Abstract: A downhole tool comprises a body made of a metal or metal alloy. In addition, the downhole tool comprises a coating disposed on the body. The coating includes at least 75 vol % tungsten carbide having an average grain size less than 1.0 ?m. The content of tungsten carbide in the coating with a grain size less than 0.5 ?m is between 40 and 64 vol % of the coating.

Abstract: A downhole tool comprises a body made of a metal or metal alloy. In addition, the downhole tool comprises a coating disposed on the body. The coating includes at least 75 vol % tungsten carbide having an average grain size less than 1.0 ?m. The content of tungsten carbide in the coating with a grain size less than 0.5 ?m is between 40 and 64 vol % of the coating.

Abstract: A polycrystalline diamond compact formed in an in-situ boron-doped process. The in-situ boron-doped process includes consolidating a mixture of diamond crystals and boron-containing alloy via liquid diffusion of boron into diamond crystals at a pressure greater than 5 Gpa and at a temperature greater than the melting temperature of the boron-containing alloy, typically less than about 1450° C.

Abstract: A hardmetal composite used as wear-resistant surfaces and inlays in earth-engaging equipment includes more than one hardphase. At least one hardphase has a high average particle size, for example, from 100 ?m to 2000 ?m. The hardphases vary in terms of particle size, hardness, and binder content, and at least one hardphase includes a particulate constituent capable of plastic deformation that comprises at least 1% residual porosity.

Abstract: A polycrystalline diamond compact formed in an in-situ boron-doped process. The in-situ boron-doped process includes consolidating a mixture of diamond crystals and boron-containing alloy via liquid diffusion of boron into diamond crystals at a pressure greater than 5 Gpa and at a temperature greater than the melting temperature of the boron-containing alloy, typically less than about 1450° C.

Abstract: A hardmetal composite used as wear-resistant surfaces and inlays in earth-engaging equipment includes more than one hardphase. At least one hardphase has a high average particle size, for example, from 100 ?m to 2000 ?m. The hardphases vary in terms of particle size, hardness, and binder content, and at least one hardphase includes a particulate constituent capable of plastic deformation that comprises at least 1% residual porosity.

Abstract: A thermally conductive sand shell molding system allows for controlling heat flow in a molten metal infiltrate powdered metal drill bit molding system to differentially cool the mold system to control differential shrinking and accompanying stress concentrations.

Abstract: A hardmetal composition comprises tungsten carbide in an amount greater than 50 weight percent of the hardmetal composition. In addition, the hardmetal composition comprises a binder material consisting of at least 90 weight percent nickel, a binder flux between 3.5 to 10.0 weight percent chosen from the group consisting of boron and silicon, and less than 1.0 weight percent other components.

Abstract: A hardmetal composition comprises tungsten carbide in an amount greater than 50 weight percent of the hardmetal composition. In addition, the hardmetal composition comprises a binder material consisting of at least 90 weight percent nickel, a binder flux between 3.5 to 10.0 weight percent chosen from the group consisting of boron and silicon, and less than 1.0 weight percent other components.

Abstract: A polycrystalline diamond compact formed in an in-situ boron-doped process. The in-situ boron-doped process includes consolidating a mixture of diamond crystals and boron-containing alloy via liquid diffusion of boron into diamond crystals at a pressure greater than 5 Gpa and at a temperature greater than the melting temperature of the boron-containing alloy, typically less than about 1450° C.

Abstract: A superhard composite material comprising a polycrystalline diamond cutter (PDC) having a cutting surface and cutting edges having a polycrystalline diamond thickness of about 3 mm is integrally formed with a sacrificial catalyst source that is removed later in the processing of the of the cutter.

Abstract: A thermally conductive sand shell moulding system allows for controlling heat flow in a molten metal infiltrate powdered metal drill bit moulding system to differentially cool the mould system to control differential shrinking and accompanying stress concentrations.

Abstract: A hardmetal composite used as wear-resistant surfaces and inlays in earth-engaging equipment includes more than one hardphase. At least one hardphase has a high average particle size, for example, from 100 ?m to 2000 ?m. The hardphases vary in terms of particle size, hardness, and binder content, and at least one hardphase includes a particulate constituent capable of plastic deformation that comprises at least 1% residual porosity.

Abstract: A composite structure includes a first portion comprising a first metallic material, a monolayer of particles extending into and bonded with the first portion, and a second portion comprising a second material, the second portion bonded with the monolayer of particles and extending into interstices between the particles. A method for fabricating a composite structure includes bonding a monolayer of particles to a first portion comprising a first metallic material, such that the monolayer of particles extends into the first portion and bonding a second portion comprising a second material to the monolayer of particles, such that the second portion extends into interstices between the particles.

Abstract: The present invention is a new method for forming a high density hard facing rod. The rod is particularly suitable for hardfacing downhole tools including both fixed cutter and rolling cutter drill bits, bias pads for downhole rotary steerable systems, and stabilizers, and for other types of tools requiring strong and wear resistant hardfacings. The method includes the steps of: preparing a powder mix comprising carbide and metal powders, a fugitive binder, and other additives to render a moldable rheology; forming the powder mix into a powder core encased with a metal sheath to form a core-sheath assembly; and isostatically compacting the core-sheath assembly to densify the core to at least 65% of theoretical density and mechanically attach the sheath. The core fugitive binder along with residual volatile constituents may be thermally removed with or without vacuum, reducing, or inert environment prior to weld application of the composite rod.