Abstract: A thermally stable ultra-hard material, a cutting element incorporating such thermally stable ultra-hard material, and methods for forming the same. A thermally stable ultra-hard diamond element is combined with a second ultra-hard material volume forming an assembly. One or more surfaces of the thermally stable diamond element that face the second diamond volume are coated with a coating prior to combining the thermally stable diamond element with the second diamond volume. The assembly is sintered at high pressure and high temperature to form PCD from the second diamond volume.

Abstract: A method of producing a steel material includes a step of adding Ca to molten steel with an amount of Ca adjusted within a range satisfying the formula (1) below: 0.5 ? { Ca · y ? / ? 100 - ( [ S · W ? / ? 100 ) · 40.08 ? / ? 32.07 } ? 56.08 40.08 ( [ Al 2 ? O 3 ] · W ? / ? 100 ) ? 1.5 ( 1 ) where Ca is the amount [kg] of Ca added, y is an yield [%] of Ca, [S] is a concentration [% by mass] of S in the steel before addition of Ca, [Al2O3] is an amount [% by mass] of Al2O3 in the steel before addition of Ca, and W is a weight [kg] of the molten steel.

Abstract: A method of making a body of polycrystalline superhard material comprising placing an aggregated mass of grains of superhard material into a canister, placing a ceramic layer either in direct contact with the aggregated mass of grains of superhard material or in indirect contact therewith, the ceramic layer being spaced from the grains by an interlayer of material when present, the ceramic layer having a surface with surface topology, the surface topology imprinting a pattern in the aggregated mass of grains of superhard material complementary to the surface topology, the ceramic material and the material of the interlayer being such that they do not react chemically with the superhard material and/or a sinter catalyst material for the grains of superhard material. The aggregated mass of grains of superhard material and ceramic layer are subjected to a pressure of greater than 5.

Abstract: A method of making a cutter structure (1) comprises placing a pre-formed body (4) of hard material having a surface topography in a canister, placing an aggregated mass of grains of superhard material (2) over said surface topography, placing a punch (10) in contact with the superhard material (2), the punch (10) having a surface with a surface topography inverse to that of the hard material body to imprint a pattern in the superhard material (2) complementary to the surface topography of the punch (10). The surface of the punch (10) contacting the superhard material (2) being formed of a ceramic material that does not react chemically with the superhard material (12) and/or a sinter catalyst for the superhard material (2).