Abstract: A method, system and apparatus for testing properties of a hard component. The apparatus includes a holder, a component, an indenter, a sensor holder, and an acoustic sensor. The holder includes a first end and a second end opposite the first end. The first end defines a first cavity extending towards the second end. The component is positioned in the first cavity. The indenter is positioned adjacent to a portion of the component and applies a load onto the component. The sensor holder includes an upper portion, a lower portion, and a second cavity therein. The upper portion is coupled to the second end. The sensor is positioned within the second cavity. In some embodiments, the apparatus includes a rod coupled to the lower portion. The rod has a lower acoustic impedance than the sensor holder, thereby allowing sound waves to pass through the sensor holder and not be reflected back into the sensor.

Abstract: A cutting element that includes a substrate; and an outer layer of polycrystalline diamond material disposed upon the outermost end of the cutting element, wherein the polycrystalline diamond material: a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the bonded diamond particles, wherein the plurality of interstitial regions contain a plurality of metal carbide phases and a plurality of metal binder phases together forming a plurality of metallic phases, wherein the plurality of metal carbide phases are formed from a plurality of metal carbide particles; wherein the plurality of interconnected diamond particles form at least about 60 to at most about 80% by weight of the polycrystalline diamond material; and wherein the plurality of metal carbide phases represent at least 50% by weight of the plurality of metallic phases is disclosed.

Abstract: An insert for a drill bit may include a metallic carbide body; an outer layer of polycrystalline diamond material on the outermost end of the insert, the polycrystalline diamond material comprising a plurality of interconnected first diamond grains and a first binder material in interstitial regions between the interconnected first diamond grains; and at least one transition layer between the metallic carbide body and the outer layer, the at least one transition layer comprising a composite of second diamond grains, first metal carbide particles, and a second binder material, wherein the second diamond grains have a larger grain size than the first diamond grains.

Abstract: A post manufacture method and apparatus for reducing residual stresses present within a component. The component includes a substrate, a polycrystalline structure coupled thereto, and residual stresses present therein. The method includes obtaining a component from a component category, determining a critical temperature and a critical time period for the component category at which the component becomes structurally impaired, determining a heat treatment temperature and a heat treatment time period based upon the critical temperature and the critical time period, and heating one or more remaining components from the component category to the heat treatment temperature for the heat treatment time period. The apparatus includes a heater defining a heating chamber and a molten bath positioned within the heating chamber. The components are placed within the pre-heated molten bath and isolated from oxygen during heating to the heat treatment temperature for the heat treatment time period.

Abstract: A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth.

Abstract: A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth.

Abstract: A target cylinder, a method for testing a superhard component thereon, and a method for selecting an untested component for use in field applications. The target cylinder includes a first end, a second end, and a side wall extending from the first end to the second end. At least one of the second end and the sidewall is an exposed portion that makes contact with the superhard component to determine at least one property of the superhard component. The target cylinder is formed from a first material evenly distributed throughout a second material. Upon testing superhard components at one or more impact frequencies, untested superhard components are selected based upon field anticipated impact frequencies.

Abstract: A mixture for fabricating a cutting table, the cutting table, and a method of fabricating the cutting table. The mixture includes a cutting table powder and a binder. The binder includes at least one carbide formed from an element selected from at least one of Groups IV, V, and VI of the Periodic Table. The carbide is in its non-stoichiometric and/or stoichiometric form. The binder can include the metal element itself. The binder can also include a catalyst. The cutting table is formed by sintering the mixture using a solid phase sintering process or a near solid phase sintering process. When forming or coupling the cutting table to a substrate, a divider is positioned and coupled therebetween to ensure that the sintering process that forms the cutting table occurs using the solid phase sintering process or the near solid phase sintering process.

Abstract: A method, system, and apparatus for non-destructively characterizing one or more regions within an ultra-hard polycrystalline structure using eddy current measurements. The apparatus includes an eddy current measuring device having at least one terminal, a leached component comprising a polycrystalline structure, a first wire, and a probe. The leached component includes a cutting surface and an opposing second surface. A portion of the polycrystalline structure extending inwardly from the cutting surface has at least a portion of a catalyst material removed from therein. The first wire electrically couples the terminal to the probe, which is placed in contact with the cutting surface. The eddy current is measured one or more times and compared to a calibration curve to determine an estimated leaching depth within the polycrystalline structure. A data scattering range is ascertained to determine a relative porosity of the polycrystalline structure or the leaching quality within the polycrystalline structure.

Abstract: A method, system, and apparatus for non-destructively characterizing one or more regions within an ultra-hard polycrystalline structure using capacitance measurements. The apparatus includes a capacitance measuring device having a positive and negative terminal, a leached component comprising a polycrystalline structure, a first wire, and a second wire. The leached component includes a first surface and an opposing second surface. The first wire electrically couples the positive terminal to one of the surfaces of the leached component and the second wire electrically couples the negative terminal to the other surface of the leached component. The capacitance is measured one or more times and compared to a calibration curve to determine an estimated leaching depth within the polycrystalline structure. A data scattering range is ascertained to determine a relative porosity of the polycrystalline structure or the leaching quality within the polycrystalline structure.

Abstract: A cleaned component having a polycrystalline structure, a method and apparatus for cleaning a leached component to form the cleaned component, and a method for determining the effectiveness of cleaning the leached component. The cleaned component includes a leached layer that has at least a portion of by-product materials removed. The by-product materials were deposited into the leached layer during a leaching process that formed the leached layer. The apparatus and method for cleaning includes a tank, a cleaning fluid placed within the tank, and at least a portion of the leached layer immersed into the cleaning fluid. Optionally, a transducer emits ultrasonic waves into the leached layer. The method for determining the effectiveness of cleaning includes cleaning the leached component to form the cleaned component, measuring one or more capacitance values of the cleaned component, repeating the cleaning and the measuring until achieving a stable lower limit capacitance value.

Abstract: A cleaned component having a polycrystalline structure, a method and apparatus for cleaning a leached component to form the cleaned component, and a method for determining the effectiveness of cleaning the leached component. The cleaned component includes a leached layer that has at least a portion of by-product materials removed. The by-product materials were deposited into the leached layer during a leaching process that formed the leached layer. The apparatus and method for cleaning includes a tank, a cleaning fluid placed within the tank, and at least a portion of the leached layer immersed into the cleaning fluid. Optionally, a transducer emits ultrasonic waves into the leached layer. The method for determining the effectiveness of cleaning includes cleaning the leached component to form the cleaned component, measuring one or more capacitance values of the cleaned component, repeating the cleaning and the measuring until achieving a stable lower limit capacitance value.

Abstract: A method for non-destructively characterizing one or more regions within a polycrystalline structure using capacitance and eddy current measurements. The eddy current measurements include at least one of an impedance amplitude and a phase shift angle. The capacitance is measured one or more times and compared to a first calibration curve to determine an estimated leaching depth within the polycrystalline structure. A first data scattering range is ascertained from the capacitance measurements to determine a relative porosity or the leaching quality within the polycrystalline structure. The eddy current is measured one or more times and compared to a second calibration curve to determine an estimated leaching depth within the polycrystalline structure. A second data scattering range is ascertained from the eddy current measurements to determine a relative porosity or the leaching quality within the polycrystalline structure.

Abstract: An acoustic emissions testing device includes a test cutter including a first surface, an acoustic sensor, an indenter coupled to the first surface, and a load. The load is exerted on the indenter, which transfers the load to the first surface. The acoustic sensor is communicably coupled to the test cutter and detects one or more acoustic events occurring therein. An acoustic emissions testing system includes a data recorder coupled to the testing device. The data recorder records the data from testing device. Based upon the data received, the toughness of the test cutter is objectively determined and can be ranked comparatively to the toughness of other test cutters. The load is ramped up to a peak load, held for a period of time, and then ramped down. Cutters from the same cutter type as the test cutters have similar toughness.

Abstract: A target cylinder and a method for testing a superhard component thereon. The target cylinder includes a first end, a second end, and a sidewall extending from the first end to the second end. At least one of the second end and the sidewall is an exposed portion that makes contact with the superhard component to determine at least one property of the superhard component. The exposed portion comprises at least one synthetic material having at least one of a compressive strength raging from about 12 kpsi to about 30 kpsi, an abrasiveness ranging from about 1 Cerchars to about 6 Cerchars, and an iron content ranging from about 5 percent to about 10 percent. Optionally, the exposed portion further comprises a second material interveningly positioned between or within the synthetic material in a predetermined and repeatable pattern.

Abstract: A target cylinder and a method for testing a superhard component thereon. The target cylinder includes a first end, a second end, and a sidewall extending from the first end to the second end. At least one of the second end and the sidewall is an exposed portion that makes contact with the superhard component to determine at least one property of the superhard component. The exposed portion comprises at least one synthetic material having at least one of a compressive strength raging from about 12 kpsi to about 30 kpsi, an abrasiveness ranging from about 1 Cerchars to about 6 Cerchars, and an iron content ranging from about 5 percent to about 10 percent. Optionally, the exposed portion further comprises a second material interveningly positioned between or within the synthetic material in a predetermined and repeatable pattern.

Abstract: A target cylinder and a method for testing a superhard component thereon. The target cylinder includes a first end, a second end, and a sidewall extending from the first end to the second end. At least one of the second end and the sidewall is an exposed portion that makes contact with the superhard component to determine at least one property of the superhard component. The exposed portion comprises at least one synthetic material having at least one of a compressive strength raging from about 12 kpsi to about 30 kpsi, an abrasiveness ranging from about 1 Cerchars to about 6 Cerchars, and an iron content ranging from about 5 percent to about 10 percent. Optionally, the exposed portion further comprises a second material interveningly positioned between or within the synthetic material in a predetermined and repeatable pattern.

Abstract: An acoustic emissions testing device includes a rock sample including a first surface, an acoustic sensor, an indenter coupled to the first surface, and a load. The load is exerted on the indenter, which transfers the load to the first surface. The acoustic sensor is communicably coupled to the rock sample and detects one or more acoustic events occurring within the rock sample. An acoustic emissions testing system includes a data recorder coupled to the testing device. The data recorder records the data from testing device. Based upon the data received, the toughness of the sample is objectively determined and can be ranked comparatively to the toughness of other samples. The load is ramped up to a peak load, held for a period of time, and then ramped down.

Abstract: An acoustic emissions testing device includes a pressurizable chamber, a rock sample, and one or ore acoustic sensors communicably coupled to the rock sample. The chamber includes a first chamber being pressurizable to a first pressure and a second chamber pressurizable to a second pressure. The rock sample is positioned within the pressurizable chamber such that a first portion of the sample is exposed to the first pressure and a second portion of the sample is exposed to the second pressure. The second pressure is increased to a threshold pressure, maintained at the threshold pressure for a time period, and then decreased. The acoustic sensors detect one or more acoustic events occurring within the rock sample. In certain embodiments, one or more of the intensity, the spatial location, and the propagating direction for one or more acoustic events are determinable. The system includes the testing device coupled to a recorder.

Abstract: A cutting element includes a substrate having an interface surface; and an ultrahard material layer disposed on the interface surface. An interface surface includes a plurality of surface features, wherein at least one of the plurality of surface features intersects a neighboring surface feature at a height that is intermediate an extremity of the at least one of the plurality of surface features and a base of the at least one of the plurality of surface features.