Abstract: A non-uniform interface is formed between a polycrystalline ultra hard material layer and a cemented tungsten carbide substrate, or a polycrystalline ultra hard material layer and a transition layer, or a transition layer and a substrate of a cutting element. A first sheet made from an intermediate material is formed and embossed on one face forming a non-uniform pattern raised in relief on the face. The embossed sheet is placed on a face of a presintered substrate. An ultra hard material sheet is formed and embossed, forming a non-uniform face complementary to the non-uniform face on the sheet of intermediate material. The ultra hard material sheet is placed over the intermediate material sheet so that the complementary faces are adjacent to each other. The assembly of substrate and sheets is sintered in a HPHT process.

Abstract: Cutting elements having a non-planar substrate interface surface including a band and an ultra hard material layer over the interface surface are provided. Also provided are earth boring bits incorporating such cutting elements.

Abstract: A gage trimmer and a bit incorporating such a gage trimmer are provided. The gage trimmer has an ultra hard material layer having a circumferential surface including a cylindrical portion and a flat surface for bearing against a circumferential wall of a hole drilled by the bit. The ultra hard material layer is formed over a substrate interface surface. The flat surface does not extend to the interface surface.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed a 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 cutting layer is provided having a radially extending depression formed on the exposed surface of the cutting element's cutting layer. A corresponding depression may be formed on the substrate end surface below the depression formed on the cutting layer. Furthermore, secondary shallower depressions may be formed on the cutting layer. The cutting element is typically mounted in a drag bit such that the cutting layer radially extending depression makes contact with the earth formations.

Abstract: A gage trimmer and a bit incorporating such a gage trimmer are provided. The gage trimmer has an ultra hard material layer having a circumferential surface including a cylindrical portion and a flat surface for bearing against a circumferential wall of the a hole drilled by the bit. The ultra hard material layer is formed over a substrate interface surface. The flat surface does not extend to the interface surface.

Abstract: Cutting elements for incorporation in a drill bit are provided having a body and an ultra hard material cutting layer over an end face of the body. A plurality of abutting shallow depressions are formed on the end face of the body. A transition layer may be incorporated between the body and the ultra hard material layer. The transition layer preferably has material properties intermediate between the properties of the body and the ultra hard material layer.

Abstract: Cutting elements for incorporation in a drill bit are provided having a body having an end face interfacing with an ultra hard material cutting layer. A main depression having a nonplanar surface is formed on the substrate and extending to the peripheral edge of the substrate subjected to the highest impact loads during drilling. This edge is immediately below the edge of the cutting layer which makes direct contact with the earth formations during drilling. The main depression is formed by forming a plurality of secondary depressions or steps. A second main depression is formed by forming a plurality of secondary depressions or steps. The second main depression also extends to the peripheral edge of the substrate. An ultra hard material layer is bonded to the end face of the cutting element body over the main depressions.

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: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

Abstract: A cutter element for use in a drill bit, comprising a substrate and a cutting layer. The substrate comprises a grip portion and an extension portion, where the grip portion has an insert axis and an extension portion including an interface surface having a first apex. The cutting layer is affixed to the interface surface and has a cutting surface having a second apex. The cutting layer is shaped such that when a plane passing through the first apex and lying parallel to the insert axis and normal to a radius from the insert axis, the plane divides the cutting layer into major and minor portions and the major portion has a major volume that is at least 60 percent of the total volume of said cutting layer. Alternative embodiments of the present invention include variations wherein the first and second apices do not coincide and wherein the interface surface of the substrate is not axisymmetric. Using these variations, cutter elements having sizeable variations in thickness are constructed.

Abstract: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

Abstract: A cutting element having a cutting table made from sheet segments of commingled ultra hard material and binder. Each segment may be made from a finer or a coarser grade of ultra hard material or from different types of ultra hard material. The segments are aligned side by side over a cutting face of the cutting element to form the cutting table. The material grade and/or the material type of each segment may alternate across the cutting face.

Abstract: Cutting elements for incorporation in a drill bit are provided having a body and an ultra hard material cutting layer over an end face of the body. A plurality of abutting shallow depressions are formed on the end face of the body. A transition layer may be incorporated between the body and the ultra hard material layer. The transition layer preferably has material properties intermediate between the properties of the body and the ultra hard material layer.

Abstract: Cutting elements for incorporation in a drill bit are provided having a body having an end face interfacing with an ultra hard material cutting layer. A main depression having a nonplanar surface is formed on the substrate and extending to the peripheral edge of the substrate subjected to the highest impact loads during drilling. This edge is immediately below the edge of the cutting layer which makes direct contact with the earth formations during drilling. The main depression is formed by forming a plurality of secondary depressions or steps. A second main depression is formed by forming a plurality of secondary depressions or steps. The second main depression also extends to the peripheral edge of the substrate. An ultra hard material layer is bonded to the end face of the cutting element body over the main depressions.

Abstract: Enhanced inserts are formed having a cylindrical grip and a protrusion extending from the grip. An ultra hard material layer is bonded on top of the protrusion. The inserts are mounted on a rock bit and contact the earth formations off center. The ultra hard material layer is thickest at a critical zone which encompasses a major portion of the region of contact between the insert and the earth formation. Transition layers may also be formed between the ultra hard material layer and the protrusion so as to reduce the residual stresses formed on the interface between the ultra hard material and the protrusion.

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

Abstract: A cutting layer is provided having a radially extending depression formed on the exposed surface of the cutting element's cutting layer. A corresponding depression may be formed on the substrate end surface below the depression formed on the cutting layer. Furthermore, secondary shallower depressions may be formed on the cutting layer. The cutting element is typically mounted in a drag bit such that the cutting layer radially extending depression makes contact with the earth formations.

Abstract: A cutting element having a cutting table made from sheet segments of commingled ultra hard material and binder. Each segment may be made from a finer or a coarser grade of ultra hard material or from different types of ultra hard material. The segments are aligned side by side over a cutting face of the cutting element to form the cutting table. The material grade and/or the material type of each segment may alternate across the cutting face.