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: Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

Abstract: An insert for a drill bit that includes diamond particles disposed in a matrix material, wherein the diamond particles have a contiguity of 15% or less is disclosed. A method of forming a diamond-impregnated cutting structure, that includes loading a plurality of substantially uniformly coated diamond particles into a mold cavity, pre-compacting the substantially uniformly coated diamond particles using a cold-press cycle, and heating the compacted, substantially uniformly coated diamond particles with a matrix material to form the diamond impregnated cutting structure is also disclosed.

Abstract: Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

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: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the crystals. A metallic substrate is attached to the diamond body. A working surface is positioned along an outside portion of the diamond body, and the diamond body comprises a first region that is substantially free of a catalyst material, and a second region that includes the catalyst material. The diamond body first region extends from the working surface to depth of at least about 0.02 mm to a depth of less than about 0.09 mm. The diamond body includes diamond crystals having an average diamond grain size of greater than about 0.02 mm, and comprises at least 85 percent by volume diamond based on the total volume of the diamond body.

Abstract: A lubricant for a drill bit that includes from about 0.1 to about 10 weight percent of at least one nanomaterial, from about 5 to 40 weight percent of a thickener, and a basestock is disclosed.

Abstract: A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB2 in exemplary embodiments.

Abstract: A method for making a thermally stable cutting element may include forming an acid mixture containing two different acid species by combining an acid solution and at least one acid-forming compound, wherein the at least one acid-forming compound is provided in solid form, and wherein the at least one acid-forming compound produces an acid that is different than the acid solution; treating at least a portion of a sintered diamond body by placing the sintered diamond body in the acid mixture, wherein the sintered diamond body comprises: a matrix phase of bonded-together diamond grains; a plurality of interstitial regions dispersed within the matrix phase; and a metal material disposed within a plurality of the interstitial regions; wherein the treating removes the metal material from at least a portion of the plurality of interstitial regions; and removing the sintered diamond body from the acid mixture after a predetermined length of time, wherein at least a portion of the diamond body removed from the acid mi

Abstract: A hardfacing composition for a drill bit, including a carbide phase comprising from about 50% to about 75% by weight of the hardfacing composition of a combination of 16 to 40 mesh cemented tungsten carbide and 80 to 200 mesh super dense tungsten carbide cobalt particles, wherein about 5% to about 50% by weight of the carbide phase comprises the super dense tungsten carbide cobalt particles, and a binder alloy including about 25% to about 50% by weight of the hardfacing composition.

Abstract: Polycrystalline diamond (PCD) carbide composites of this invention have a microstructure comprising a plurality of granules formed from PCD, polycrystalline cubic boron nitride, or mixture thereof, that are distributed within a substantially continuous second matrix region that substantially surrounds the granules and that is formed from a cermet material. In an example embodiment, the granules are polycrystalline diamond and the cermet material is cemented tungsten carbide. PCD carbide composites of this invention display improved properties of fracture toughness and chipping resistance, without substantially compromising wear resistance, when compared to conventional pure PCD materials.

Abstract: A bit body formed of a mixture of matrix material and superabrasive powder and including pockets lined with superabrasive-free matrix material, and a method for forming the same, are provided. The pockets are shaped to receive cutting elements therein. The superabrasive-free matrix material enhances braze strength when a cutting element is brazed to surfaces of the pocket. The method for forming the drill bit body includes providing a mold and displacements. The displacements are coated with a mixture of superabrasive free matrix-material and an organic binder. The mold is packed with a mixture of matrix material and superabrasive powder and the arrangement heated to form a solid drill bit body. When the solid bit body is removed from the mold, pockets are formed by the displacements in the bit body and are lined with the layer of superabrasive-free matrix material. The superabrasive material may be diamond, polycrystalline cubic boron nitride, SiC or TiB2 in exemplary embodiments.

Abstract: Polycrystalline diamond constructions include a diamond body comprising a matrix phase of bonded together diamond crystals formed at high pressure/high temperature conditions with a catalyst material. The sintered body is treated remove the catalyst material disposed within interstitial regions, rendering it substantially free of the catalyst material used to initially sinter the body. Accelerating techniques can be used to remove the catalyst material. The body includes an infiltrant material disposed within interstitial regions in a first region of the construction. The body includes a second region adjacent the working surface and that is substantially free of the infiltrant material. The infiltrant material can be a Group VIII material not used to initially sinter the diamond body. A metallic substrate is attached to the diamond body, and can be the same or different from a substrate used as a source of the catalyst material used to initially sinter the diamond body.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.

Abstract: Roller cone bits of this invention include a steel bit body having at least one leg extending therefrom. A steel cone is rotatably disposed on the leg. The steel cone includes a plurality of steel cutting elements that each project outwardly a distance therefrom. At least one of the cutting elements comprises a steel base portion that is integral with the cone and that projects a distance therefrom. A cutting element end portion is attached to the base portion and extends therefrom to form a tip of the cutting element. The base and end portions are permanently attached together when the cone and base are in a preexisting rigid state. The cutting element end portion is formed from a wear resistant material having a material microstructure comprising a first phase of grains selected from the group of carbides, borides, nitrides, and carbonitrides of W, Ti, Mo, Nb, V, Hf, Ta, and Cr refractory metals; and a second phase of a binder material selected from the group consisting of Co, Ni, Fe, and alloys thereof.

Abstract: Thermally-stable polycrystalline diamond materials of this invention comprise a first phase including a plurality of bonded together diamond crystals, and a second phase including a reaction product formed between a binder/catalyst material and a material reactive with the binder/catalyst material. The reaction product is disposed within interstitial regions of the polycrystalline diamond material that exists between the bonded diamond crystals. The first and second phases are formed during a single high pressure/high temperature process condition. The reaction product has a coefficient of thermal expansion that is relatively closer to that of the bonded together diamond crystals than that of the binder/catalyst material, thereby providing an improved degree of thermal stability to the polycrystalline diamond material.

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: Ultra-hard composite constructions comprise an ultra-hard body having a plurality of diamond crystals bonded to one another by a carbide reaction product. A reactant material is selected from materials that are strong carbide formers to form a carbide reaction product with diamond at HPHT conditions. The body includes a high-density diamond region positioned along a surface portion of the body and that is substantially exclusively diamond, and that has a diamond volume content of 95 to 99 percent or more. The high-density diamond region can form a working surface of the composite construction. A substrate can be attached to the body, thereby forming a compact, and can include metallic materials, ceramic materials, carbides, nitrides, cermets, and mixtures thereof. An intermediate layer can be interposed between the body and the substrate depending on the substrate and/or method of attaching the same.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.

Abstract: A bit for drilling subterranean formations that includes a bit body including a bearing surface; a cutting structure mounted on the bit body, and including a bearing surface, and an annular seal for retaining a grease between the bearing surfaces, the annular seal comprising a flexible and resilient seal body formed from an elastomer composition, wherein the elastomer composition comprises an elastomer material, a curing agent, and 10% or less by volume of a nanomaterial additive selected from one of nanotubes and clustered nanodiamonds is disclosed.