Abstract: The strength of the bond formed by a braze material between a polycrystalline hard material and a hard composite may be physically strengthened. For example, a method of physical strengthening may include etching a bonding surface of a polycrystalline material body to produce a synthetic topography on the bonding surface of the polycrystalline material body, the bonding surface opposing a contact surface of the polycrystalline material body; and brazing the bonding surface of the polycrystalline material body having the synthetic topography to a bonding surface of a hard composite using a braze material.

Abstract: The present disclosure relates to a polycrystalline diamond compact (PDC) with a fiber-reinforces substrate. The disclosure further relates to method of forming such a PDC.

Abstract: A cutter for a drill bit and method of manufacturing same is disclosed. The cutter has a non-leached polycrystalline diamond (PCD) table bonded to a substrate and a leached PCD table bonded to one or both of the substrate and non-leached PCD table. The leached PCD table may be ring-shaped and acts as the working surface of the cutting element. It may have a jagged inner surface which cooperates with complementary jagged-shaped outer surface of the non-leached PCD table to prevent rotation of the leached PCD table relative to the non-leached PCD table during a cutting operation. A surface of the leached PCD table may be tapered and fit together in a complementary manner with an oppositely tapered surface of the non-leached PCD table so as to mechanically lock the leached PCD table to the non-leached PCD table.

Abstract: A cutter for a drill bit includes a substrate defining a hole at least partially through the substrate. A diamond table including a protrusion is received within the hole such that a gap is defined between the protrusion and the substrate ranging between 0.001 and 0.010 inches when the substrate and diamond table are at standard temperature and pressure (STP). A braze alloy couples the diamond table to the substrate at an interface between the diamond table and the substrate. At least a portion of the braze alloy is disposed in the gap in compression between the protrusion on the diamond and the hole in the substrate.

Abstract: Induced material segregation methods of manufacturing a polycrystalline diamond compact (PDC) cutter result in formation of a polycrystalline diamond/tungsten carbide (WC) composite material having a smooth compositional gradient from maximum WC concentration at one face to maximum diamond concentration at another face. Because the compositional gradient is smooth, very little or no mismatch of coefficient of thermal expansion occurs, which improves a service lifetime of the PDC cutter.

Abstract: The present disclosure relates to a polycrystalline diamond compact (PDC) including a gradient interfacial layer between a thermally stable diamond (TSP) table and a base, such as a substrate or an earth-boring drill bit body. The gradient interfacial layer has a gradient of coefficients of thermal expansion between that of the diamond and the base. The disclosure also relates to methods of forming a gradient interfacial layer and a PDC containing such a layer.

Abstract: Catalyst extraction from polycrystalline diamond table may be achieved by treating with a halogen (in the gas phase or dissolved in a nonpolar organic solvent) to convert the catalyzing material to a salt. Then, polar organic solvents may optionally be used to leach the salt from the polycrystalline diamond table. The polycrystalline diamond (with the salt of the catalyzing material present or at least partially leached therefrom) may be brazed to a hard composite substrate to produce a cutter suitable for use in a matrix drill bit.

Abstract: The instant invention provides a polyolefin composition suitable for sealant applications, sealant compositions, method of producing the same, and films and multilayer structures made therefrom. The polyolefin composition suitable for sealant applications according to the present invention comprises: an ethylene/?-olefin interpolymer composition having a Comonomer Distribution Constant (CDC) in the range of from 40 to 110, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the ethylene-based polymer composition; a zero shear viscosity ratio (ZSVR) in the range of from 1.01 to 2.0; a density in the range of from 0.908 to 0.922 g/cm3, a melt index (I2 at 190° C./2.16 kg) in the range of from 0.5 to 5.0 g/10 minutes, a molecular weight distribution (defined as the weight average molecular weight divided by the number average molecular weight, Mw/Mn) in the range of from 2.0 to 4.0, and tan delta at 0.1 radian/second, determined at 190° C.

Abstract: In accordance with some embodiments of the present disclosure, systems and methods for determining the leaching profile of cutter on a drilling tool are disclosed. The method includes applying an X-ray impermeable layer to a surface of a leached PCD element with residual infiltrant. The method also includes moving the element through an X-ray beam. The method further includes detecting an X-ray intensity received by an X-ray detector. The method further includes generating a leaching profile of the leached PCD element based on the X-ray intensity.

Abstract: Catalyst extraction from polycrystalline diamond table may be achieved by treating with a halogen (in the gas phase or dissolved in a nonpolar organic solvent) to convert the catalyzing material to a salt. Then, polar organic solvents may optionally be used to leach the salt from the polycrystalline diamond table. The polycrystalline diamond (with the salt of the catalyzing material present or at least partially leached therefrom) may be brazed to a hard composite substrate to produce a cutter suitable for use in a matrix drill bit.

Abstract: The present disclosure related to polycrystalline diamond (PCD) having chemical vapor deposition (CVD) deposits and to PCD elements and drill bits containing such CVD-modified PCD. The present disclosure further relates to method of forming such materials.

Abstract: The microstructure of braze joints in polycrystalline diamond compact (PDC) cutters may be tailored to increase the shear strength of the braze joint, for example, by increasing the amount of a dispersed particulate microstructure therein. A method for forming a dispersed particulate microstructure may include brazing a polycrystalline diamond table to a hard composite substrate with a braze alloy at a braze temperature between 5° C. above a solidus temperature of the braze alloy and 200° C. above a liquidus temperature of the braze alloy; and forming a braze joint between the polycrystalline diamond table and the hard composite substrate that comprises at least 40% by volume of the dispersed particulate microstructure composed of a particulate inter-metallic phase having a diameter of 0.5 ?m to 2.0 ?m and an aspect ratio of 1 to 5 dispersed in a ductile matrix.

Abstract: An example polycrystalline diamond compact includes a substrate and a diamond table attached to the substrate. A multilayer joint interposes the substrate and the diamond table and comprises at least two component parts selected from the group consisting of a base layer, one or more intermediate layers, and a braze layer. The at least two component parts are formed via a thin film deposition process.

Abstract: Chemical methods, optionally in combination with physical methods, may be used to increase the strength of the bond formed by a braze material between a polycrystalline material and a hard composite. Such polycrystalline materials brazed to hard composites may be found in various wellbore tools include drill bit cutters. An exemplary method may include forming a bonding layer on a bonding surface of a polycrystalline material body that comprises a hard material, the bonding surface opposing a contact surface of the polycrystalline material body, and the bonding layer substantially formed by a [111] crystal structure of the hard material, a [100] crystal structure of the hard material, or a combination thereof; and brazing the bonding layer to a hard composite using a braze material.

Abstract: The present disclosure is directed to processes for producing ultrasonic sealable film structures and flexible containers with ultrasonic seals. The film structure includes a first multilayer film and a second multilayer film Each multilayer film includes a backing layer and a seal layer. Each seal layer includes an ultrasonic sealable olefin-based polymer (USOP) having the following properties: (a) a heat of melting, ?Hm, less than 130 J/g, (b) a peak melting temperature, Tm, less than 125° C., (c) a storage modulus in shear (G?) from 50 MPa to 500 MPa, and (d) a loss modulus in shear (G?) greater than 10 MPa. The multilayer films are arranged such that the seal layer of the first multilayer film is in contact with the seal layer of the second multilayer film The seal layers form an ultrasonic seal having a seal strength from 30 N/15 mm to 80 N/15 mm when ultrasonically sealed at 4 N/mm seal force.

Abstract: The instant invention provides a polyolefin composition suitable for sealant applications, sealant compositions, method of producing the same, and films and multilayer structures made therefrom. The polyolefin composition suitable for sealant applications according to the present invention comprises: an ethylene/?-olefin interpolymer composition having a Comonomer Distribution Constant (CDC) in the range of from 40 to 110, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of the ethylene-based polymer composition; a zero shear viscosity ratio (ZSVR) in the range of from 1.01 to 2.0; a density in the range of from 0.908 to 0.922 g/cm3, a melt index (I2 at 190° C./2.16 kg) in the range of from 0.5 to 5.0g/10 minutes, a molecular weight distribution (defined as the weight average molecular weight divided by the number average molecular weight, Mw/Mn) in the range of from 2.0 to 4.0, and tan delta at 0.1 radian/second, determined at 190 ° C.

Abstract: The instant invention provides a sealant composition, method of producing the same, film layers and multilayer structures made therefrom. The linear low density polyethylene composition suitable for sealant applications according to the present invention comprises: less than or equal to 100 percent by weight of the units derived from ethylene; less than 35 percent by weight of units derived from one or more ?-olefin comonomers; wherein said linear low density polyethylene composition has a density in the range of 0.900 to 0.920 g/cm3, a molecular weight distribution (Mw/Mn) in the range of 2.5 to 4.5, a melt index (I2) in the range of 0.5 to 3 g/10 minutes, a molecular weight distribution (Mz/Mw) in the range of from 2.2 to 3, vinyl unsaturation of less than 0.1 vinyls per one thousand carbon atoms present in the backbone of said composition, and a zero shear viscosity ratio (ZSVR) in the range from 1.0 to 1.2.

Abstract: The instant invention is a sealant composition, method of producing the same, articles made therefrom, and method for forming such articles. The sealant composition according to the present invention comprises: (a) from 70 to 99.5 percent by weight of an ethylene/?-olefin interpolymer composition, based on the total weight of the sealant composition, wherein said ethylene/?-olefin interpolymer composition comprises an ethylene/?-olefin interpolymer, wherein ethylene/?-olefin interpolymer has a Comonomer Distribution Constant (CDC) in the range of from 15 to 250, and a density in the range of from 0.875 to 0.963 g/cm3, a melt index (I2) in a range of from 0.2 to 20 g/10 minutes, and long chain branching frequency in the range of from 0.02 to 3 long chain branches (LCB) per 1000 C; (b) from 0.

Abstract: The instant invention is a sealant composition, method of producing the same, articles made therefrom, and method for forming such articles. The sealant composition according to the present invention comprises: (a) from 70 to 99.5 percent by weight of an ethylene/?-olefin interpolymer composition, based on the total weight of the sealant composition, wherein said ethylene/?-olefin interpolymer composition comprises an ethylene/?-olefin interpolymer, wherein ethylene/?-olefin interpolymer has a Comonomer Distribution Constant (CDC) in the range of from 15 to 250, and a density in the range of from 0.875 to 0.963 g/cm3, a melt index (I2) in a range of from 0.2 to 20 g/10 minutes, and long chain branching frequency in the range of from 0.02 to 3 long chain branches (LCB) per 1000C; (b) from 0.