabrasive table bonded to the substrate. At least one heat-absorbing material is positioned within the bit body at least proximate to the at least one cutting element.