Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A polycrystalline diamond (PCD) compact and method for making the compact are provided. The method includes bringing a first PCD wafer and a second PCD wafer together at an interface in the presence of a bonding agent to form an unbonded assembly and bonding the wafers together at the interface at a pressure and temperature at which diamond is thermodynamically stable. The first PCD wafer is more thermally stable than the second PCD wafer.

Abstract: A temperature sensor comprises a body of polycrystalline superhard material comprising a plurality of intergrown grains and a binder phase, the polycrystalline material defining a plurality of interstices between the grains, the binder phase being distributed in a plurality of the interstices; and two or more electrodes attached to or embedded in the body of polycrystalline material arranged to measure bulk resistance of the polycrystalline superhard material between the electrodes, the measured resistance being indicative of the temperature of the body of polycrystalline material.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A polycrystalline diamond (PCD) compact and method for making the compact are provided. The method includes bringing a first PCD wafer and a second PCD wafer together at an interface in the presence of a bonding agent to form an unbonded assembly and bonding the wafers together at the interface at a pressure and temperature at which diamond is thermodynamically stable. The first PCD wafer is more thermally stable than the second PCD wafer.

Abstract: A PCD insert comprises a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or all of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A polycrystalline diamond (PCD) compact and method for making the compact are provided. The method includes bringing a first PCD wafer and a second PCD wafer together at an interface in the presence of a bonding agent to form an unbonded assembly and bonding the wafers together at the interface at a pressure and temperature at which diamond is thermodynamically stable. The first PCD wafer is more thermally stable than the second PCD wafer.

Abstract: A cutting element is described comprising a super-hard cutting table, a substrate and a metal or alloy layer. A surface of the superhard cutting table, is joined to the substrate by means of the metal or alloy layer which is positioned between them. At least a first surface of the metal or alloy layer and at least a first surface of the cutting table are co-operatively shaped with each other such that the co-operative shaping substantially prevents relative movement between the cutting table and the metal or alloy layer.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element further comprises a working surface and a low melting point region adjacent the working surface in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1,300 degrees centigrade at atmospheric pressure, or less than about 1,200 degrees centigrade at atmospheric pressure. The PCD clement includes an intermediate region, the interstices of the intermediate region being at least partially filled with a catalyst material for diamond.

Abstract: A cutter insert assembly for a drill bit for boring into the earth, comprising a super-hard structure clampable to a support body by means of a clamp mechanism; the clamp mechanism comprising opposed or opposable compression members connected or connectable by a tension member capable of sustaining a clamping force between the compression members when the cutter insert assembly is in a clamped condition, in which condition the compression members exert opposing compressive forces on the super-hard structure and the support body, operable to clamp the super-hard structure to the support body, and in which condition the cutter insert assembly is self-supporting and capable of being mounted onto a drill bit body.

Abstract: A temperature sensor comprises a body of polycrystalline superhard material comprising a plurality of intergrown grains and a binder phase, the polycrystalline material defining a plurality of interstices between the grains, the binder phase being distributed in a plurality of the interstices; and two or more electrodes attached to or embedded in the body of polycrystalline material arranged to measure bulk resistance of the polycrystalline superhard material between the electrodes, the measured resistance being indicative of the temperature of the body of polycrystalline material.

Abstract: A cutting element is described comprising a super-hard cutting table, a substrate and a metal or alloy layer. A surface of the superhard cutting table, is joined to the substrate by means of the metal or alloy layer which is positioned between them. At least a first surface of the metal or alloy layer and at least a first surface of the cutting table are co-operatively shaped with each other such that the co-operative shaping substantially prevents relative movement between the cutting table and the metal or alloy layer.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element further comprises a working surface and a low melting point region adjacent the working surface in which the interstices are at least partially filled with a low melting point metallic material having a melting point of less than about 1,300 degrees centigrade at atmospheric pressure, or less than about 1,200 degrees centigrade at atmospheric pressure. The PCD element includes an intermediate region, the interstices of the intermediate region being at least partially filled with a catalyst material for diamond.

Abstract: An embodiment of a PCD insert comprises an embodiment of a PCD element joined to a cemented carbide substrate at an interface. The PCD element has internal diamond surfaces defining interstices between them. The PCD element comprises a masked or passivated region and an unmasked or unpassivated region, the unmasked or unpassivated region defining a boundary with the substrate, the boundary being the interface. At least some of the internal diamond surfaces of the masked or passivated region contact a mask or passivation medium, and some or ail of the interstices of the masked or passivated region and of the unmasked or unpassivated region are at least partially filled with an infiltrant material.

Abstract: A superhard insert for a rotary earth borer tool comprises a cutter end having a peripheral cutter edge, at least part of the peripheral cutter edge being defined by a plurality of edges of a plurality of alternate hard and superhard regions. The edges of the superhard regions are arranged spaced apart from each other and are separated by edges of hard regions. The hardness of each hard region is at most 50% of the hardness of each superhard region.

Abstract: A cutter insert assembly for a drill bit for boring into the earth, comprising a super-hard structure clampable to a support body by means of a clamp mechanism; the clamp mechanism comprising opposed or opposable compression members connected or connectable by a tension member capable of sustaining a clamping force between the compression members when the cutter insert assembly is in a clamped condition, in which condition the compression members exert opposing compressive forces on the super-hard structure and the support body, operable to clamp the super-hard structure to the support body, and in which condition the cutter insert assembly is self-supporting and capable of being mounted onto a drill bit body.

Abstract: A polycrystalline diamond (PCD) compact and method for making the compact are provided. The method includes bringing a first PCD wafer and a second PCD wafer together at an interface in the presence of a bonding agent to form an unbonded assembly and bonding the wafers together at the interface at a pressure and temperature at which diamond is thermodynamically stable. The first PCD wafer is more thermally stable than the second PCD wafer.