Abstract: A polycrystalline diamond compact (PDC) is fabricated using a process of delayed diffusion (i.e., post-sintering) of a diffusion species (i.e., a metalloid) introduced from the back side of a carbide further away from the diamond grit or from the flank side of the carbide, as opposed to the side of the carbide adjacent to the diamond grit. The process of fabricating the PDC includes depositing, in a metal container, a synthetic diamond grit, a carbide, and a diffusion species, then applying a high pressure and high temperature (HPHT) to the contents of the metal container wherein (1) the carbide diffuses across the diamond grit, and (2) the diffusion species diffuses across the carbide followed by the diamond grit, thus providing a protective coating to the PDC.

Abstract: A polycrystalline diamond compact (PDC) is fabricated using a process of delayed diffusion (i.e., post-sintering) of a diffusion species (i.e., a metalloid) introduced from the back side of a carbide further away from the diamond grit or from the flank side of the carbide, as opposed to the side of the carbide adjacent to the diamond grit. The process of fabricating the PDC includes depositing, in a metal container, a synthetic diamond grit, a carbide, and a diffusion species, then applying a high pressure and high temperature (HPHT) to the contents of the metal container wherein (1) the carbide diffuses across the diamond grit, and (2) the diffusion species diffuses across the carbide followed by the diamond grit, thus providing a protective coating to the PDC.

Abstract: A cutting element and a method of making the superabrasive cutter are disclosed. The cutting element has a substrate and a superabrasive layer. The substrate has an inner face and an annular face. The inner face may have a center. The annular face may have a periphery. A superabrasive layer attaches to the substrate along the inner face and the annular face, wherein the inner face slopes outwardly and upwardly from the center at an angle ranging from between about 1° and about 7° from horizontal.

Abstract: A polycrystalline diamond compact (PDC) is fabricated using a process of delayed diffusion of a diffusion species (e.g., a metalloid) introduced from the back side of a cemented carbide further away from the diamond grit or from the flank side of the cemented carbide, as opposed to the side of the cemented carbide adjacent to the diamond grit. The process of fabricating the PDC includes depositing, in a metal container, a diamond grit, a cemented carbide, and a diffusion species, then applying a high pressure and high temperature (HPHT) to the contents of the metal container wherein (1) the binder of cemented carbide diffuses across the diamond grit, and (2) the diffusion species diffuses through the cemented carbide, and then through the diamond grit, thus providing a protective coating to the diamond grains of the PDC.

Abstract: A polycrystalline diamond compact (PDC) is fabricated using a process of delayed diffusion of a diffusion species (e.g., a metalloid) introduced from the back side of a cemented carbide further away from the diamond grit or from the flank side of the cemented carbide, as opposed to the side of the cemented carbide adjacent to the diamond grit. The process of fabricating the PDC includes depositing, in a metal container, a diamond grit, a cemented carbide, and a diffusion species, then applying a high pressure and high temperature (HPHT) to the contents of the metal container wherein (1) the binder of cemented carbide diffuses across the diamond grit, and (2) the diffusion species diffuses through the cemented carbide, and then through the diamond grit, thus providing a protective coating to the diamond grains of the PDC.

Abstract: A cutting element and a method of making the superabrasive cutter are disclosed. The cutting element has a substrate and a superabrasive layer. The substrate has an inner face and an annular face. The inner face may have a center. The annular face may have a periphery. A superabrasive layer attaches to the substrate along the inner face and the annular face, wherein the inner face slopes outwardly and upwardly from the center at an angle ranging from between about 1° and about 7° from horizontal.

Abstract: A preform superabrasive cutter and a method of testing the preform superabrasive cutter are disclosed. The preform superabrasive cutter may comprise a superabrasive volume, metal carbide, and a slop. The superabrasive volume may have a top surface and superabrasive particles. The metal carbide may be attached to the superabrasive volume via an interface between the superabrasive volume and the metal carbide. The slope may be situated from the top surface of the superabrasive volume toward the metal carbide, wherein the slope is at an angle from about 5 to about 18 degrees relative to a longitudinal axis of the preform superabrasive cutter.

Abstract: A method of testing a superabrasive cutter is disclosed. The method of testing a superabrasive cutter may comprise steps of choosing a set of tests with various parameters under which to test superabrasive cutter; comparing to a reference chart; and deciding whether the superabrasive cutter fits an application for a high probability of performance success.

Abstract: A polycrystalline diamond compact made from a high pressure, high temperature process is provided. The compact includes a metal carbide substrate including a binder and at least one inner layer of polycrystalline diamond disposed on the substrate. The polycrystalline diamond has a diamond phase and a metal phase forming an interconnected mutually exclusive network. The metal phase is a material different than that of the binder of the substrate to provide improved diamond sintering and final polycrystalline diamond compact properties. Prior to processing at least one coating is disposed on the substrate, and the layer of diamond particles is disposed on the at least one coating. During the high pressure, high temperature process the coating melts and fully sweeps into the diamond layer.

Abstract: An abrasive tool insert includes (a) a substrate having a support face that includes (1) an inner support table, (2) an outer shoulder having a width, Sw, and (3) a downwardly sloping interface from the support table to the shoulder, which interface has a slope angle, Sa. A continuous abrasive layer, integrally formed on the substrate support face, includes (1) a center having a height, Dc, (2) a diameter, Dd, (3) a periphery having a height, Dp, in contact with the shoulder and which periphery forms a cutting edge. Sw:Dd ranges from between 0 and about 0.5. For each Sa and Sw:Dd, Dc:Dp is selected so as to diminish residual stress in the abrasive layer.

Abstract: An abrasive tool insert includes (a) a substrate having a support face that includes (1) an inner support table, (2) an outer shoulder having a width, Sw, and (3) a downwardly sloping interface from the support table to the shoulder, which interface has a slope angle, Sa. A continuous abrasive layer, integrally formed on the substrate support face, includes (1) a center having a height, Dc, (2) a diameter, Dd, (3) a periphery having a height, Dp, in contact with the shoulder and which periphery forms a cutting edge. Sw:Dd ranges from between 0 and about 0.5. For each Sa and Sw:Dd, Dc:Dp is selected so as to diminish residual stress in the abrasive layer.

Abstract: The present invention relates to supported polycrystalline diamond compact cutters (PDC cutters) made under high temperature, high pressure (HT/HP) processing conditions, and more particularly to supported PDC cutters having non-planar cutting surfaces. More specifically, the present invention is for an oriented PDC cutter wherein chips and debris are funneled away from the cutting edge by a raised top surface of the polycrystalline diamond layer (PCD layer). The redirection of the debris is achieved by the creation of high and low regions on the PCD layer, of which there can be a variety of different surface geometry's. Thus, an object of the present invention is to provide a PDC cutter with improved performance through channeling debris away from its cutting edge.

Abstract: The present invention relates to a novel domed polycrystalline diamond cutting element wherein a hemispherical diamond layer is bonded to a tungsten carbide substrate, commonly referred to as a tungsten carbide stud. Broadly, the inventive cutting element includes a metal carbide stud having a proximal end adapted to be placed into a drill bit and a distal end portion. A layer of cutting polycrystalline abrasive material disposed over said distal end portion such that an annulus of metal carbide adjacent and above said drill bit is not covered by said abrasive material layer. The geometry of the diamond cutting element provides control of interfacial stresses and reduces fabrication costs. The diamond cutting element may contain a pattern of ridges or bumps integrally formed in the abrasive layer which ridges are designed to cause high localized stresses in the rock, thus starting a crack. By initiating cracks in localized areas, the crushing action could be performed with less force.

Abstract: This invention relates to a novel domed polycrystalline diamond cutting element wherein a hemispherical diamond layer is bonded to a tungsten carbide substrate, commonly referred to as a tungsten carbide stud. Broadly, a pattern of ridges or bumps is integrally formed in the abrasive layer which ridges are designed to cause high localized stresses in the rock, thus starting a crack. By initiating cracks in localized areas, the crushing action could be performed with less force.

Abstract: An abrasive cutting element comprised of an abrasive cutting layer and a metal substrate wherein the interface therebetween has a tangential chamfer, the plane of which forms an angle of about 5.degree. to about 85.degree. with the plane of the surface of the cylindrical part of the metal substrate. The abrasive cutting layer is preferably diamond or cubic boron nitride and the metal substrate is preferably tungsten carbide.