Abstract: A cutting element includes a substrate and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer having a ridge extending along a major dimension of the top surface from an edge of the top surface, where the ridge has a peak with at least two different roof radii of curvature, and at least two sidewalls sloping in opposite directions from the peak of the ridge at a roof angle, where a first roof angle of the ridge proximate the edge is smaller than a second roof angle in a central portion of the ridge around a longitudinal axis of the cutting element.

Abstract: A cutting element includes a substrate and an ultrahard layer on an upper surface of the substrate, a top surface of the ultrahard layer having a ridge extending along a major dimension of the top surface from an edge of the top surface, where the ridge has a peak with at least two different roof radii of curvature, and at least two sidewalls sloping in opposite directions from the peak of the ridge at a roof angle, where a first roof angle of the ridge proximate the edge is smaller than a second roof angle in a central portion of the ridge around a longitudinal axis of the cutting element.

Abstract: A method for sintering includes loading a tool material into a resistance heating element within a HPHT press and heating the resistance heating element at a first axial portion to a control temperature, where a temperature difference is measured between the control temperature and a second temperature measured at a distal axial portion along the resistance heating element, wherein a difference between the control temperature and the second temperature ranges between about 5 percent to about 11 percent of the control temperature.

Abstract: A method for sintering includes loading a tool material into a resistance heating element within a HPHT press and heating the resistance heating element at a first axial portion to a control temperature, where a temperature difference is measured between the control temperature and a second temperature measured at a distal axial portion along the resistance heating element, wherein a difference between the control temperature and the second temperature ranges between about 5 percent to about 11 percent of the control temperature.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the crystals. A metallic substrate is attached to the diamond body. A working surface is positioned along an outside portion of the diamond body, and the diamond body comprises a first region that is substantially free of a catalyst material, and a second region that includes the catalyst material. The diamond body first region extends from the working surface to depth of at least about 0.02 mm to a depth of less than about 0.09 mm. The diamond body includes diamond crystals having an average diamond grain size of greater than about 0.02 mm, and comprises at least 85 percent by volume diamond based on the total volume of the diamond body.

Abstract: Polycrystalline diamond (PCD) carbide composites of this invention have a microstructure comprising a plurality of granules formed from PCD, polycrystalline cubic boron nitride, or mixture thereof, that are distributed within a substantially continuous second matrix region that substantially surrounds the granules and that is formed from a cermet material. In an example embodiment, the granules are polycrystalline diamond and the cermet material is cemented tungsten carbide. PCD carbide composites of this invention display improved properties of fracture toughness and chipping resistance, without substantially compromising wear resistance, when compared to conventional pure PCD materials.

Abstract: A friction stirring tool and a method for removing the catalytic phase from the friction stirring tool having a superabrasive coating by chemically etching, electrolytic etching or similar means to thereby at least partially remove a portion of the secondary catalytic phase metal from the superabrasive coating to thereby enhance the thermal stability of the tool and allow for longer life and the reduction or elimination of chemical reaction between the secondary metallic phase of the tool and a workpiece.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and to a bit incorporating such cutting element. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: Ultrahard composite constructions comprise a plurality of first phases dispersed within a matrix second phase, wherein each can comprise an ultrahard material including PCD, PcBN, and mixtures thereof. The constructions are formed from a plurality of granules that are combined and sintered at HP/HT conditions. The granules include a core surrounded by a shell and both are formed from an ultrahard material or precursor comprising an ultrahard constituent for forming the ultrahard material. When sintered, the cores form the plurality of first phases, and the shells form at least a portion of the second phase. The ultrahard material used to form the granule core may have an amount of ultrahard constituent different from that used to form the granule shell to provide desired different properties. The ultrahard constituent in the granule core and shell can have approximately the same particle size.

Abstract: A method is provided for controlling the consistency of the quality of ultra hard materials formed over tungsten carbide substrates formed from different batches of tungsten carbide powder by controlling the tungsten carbide particle size distribution in each batch.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals and interstitial regions disposed among the crystals. A metallic substrate is attached to the body. The body includes a first region substantially free of a catalyst material that extends a partial depth from a surface into the body, and a second region that includes the catalyst material. The body can include natural diamond grains and/or a blend of natural and synthetic diamond grains, and is treated to form the first region. Before treatment, a portion of the body to be treated is finished to an approximate final dimension so that the depth of the first region of the finished product is substantially the same as when treated. During treatment, catalyst materials as well as non-catalyst metallic materials are removed from the diamond body to provide a further enhanced degree of thermal stability.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals and a plurality of interstitial regions disposed among the crystals. A metallic substrate is attached to the diamond body. A working surface is positioned along an outside portion of the diamond body, and the diamond body comprises a first region that is substantially free of a catalyst material, and a second region that includes the catalyst material. The diamond body first region extends from the working surface to depth of at least about 0.02 mm to a depth of less than about 0.09 mm. The diamond body includes diamond crystals having an average diamond grain size of greater than about 0.02 mm, and comprises at least 85 percent by volume diamond based on the total volume of the diamond body.

Abstract: Thermally stable diamond constructions comprise a diamond body having a plurality of bonded diamond crystals, a plurality of interstitial regions disposed among the crystals, and a substrate attached to the body. The body includes a working surface and a side surface extending away from the working surface to the substrate. The body comprises a first region adjacent the side surface that is substantially free of a catalyst material and that extends a partial depth into the diamond body. The first region can further extend to at least a portion of the working surface and a partial depth therefrom into the diamond body. The diamond body can be formed from natural diamond grains and/or a mixture of natural and synthetic diamond grains. A surface of the diamond body is treated to provide the first region, and before treatment is finished to an approximate final dimension.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and a method of forming the same. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: A method for manufacturing an ultrahard compact includes assembling a mass of ultrahard material with a mass of substrate material such that the mass of ultrahard material extends radially outward a greater extent than the substrate material to compensate for a difference in the radial shrinkage of the ultrahard material compared to the substrate material during a sintering process. The method may further includes subjecting the assembled compact to a high pressure high temperature process that results in the forming of an ultrahard compact including an ultrahard layer integrally bonded with a substrate.

Abstract: A compact having a tungsten carbide substrate and an ultra hard material layer is provided. Also provided is a method of forming such a compact and a bit incorporating such compact. The compact tungsten carbide substrate has a lower content of cobalt than conventional compact substrates. The compact substrate may have tungsten carbide particles having a median particle size greater than conventional compact substrates.