Abstract: Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

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).

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 tip for twist drill, comprising a super-hard structure joined to a substrate at an interface boundary coterminous with an end of the substrate, the super-hard structure comprising sintered polycrystalline material comprising super-hard grains, the super-hard structure defining a super-hard end surface opposite the interface boundary and a plurality of cutting edges configured for boring into a body in use; the super-hard end surface including a center point or chisel edge, and comprising a plurality of surface regions configured such that respective planes tangential to each of the surface regions are disposed at substantially different angles from the axis of rotation of the tip in use. Precursor constructions for use in manufacturing the tips as well as methods for making the precursor constructions and the tips are disclosed.

Abstract: A tip (20) for a rotary machine tool comprising a superhard structure (12) joined to a cemented carbide substrate 14 by means of at least one intermediate layer (161, 62, 163) disposed between the superhard structure (12) and the cemented carbide substrate (14), the intermediate layer or layers (161, 162, 163) comprising grains of superhard material and grains of a metal carbide material dispersed in a metal binder material.

Abstract: The invention relates to an insert for an attack tool, the insert comprising a super-hard cap having a volume and bonded to a substrate at an interface, the super-hard cap having an average Young's modulus of greater than 900 GPa and the substrate characterized in that it comprises a reinforcing bolster portion as a means for stiffening a region of the substrate proximate the interface, the reinforcing bolster portion having an aggregate volume that is greater than that of the super-hard cap and an average Young's modulus at least 60% that of the super-hard cap. The invention further relates to a method for manufacturing such an insert and a method for using such an insert.

Abstract: A tip for a pick tool, comprising a polycrystalline diamond (PCD) structure joined to a substrate body. The PCD structure has a strike surface including an apex opposite a boundary with the substrate body. At least an outer volume of the PCD structure contains filler material between diamond grains, the content of the filler material being more than 5 weight percent of the PCD material in the outer volume. The outer volume is proximate at least an area of the strike surface including the apex, and the thickness of the PCD structure between the apex and the boundary with the substrate body is at least 2.5 mm.

Abstract: Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

Abstract: A pick tool comprising a super-hard strike tip, a base and a unitary cemented carbide support body comprising a head portion including an overhang portion, and an insertion shaft extending from the head portion, a surface of the overhang portion extending laterally from the insertion shaft; the strike tip is attached to the head portion of the support body and the base is provided with a bore into which the insertion shaft is shrink fitted; the base has an external surface adjacent the bore and overhang portion of the head portion is configured to extend over at least an area of the external surface operative to shield the area from wear when in use.

Abstract: Tips for pick tools and pick tools comprising same are provided. The tip comprises an impact structure formed joined at a non-planar boundary surface of a substrate. The boundary surface includes a depression. The impact structure comprises super-hard material and has a working end including an apex opposite the depression. The boundary surface of the substrate comprises a ridge at the periphery of the depression and a generally tapered circumferential region depending away from the ridge towards a side of the tip, a lowest point of the depression being directly opposite the apex.

Abstract: A tip for a degradation tool, the tip comprising a PCD structure (20) joined to a cemented carbide substrate (30); the PCD structure comprising a plurality of strata (24, 25) arranged so that adjacent strata have alternating compressive and tensile stress states, adjacent strata comprising different PCD grades and being directly bonded to each other by inter-growth of diamond grains; each stratum having a mean thickness of at most 500 microns; the PCD structure defining a working end including a rounded conical apex (22) having a radius of curvature of 1.3 mm to 4 mm.

Abstract: Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body.

Abstract: A strike tip for a pick tool, comprising a strike structure joined to a substrate at an interface boundary, the strike structure comprising super-hard material and the substrate comprising carbide material. The strike structure has a strike end opposite the interface boundary, the strike end including a rounded apex having a radius of curvature in a longitudinal plane of at least 3.2 mm and at most 6 mm.

Abstract: A pick tool for degrading asphalt or rock, comprising a PCD element; the PCD element comprising a PCD structure (20) bonded to a cemented carbide support body (30) at an interface; the PCD structure comprising a first region (24) and a second region (25) adjacent the first region, the second region bonded to the first region by intergrowth of diamond grains; the first region (24) comprising a plurality of alternating strata (24c, 24t), each stratum having a thickness in the range of about 30 to 300 microns; the second region comprising a plurality of strata (25a, 25b), one or more strata in the second region (25a) having a thickness greater than the thicknesses of the individual strata in the first region (24c, 24t), wherein the alternating strata in the first region (24) comprise first strata alternating with second strata, the first strata being in a state of residual compressive stress and the second strata being in a state of residual tensile stress.

Abstract: A pick assembly (100) comprising a pick tool (200), a pick holder (300) and a rotatable drive means (400); in which the pick holder is attached to the rotatable drive means and the pick tool comprises a base (220) and a strike element (210) capable of being attached to the base, the strike element comprising a strike tip (212) defining a strike tip axis (213) and the base capable of being attached to the pick holder; the pick holder and pick tool being configured in relation to the drive means operative to the strike tip axis being oriented to within a strike angle of at most 5 degrees with a strike plane on which the strike tip will travel when driven by the drive means.

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).

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 pick tool comprising a super-hard strike tip, a base and a unitary cemented carbide support body comprising a head portion including an overhang portion, and an insertion shaft extending from the head portion, a surface of the overhang portion extending laterally from the insertion shaft; the strike tip is attached to the head portion of the support body and the base is provided with a bore into which the insertion shaft is shrink fitted; the base has an external surface adjacent the bore and overhang portion of the head portion is configured to extend over at least an area of the external surface operative to shield the area from wear when in use.

Abstract: A strike tip for a pick tool, comprising a strike structure joined to a substrate at an interface boundary, the strike structure comprising super-hard material and the substrate comprising carbide material. The strike structure has a strike end opposite the interface boundary, the strike end including a rounded apex having a radius of curvature in a longitudinal plane of at least 3.2 mm and at most 6 mm.

Abstract: A tip for a pick tool, comprising a polycrystalline diamond (PCD) structure joined to a substrate body. The PCD structure has a strike surface including an apex opposite a boundary with the substrate body. At least an outer volume of the PCD as structure contains filler material between diamond grains, the content of the filler material being more than 5 weight percent of the PCD material in the outer volume. The outer volume is proximate at least an area of the strike surface including the apex, and the thickness of the PCD structure between the apex and the boundary with the substrate body is at least 2.5 mm.