Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A method of fabricating a structure having an open cell foam element includes providing an open cell foam element of metallic, diamond, ceramic and/or refractory material form, and/or having one or more metallic, diamond, ceramic and/or refractory material coatings, the foam element defining a plurality of interconnected cells. The method further includes locating a material within the cells, and treating the material, in situ, by sintering and/or infiltration, to form a continuous mesh or lattice structure that extends within and through the cells of the open cell foam element. Structures fabricated using the method are also described.

Abstract: A cutting element comprises a table of superhard material bonded to a substrate, wherein the table defines a cutting edge and has a chamfered peripheral edge, and a groove in a sidewall of the cutting element passes through the chamfered peripheral edge, so as to reduce the depth of the chamfer at the location of the groove.

Abstract: A cutting element comprises a table of superhard material bonded to a substrate, wherein the table defines a cutting edge and has a chamfered peripheral edge, and a groove in a sidewall of the cutting element passes through the chamfered peripheral edge, so as to reduce the depth of the chamfer at the location of the groove.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.

Abstract: A polycrystalline-diamond cutting element for a drill bit of a downhole tool. The cutting element includes a substrate and a diamond table bonded to the substrate. The diamond table includes a diamond filler with at least one leached polycrystalline diamond segment packed therein along at least one working surface thereof. The cutting element may be formed by positioning the diamond table on the substrate and bonding the diamond table onto the substrate such that the polycrystalline diamond segment is positioned along at least one working surface of the diamond table. A spark plasma sintering or double press operation may be used to bond the diamond table onto the substrate.