Abstract: A polycrystalline compact comprises a plurality of diamond grains of micron size, submicron size, or both, and a plurality of crushed diamond nanoparticles disposed in interstitial spaces between the plurality of diamond grains. A method of forming a polycrystalline compact comprises combining a plurality of micron and/or submicron-sized diamond grains and a plurality of crushed diamond nanoparticles to form a mixture and sintering the mixture in a presence of a binder to form a polycrystalline hard material comprising a plurality of inter-bonded diamond grains and diamond nanoparticles. Cutting elements comprising a polycrystalline compact and earth-boring tools bearing such compacts are also disclosed.

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: 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 are also disclosed.

Abstract: A polycrystalline compact comprises a plurality of grains of hard material and a plurality of nanoparticles disposed in interstitial spaces between the plurality of grains of hard material. The plurality of nanoparticles has a thermal conductivity less than a thermal conductivity of the plurality of grains of hard material. An earth-boring tool comprises such a polycrystalline compact. A method of forming a polycrystalline compact comprises combining a plurality of hard particles and a plurality of nanoparticles to form a mixture and sintering the mixture to form a polycrystalline hard material comprising a plurality of interbonded grains of hard material. A method of forming a cutting element comprises infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of nanoparticles. The plurality of nanoparticles have a lower thermal conductivity than the interbonded grains of hard material.

Abstract: Polycrystalline compacts include non-catalytic, non-carbide-forming particles in interstitial spaces between interbonded grains of hard material in a polycrystalline hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming polycrystalline compacts include forming a polycrystalline material including a hard material and a plurality of particles comprising a non-catalytic, non-carbide-forming material. Methods of forming cutting elements include infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of non-catalytic, non-carbide-forming particles.

Abstract: A method of forming polycrystalline diamond includes forming metal nanoparticles having a carbon coating from an organometallic material; combining a diamond material with the metal nanoparticles having the carbon coating; and processing the diamond material and the metal nanoparticles having the carbon coating to form the polycrystalline diamond. Processing includes catalyzing formation of the polycrystalline diamond by the metal nanoparticles; and forming interparticle bonds that bridge the diamond material by carbon from the carbon coating.

Abstract: Methods of forming a polycrystalline element comprise forming a polycrystalline table on a first substrate. Catalyst material may be removed from at least a portion of the polycrystalline table. The polycrystalline table and a portion of a first substrate attached to the polycrystalline table may be removed from a remainder of the first substrate. The portion of the first substrate may be attached to another substrate. Polycrystalline elements comprise a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed another substrate attached to the portion of the first substrate.

Abstract: Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprise a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material.

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: A pressure pulse is initiated from the wellbore into the fractured formation where the frac fluid brings into the fractures a material that is responsive to the pressure pulse alone. Alternatively, or with a combination with a wellbore pressure pulse, well conditions such as time exposure and temperature can initiate local pressure pulses within the fracture with the result being signal generation of an electromagnetic signal that is measured with multiple sensors to allow triangulation of the location of the fracture extremities. The material can be a piezoelectric material that responds to the pressure pulse or ferromagnetic materials that similarly respond to the pulse to create the measured signals. The material can be delivered initially with the frac fluid or at different points in time during the fracture operation. Different materials with unique signal generating characteristics can be used to get a clearer picture of the extent of the fracture.

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 are also disclosed.

Abstract: A polycrystalline compact comprises a plurality of diamond grains of micron size, submicron size, or both, and a plurality of diamond nanoparticles disposed in interstitial spaces between the plurality of diamond grains. A method of forming a polycrystalline compact comprises combining a plurality of micron and/or submicron-sized diamond grains and a plurality of diamond nanoparticles to form a mixture and sintering the mixture in a presence of a carburized binder to form a polycrystalline hard material comprising a plurality of inter-bonded diamond grains and diamond nanoparticles. Cutting elements comprising a polycrystalline compact and earth-boring tools bearing such compacts are also disclosed.

Abstract: Polycrystalline compacts include a hard polycrystalline material comprising first and second regions. The first region comprises a first plurality of grains of hard material having a first average grain size, and a second plurality of grains of hard material having a second average grain size smaller than the first average grain size. The first region comprises catalyst material disposed in interstitial spaces between inter-bonded grains of hard material. Such interstitial spaces between grains of the hard material in the second region are at least substantially free of catalyst material. In some embodiments, the first region comprises a plurality of nanograins of the hard material. Cutting elements and earth-boring tools include such polycrystalline compacts.

Abstract: Method of fabricating polycrystalline diamond include functionalizing surfaces of diamond nanoparticles with fluorine, combining the functionalized diamond nanoparticles with a polymer to form a mixture, and subjecting the mixture to high pressure and high temperature (HPHT) conditions to form inter-granular bonds between the diamond nanoparticles. A green body includes a plurality of diamond nanoparticles functionalized with fluorine, and a polymer material interspersed with the plurality of diamond nanoparticles. A method of forming cutting element includes functionalizing surfaces of diamond nanoparticles with fluorine, and combining the functionalized diamond nanoparticles with a polymer to form a mixture. The mixture is formed over a body, and the mixture and the body are subjected to HPHT conditions to form inter-granular bonds between the diamond nanoparticles and secure the bonded diamond nanoparticles to the body.

Abstract: Earth-boring tools may comprise a body comprising a first region and a second region. The first region may be located closer to a rotational axis of the body than the second region. A first cutting element may be located in the first region and a second cutting element may be located in the second region. A first polycrystalline table of the first cutting element may be substantially free of catalyst material to a first depth and a second polycrystalline table of the second cutting element may be substantially free of catalyst material to a second, greater depth.

Abstract: Polycrystalline compact tables for cutting elements include regions of grains of super hard material. One region of grains (“first grains”) and another region of grains (“second grains”) have different properties, such as different average grain sizes, different super hard material volume densities, or both. The region of first grains and the region of second grains adjoin one another at grain interfaces that may include a curved portion in a vertical cross-section of the table. In some embodiments, discrete regions of the first grains may be vertically disposed between discrete regions of the second grains. As such, the tables have ordered grain regions of different properties that may inhibit delamination and crack propagation through the table when used in conjunction with a cutting element. Methods of forming the tables include forming the regions and subjecting the grains to a high-pressure, high-temperature process to sinter the grains.

Abstract: Polycrystalline compacts include smaller and larger hard grains that are interbonded to fox in a polycrystalline hard material. The larger grains may be at least about 150 times larger than the smaller grains. An interstitial material comprising one or more of a boride, a carbide, a nitride, a metal carbonate, a metal bicarbonate, and a non-catalytic metal may be disposed between the grains. The compacts may be used as cutting elements for earth-boring tools such as drill bits, and may be disposed on a substrate. A particulate mixture includes a first plurality of grains of hard material having a first average grain size of about five hundred nanometers (500 nm) or less and having a coating formed over the grains of hard material. The coating comprises at least one of a boride, a carbide, a nitride, a metal carbonate, a metal bicarbonate, and a non-catalytic metal.

Abstract: A Polycrystalline Diamond Compact (PDC) cutter for a rotary drill bit is provided with an integrated sensor and circuitry for making measurements of a property of a fluid in the borehole and/or an operating condition of the drill bit. A method of manufacture of the PDC cutter and the rotary drill bit is discussed.

Abstract: Cutting elements include at least one metal diffused into interbonded grains of diamond. Earth-boring tools include at least one such cutting element. Methods of fanning cutting elements may include forming a mixture of the at least one metal salt and a plurality of grains of hard material and sintering the mixture to form a hard polycrystalline material. During sintering, the metal salt may melt or react with another compound to form a liquid that acts as a lubricant to promote rearrangement and packing of the grains of hard material. The metal salt may, thus, enable formation of hard polycrystalline material having increased density, abrasion resistance, or strength. The metal salt may also act as a getter to remove impurities (e.g., catalyst material) during sintering. The methods may also be employed to form cutting elements and earth-boring tools.

Abstract: Polycrystalline compacts include non-catalytic, non-carbide-forming particles in interstitial spaces between interbonded grains of hard material in a polycrystalline hard material. Cutting elements and earth-boring tools include such polycrystalline compacts. Methods of forming polycrystalline compacts include forming a polycrystalline material including a hard material and a plurality of particles comprising a non-catalytic, non-carbide-forming material. Methods of forming cutting elements include infiltrating interstitial spaces between interbonded grains of hard material in a polycrystalline material with a plurality of non-catalytic, non-carbide-forming particles.