Abstract: A tool component comprising a wear part covered at least in part by a connection member, the wear part having a specified hardness and the connection member being a metal or alloy, and the wear part comprising a surface that includes one or more depressions or projections therefrom, and the connection member having been pressed against that surface so that at least the surface of the connection member that faces the wear part surface follows the profile of the wear part, whereby relative movement between the wear part and connection member is substantially prevented. The metal or alloy connection member may be readily attached to a tool body for example by brazing of the like. The wear part may comprise a material that is not readily brazeable, for example a ceramic material or a cermet or a superhard material or a composite of such materials.

Abstract: A composite part comprises (a) a cutting element which comprises super-hard cutting table and a substrate and (b) a metal or alloy layer. Respective first surfaces of the superhard cutting table and the substrate are joined to each other, and the metal or alloy layer is located adjacent to second surfaces of the cutting table and the substrate so as to surround the joined first surfaces of the cutting table and the substrate. The metal or alloy layer and the second surfaces of one or both of the cutting table and substrate are co-operatively shaped substantially to prevent relative movement therebetween. The metal or alloy layer may be used to secure the cutting element within a tool body, and advantageously provides a convenient means to effect that securement, while simultaneously protecting the join between the superhard cutting table and the substrate during the process of securement of the cutting element to the tool body.

Abstract: Bearings for downhole tools including a first bearing member and a second bearing member, at least one of the first and second bearing members having a channel formed therein. Methods of cooling bearings of downhole tools comprise flowing a fluid within a channel formed in at least one bearing member. Heat is transferred from at least the at least one bearing member to the fluid. The fluid is flowed away from the at least one bearing member.

Abstract: Bearings for downhole tools including a first bearing member and a second bearing member, at least one of the first and second bearing members having a channel formed therein. Methods of cooling bearings of downhole tools comprise flowing a fluid within a channel formed in at least one bearing member. Heat is transferred from at least the at least one bearing member to the fluid. The fluid is flowed away from the at least one bearing member.

Abstract: Bearings for downhole tools including a first bearing member and a second bearing member, at least one of the first and second bearing members having a channel formed therein. Methods of cooling bearings of downhole tools comprise flowing a fluid within a channel formed in at least one bearing member. Heat is transferred from at least the at least one bearing member to the fluid. The fluid is flowed away from the at least one bearing member.

Abstract: A composite part comprises (a) a cutting element which comprises super-hard cutting table and a substrate and (b) a metal or alloy layer. Respective first surfaces of the superhard cutting table and the substrate are joined to each other, and the metal or alloy layer is located adjacent to second surfaces of the cutting table and the substrate so as to surround the joined first surfaces of the cutting table and the substrate. The metal or alloy layer and the second surfaces of one or both of the cutting table and substrate are co-operatively shaped substantially to prevent relative movement therebetween. The metal or alloy layer may be used to secure the cutting element within a tool body, and advantageously provides a convenient means to effect that securement, while simultaneously protecting the join between the superhard cutting table and the substrate during the process of securement of the cutting element to the tool body.

Abstract: A tool component comprising a wear part covered at least in part by a connection member, the wear part having a specified hardness and the connection member being a metal or alloy, and the wear part comprising a surface that includes one or more depressions or projections therefrom, and the connection member having been pressed against that surface so that at least the surface of the connection member that faces the wear part surface follows the profile of the wear part, whereby relative movement between the wear part and connection member is substantially prevented. The metal or alloy connection member may be readily attached to a tool body for example by brazing of the like. The wear part may comprise a material that is not readily brazeable, for example a ceramic material or a cermet or a superhard material or a composite of such materials.

Abstract: A polycrystalline diamond abrasive element, particularly a cutting element, comprises a table of polycrystalline diamond bonded to a substrate, particularly a cemented carbide substrate, along a non-planar interface. The non-planar interface typically has a cruciform configuration. The polycrystalline diamond has a high wear-resistance, and has a region adjacent the working surface lean in catalysing material and a region rich in catalysing material. The region lean in catalysing material extends to a depth of 40 to 90 microns, which is much shallower than in the prior art. Notwithstanding the shallow region lean in catalysing material, the polycrystalline diamond cutters have a wear resistance, impact strength and cutter life comparable to that of prior art cutters, but requiring only 20% of the treatment times of the prior art cutters.

Abstract: An abrasive compact having at least a tri-modal particle size distribution, and a binder phase, define a plurality of interstices. The binder phase is distributed in the interstices to form binder pools that correspond substantially in average size to that of an ultrahard polycrystalline composite material having a monomodal particle size distribution and substantially the same overall average particle grain size.

Abstract: A method of manufacturing a tool component, which is typically a cutting element or a gauge stone in a rotary drill bit, including a layer of ultra-hard abrasive material bonded to a substrate, the layer of ultra-hard abrasive material comprising a pair of opposed end surfaces, an upper surface defined between the end surfaces, and at least one curved and tapered cutting edge defined at the intersection of the respective end surfaces and the upper surface. The respective cutting edges of the tool component and the respective end surfaces leading to the cutting edges are generally wedge-shaped, the upper surface of the layer following generally the same or a similar profile, at least in the region of the cutting edges.

Abstract: Bearings for downhole tools including a first bearing member and a second bearing member, at least one of the first and second bearing members having a channel formed therein. Methods of cooling bearings of downhole tools comprise flowing a fluid within a channel formed in at least one bearing member. Heat is transferred from at least the at least one bearing member to the fluid. The fluid is flowed away from the at least one bearing member.

Abstract: A polycrystalline diamond abrasive element, particularly a cutting element, comprises a table of polycrystalline diamond bonded to a substrate, particularly a cemented carbide substrate, along a non-planar interface. The non-planar interface typically has a crucifonn configuration. The polycrystalline diamond has a high wear-resistance, and has a region adjacent the working surface leanin catalysing material and a region rich in catalysing material. The region lean in catalysing material extends to a depth of 40 to 90 microns, which is much shallower than in the prior art. Notwithstanding the shallow region lean in catalysing material, the polycrystalline diamond cutters have a wear resistance, impact strength and cutter life comparable to that of prior art cutters, but requiring only 20% of the treatment times of the prior art cutters.

Abstract: A polycrystalline diamond abrasive element, particularly a cutting element, comprises a table of polycrystalline diamond bonded to a substrate, particularly a cemented carbide substrate, along a non-planar interface. The non-planar interface typically has a cruciform configuration. The polycrystalline diamond has a high wear-resistance, and has a region adjacent the working surface lean in catalysing material and a region rich in catalysing material. The region lean in catalysing material extends to a depth of 40 to 90 microns, which is much shallower than in the prior art. Notwithstanding the shallow region lean in catalysing material, the polycrystalline diamond cutters have a wear resistance, impact strength and cutter life comparable to that of prior art cutters, but requiring only 20% of the treatment times of the prior art cutters.

Abstract: The invention is for a polycrystalline diamond abrasive compact comprising a primary polycrystalline diamond material of bonded diamond particles and a secondary polycrystalline diamond material interspersed through the primary polycrystalline diamond material or a region thereof. The invention is characterised in that the secondary polycrystalline diamond material comprises particulates or granules of thermally stable polycrystalline diamond material. The invention extends to an abrasive cutting element suitable for cutting or abrading a substrate or in drilling applications.

Abstract: An abrasive compact having at least a tri-modal particle size distribution, and a binder phase, define a plurality of interstices. The binder phase is distributed in the interstices to form binder pools that correspond substantially in average size to that of an ultrahard polycrystalline composite material having a monomodal particle size distribution and substantially the same overall average particle grain size.

Abstract: A tool insert comprises a substrate (10) having a support surface and a support ring extending laterally from the support surface. The support ring is sized to define a recess (14) within the confines thereof and a shelf about the periphery thereof. A layer (12) of ultra-hard abrasive material is located within the recess and bonded to the substrate and the support ring (16), and presents a primary cutting edge (22) for the tool insert. A protective layer (18) is bonded to the shelf about the support ring so as to protect the primary cutting edge. The protective layer provides a secondary cutting edge (20) for the tool insert, the depth of the protective layer being selected so as to be sufficient to protect the primary cutting edge whilst cutting, milling or drilling through a first substance but to expose the primary cutting edge upon encountering a second substance.

Abstract: A polycrystalline diamond abrasive element, particularly a cutting element, comprises a layer of polycrystalline diamond having a working surface and bonded to a substrate, particularly a cemented carbide substrate, along an interface. The polycrystalline diamond abrasive element is characterized by using a binder phase that is homogeneously distributed through the polycrystalline diamond layer and that is of a fine scale. The polycrystalline diamond also has a region adjacent the working surface lean in catalyzing material and a region rich in catalyzing material.

Abstract: A composite diamond compact is provided which has a diamond compact (12) bonded to a cemented carbide substrate (10). The composite diamond compact is characterised by the second phase for the diamond compact (12) and the binder for the cemented carbide substrate (10) both being a nickel/cobalt alloy.

Abstract: A method of manufacturing a tool component, which is typically a cutting element or a gauge stone in a rotary drill bit, including a layer of ultra-hard abrasive material bonded to a substrate, the layer of ultra-hard abrasive material comprising a pair of opposed end surfaces, an upper surface defined between the end surfaces, and at least one curved and tapered cutting edge defined at the intersection of the respective end surfaces and the upper surface. The respective cutting edges of the tool component and the respective end surfaces leading to the cutting edges are generally wedge-shaped, the upper surface of the layer following generally the same or a similar profile, at least in the region of the cutting edges.

Abstract: A composite abrasive compact comprises an abrasive compact layer, generally a diamond abrasive compact layer, bonded to a substrate. The abrasive compact layer is characterized by: (i) an inner region, in contact with a surface of the substrate, (ii) a first intermediate region in contact with the inner region, (iii) a second intermediate region in contact with the first intermediate region, (iv) an outer region in contact with the second intermediate region and containing ultra-hard abrasive particles having at least three different average particle sizes, and (v) the composition in the inner region, and first and second intermediate regions varying in composition such that there is a gradulated change in thermal expansion of the abrasive compact layer between the substrate and the outer region.