Abstract: Disclosed herein, in certain embodiments, are composite materials, methods, tools and abrasive materials comprising a tungsten-based metal composition, a tungsten carbide, and an alloy. In some cases, the composite materials or matrix are resistant to oxidation.

Abstract: A cutting tool may includes a tool body; a plurality of blades extending from the tool body; and a plurality of non-planar cutting elements disposed along each of the plurality of blades, the plurality of non-planar cutting elements form a cutting profile, in a rotated view of the plurality of non-planar cutting elements into a single plane, the cutting profile including a cone region, a nose region, a shoulder region, and a gage region. The plurality of non-planar cutting elements include a first shape in at least one of the cone region, nose region, shoulder region, and gage region, and a second, different shape in at least one other region.

Abstract: A cutting element includes a polycrystalline diamond layer having a cutting face and a diamond layer side surface, a substrate attached to the polycrystalline diamond layer, the substrate having a bottom surface and a substrate side surface, an interface between the diamond layer and the substrate, and a mask covering at least the bottom surface and the substrate side surface of the cutting element.

Abstract: A carbide composite for a downhole tool may be formed by depositing a first layer on a substrate, and a second layer at least partially adjacent to the first layer. The first and second layers may each include carbides, metal binders, organic binders, or a combination thereof. The first and second carbide layers may have a different particle size, particle shape, carbide concentration, metal binder concentration, or organic binder concentration from one another.

Abstract: A downhole cutting tool may include a tool body; a plurality of blades extending azimuthally from the tool body; and a plurality of cutting elements disposed on the plurality of blades, the plurality of cutting elements comprising: at least two conical cutting elements comprising a substrate and a diamond layer having a conical cutting end, wherein at least one of the at least two conical cutting elements has a positive back rake angle, and at least one of the at least two conical cutting elements has a negative back rake angle.

Abstract: A carbide composite for a downhole tool may be formed by depositing a first layer on a substrate, and a second layer at least partially adjacent to the first layer. The first and second layers may each include carbides, metal binders, organic binders, or a combination thereof. The first and second carbide layers may have a different particle size, particle shape, carbide concentration, metal binder concentration, or organic binder concentration from one another.

Abstract: A method of forming a thermally stable cutting element that includes disposing at least a portion of a polycrystalline abrasive body containing a catalyzing material to be leached into a leaching agent; and subjecting the polycrystalline abrasive object to an elevated temperature and pressure is disclosed. Thermally stable cutting elements and systems and other methods for forming thermally stable cutting elements are also disclosed.

Abstract: A method of forming a mold used to manufacture downhole tools includes depositing successive layers of a material mixture and an adhesive using an automated layering device according to a computer aided pattern, the material mixture including a first composition and a second composition, the first composition having at least a different shape, size, or chemical composition than the second composition, at least one of the first composition or the second composition being granulated.

Abstract: A drill bit for drilling a borehole in earth formations may include a bit body having a bit axis and a bit face; a plurality of blades extending radially along the bit face; and a plurality of cutting elements disposed on the plurality of blades. The plurality of cutting elements may include: at least one cutter including a substrate and a diamond table having a substantially planar cutting face; and at least two conical cutting elements including a substrate and a diamond layer having a conical cutting end. In a rotated view of the plurality of cutting elements into a single plane, the at least one cutter may be located a radial position from the bit axis that is intermediate the radial positions of the at least two conical cutting elements.

Abstract: A cutting element includes a polycrystalline diamond layer having a cutting face and a diamond layer side surface, a substrate attached to the polycrystalline diamond layer, the substrate having a bottom surface and a substrate side surface, an interface between the diamond layer and the substrate, and a mask covering at least the bottom surface and the substrate side surface of the cutting element.

Abstract: A cutting element may include a substrate, an upper surface of the substrate including a crest, the crest transitioning into a depressed region, and an ultrahard layer on the upper surface, thereby forming a non-planar interface between the ultrahard layer and the substrate. A top surface of the ultrahard layer includes a cutting crest extending along at least a portion of a diameter of the cutting element, the top surface having a portion extending laterally away from the cutting crest having a lesser height than a peak of the cutting crest.

Abstract: A method of re-processing used TSP material layers to form cutting elements, bits with such cutting elements mounted on their bodies, and bits having re-processed TSP material layers attached to their bodies, as well as such cutting elements and bits are provided. The method includes providing a used TSP material cutting element having a TSP material layer and substrate, or a bit having a TSP material layer attached to the bit, removing the used TSP material layer from the cutting element or bit, cutting the used TSP material layer to a new shape, if necessary, optionally re-leaching the used TSP layer and re-using the TSP material layer to form a cutting element, or in forming a bit body. The formed cutting element may be mounted on a bit body.

Abstract: Polycrystalline diamond composites comprise a polycrystalline diamond body having a plurality of ultra-hard discrete regions dispersed within a polycrystalline diamond second region. The plurality of discrete regions has an density different from of the polycrystalline diamond second region. A metallic substrate can be joined to the body. The discrete regions can be relatively more thermal stable than, have a higher diamond density than, and/or may comprise a binder material that is different from the polycrystalline diamond second region. Polycrystalline diamond composites can be formed by combining already sintered granules with diamond grains to form a mixture, and subjecting the mixture to high pressure/high temperature conditions, wherein the granules form the plurality of discrete regions, or can be made by forming a plurality of unsintered granules, combining them with diamond grains to form a mixture, and then subjecting the mixture to first and second high pressure/high temperature conditions.

Abstract: A cutting element for a drill bit includes an outer support element and an inner rotatable cutting element, a portion of which is disposed in the outer support element, where the inner rotatable cutting element has a body with a non-planar cutting face.

Abstract: A cutting element may include a substrate including a plurality of metal carbide particles and a first metal binder having a first metal binder content; an outer layer of polycrystalline diamond material at an end of the cutting element, the polycrystalline diamond material including a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the interconnected diamond particles, the plurality of interstitial regions containing a second metal binder having a second metal binder content. The cutting element also includes at least one transition zone between the substrate and the outer layer, the at least one transition zone including a plurality of refractory metal carbide particles and a third metal binder having a third metal binder content, the third metal binder content being less than the first metal binder content and the second metal binder content.

Abstract: A downhole tool for increasing a diameter of a wellbore disposed within a subterranean formation. The downhole tool includes an underreamer having a plurality of cutter blocks moveably coupled thereto that move radially-outward from a refracted state to an expanded state. The cutter blocks cut the subterranean formation to increase the diameter of the wellbore from a first diameter to a second diameter when in the expanded state. A formation weakening tool may be coupled to the underreamer. The formation weakening tool weakens a portion of the subterranean formation positioned radially-outward therefrom.

Abstract: A roller cone drill bit includes a bit body, at least one leg extending downward from the bit body, a journal on each leg, and a roller cone mounted on each journal. A ball race is configured between each journal and roller cone, and a plurality of retention balls is disposed within each ball race. A ball hole extends from the back face of each leg to the ball race, and a ball hole plug fits within the ball hole. The ball hole plug is secured to the leg by a friction stir weld.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.

Abstract: A downhole cutting tool may include a tool body; a plurality of blades extending azimuthally from the tool body; and a plurality of cutting elements disposed on the plurality of blades, the plurality of cutting elements comprising: at least two non-planar cutting elements comprising a substrate and a diamond layer having a non-planar cutting end, wherein at least one of the at least two conical cutting elements has a positive back rake angle or positive side rake angle, and at least one of the at least two non-planar cutting elements has a negative back rake angle or a negative side rake angle.

Abstract: A cutting element for a drill bit that includes an outer support element having at least a bottom portion and a side portion; and an inner rotatable cutting element, a portion of which is disposed in the outer support element, wherein the inner rotatable cutting element includes a substrate and a diamond cutting face having a thickness of at least 0.050 inches disposed on an upper surface of the substrate; and wherein a distance from an upper surface of the diamond cutting face to a bearing surface between the inner rotatable cutting element and the outer support element ranges from 0 to about 0.300 inches is disclosed.