Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline diamond cutting (PDC) element of a drill bit of a downhole drilling tool is provided. The PDC element having a substrate, a diamond table and at least one pattern. The diamond table has an initial cutting edge along a periphery thereof. The pattern integrally formed within the diamond table. The pattern(s) defining at least one discontinuity about the diamond table that, in operation, selectively breaks away upon impact to create new cutting edges in the diamond table whereby a sharp cutting edge is continuously exposed to a material being cut.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline diamond cutting (PDC) element of a drill bit of a downhole drilling tool is provided. The PDC element having a substrate, a diamond table and at least one pattern. The diamond table has an initial cutting edge along a periphery thereof. The pattern integrally formed within the diamond table. The pattern(s) defining at least one discontinuity about the diamond table that, in operation, selectively breaks away upon impact to create new cutting edges in the diamond table whereby a sharp cutting edge is continuously exposed to a material being cut.

Abstract: A cutting element has a substrate with a non-planar, non-linear surface bonded to a superhard element. The substrate provides one or more non-linear grooves radially mounted in spaced relationships on the surface of the substrate. Each groove has a generally curved shape that unfurls from a first circle on the substrate towards a perimeter of the substrate. The groove shape is defined by complex functions, examples of which include high order polynomials and involutes. The depth and width of the groove varies, generally in an increasing manner, along the path from the first circle towards the substrate perimeter. Further, the pitch of the groove also varies along the path from the first circle towards the substrate perimeter.