Abstract: A method of manufacturing a component for use in a high pressure press includes successively depositing a volume of one or more materials using a deposition device to build a three dimensional body of the component having a selected material property varied along at least one direction of the component for use in the high pressure press.

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 of manufacturing a component for use in a high pressure press includes successively depositing a volume of one or more materials using a deposition device to build a three dimensional body of the component having a selected material property varied along at least one direction of the component for use in the high pressure press.

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: 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: 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: Thermally stable ultra-hard polycrystalline materials and compacts comprise an ultra-hard polycrystalline body that wholly or partially comprises one or more thermally stable ultra-hard polycrystalline region. A substrate can be attached to the body. The thermally stable ultra-hard polycrystalline region can be positioned along all or a portion of an outside surface of the body, or can be positioned beneath a body surface. The thermally stable ultra-hard polycrystalline region can be provided in the form of a single element or in the form of a number of elements. The thermally stable ultra-hard polycrystalline region can be formed from precursor material, such as diamond and/or cubic boron nitride, with an alkali metal catalyst material. The mixture can be sintered by high pressure/high temperature process.

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: Thermally stable diamond-bonded compacts include a diamond-bonded body having a thermally stable region extending a distance below a diamond-bonded body surface. The thermally stable region comprises a matrix first phase of bonded together diamond crystals, and a second phase interposed within the matrix phase. At least some population of the second phase comprises a reaction product formed between an infiltrant material and the diamond crystals at high pressure/high temperature conditions. The diamond bonded body further includes a polycrystalline diamond region that extends a depth from the thermally stable region and has a microstructure comprising a polycrystalline diamond matrix phase and a catalyst material disposed within interstitial regions of the matrix phase. The compact includes a substrate attached to the diamond-bonded body.

Abstract: PCD composite constructions comprise a diamond body bonded to a substrate. The diamond body comprises a thermally stable diamond bonded region that is made up of a single phase of diamond crystals bonded together. The diamond body includes a PCD region bonded to the thermally stable region and that comprises bonded together diamond crystals and interstitial regions interposed between the diamond crystals. The PCD composite is prepared by combining a first volume of PCD with a second volume of diamond crystal-containing material consisting essentially of a single phase of bonded together diamond crystals. A substrate is positioned adjacent to or joined to the first volume. The first and second volumes are subjected to high pressure/high temperature process conditions, during process the first and second volumes form a diamond bonded body that is attached to the substrate, and the second volume forms the thermally stable diamond bonded region.

Abstract: Thermally stable ultra-hard compact constructions of this invention comprise an ultra-hard material body that includes a thermally stable region positioned adjacent a surface of the body. The thermally stable region is formed from consolidated materials that are thermally stable at temperatures greater than about 750° C. The thermally stable region can occupy a partial portion of or the entire ultra-hard material body. The ultra-hard material body can comprise a composite of separate ultra-hard material elements that each form different regions of the body, at least one of the regions being thermally stable. The ultra-hard material body is attached to a desired substrate, an intermediate material is interposed between the body and the substrate, and the intermediate material joins the substrate and body together by high pressure/high temperature process.

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: Cutting elements of this invention include an ultra hard body joined with a metallic substrate. The body includes an uppermost layer comprising a plurality of bonded ultra hard crystals and interstitial regions, and that defines a body working surface. The uppermost layer includes an outer region that is relatively more thermally stable than a remaining portion of the uppermost layer. The body further includes an intermediate layer joined to the uppermost layer, comprising a plurality of bonded ultra hard crystals, and having a wear resistance less than that of the uppermost layer remaining region. The body may additionally include a lowermost PCD layer that is interposed between and attached to the intermediate layer and the substrate.

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: Thermally stable diamond bonded materials and compacts include a diamond body having a thermally stable region and a PCD region, and a substrate integrally joined to the body. The thermally stable region has a microstructure comprising a plurality of diamond grains bonded together by a reaction with a reactant material. The PCD region extends from the thermally stable region and has a microstructure of bonded together diamond grains and a metal solvent catalyst disposed interstitially between the bonded diamond grains. The compact is formed by subjecting the diamond grains, reactant material, and metal solvent catalyst to a first temperature and pressure condition to form the thermally stable region, and then to a second higher temperature condition to both form the PCD region and bond the body to a desired substrate.

Abstract: Thermally-stable polycrystalline diamond materials of this invention comprise a first phase including a plurality of bonded together diamond crystals, and a second phase including a reaction product formed between a binder/catalyst material and a material reactive with the binder/catalyst material. The reaction product is disposed within interstitial regions of the polycrystalline diamond material that exists between the bonded diamond crystals. The first and second phases are formed during a single high pressure/high temperature process condition. The reaction product has a coefficient of thermal expansion that is relatively closer to that of the bonded together diamond crystals than that of the binder/catalyst material, thereby providing an improved degree of thermal stability to the polycrystalline diamond material.

Abstract: A cutting element and bit incorporating the cutting element is provided, as well as a method for forming the same. The cutting element includes an ultra hard material layer including chromium and carbon and exhibiting increased abrasion resistance without sacrificing toughness. The method for manufacturing the cutting element includes providing a layer of ultra hard material particles and chromium carbide over the substrate, and then sintering to form the cutting element.

Abstract: An ultra-hard semiconductive polycrystalline diamond (PCD) material formed with semiconductive diamond particles doped with Li, Be or Al and/or insulative diamond particles having semiconductive surfaces, tools incorporating the same, and methods for forming the same, are provided. The ultra-hard PCD material may be formed using a layer of insulative diamond grit feedstock that includes additives therein, then sintering to convert a plurality of the diamond crystals to include a semiconductive surface. In another embodiment, the ultra-hard PCD material is formed by sintering semiconductive diamond grit feedstock consisting of diamond crystals doped with Li, Al or Be. The ultra-hard semiconductive PCD cutting layer exhibits increased cuttability, especially in EDM and EDG cutting operations.

Abstract: An ultra-hard semiconductive polycrystalline diamond (PCD) material formed with semiconductive diamond particles doped with and additive, as for example, Li, Be or Al and/or insulative diamond particles having semiconductive surfaces, tools incorporating the same, and methods for forming the same, are provided. The ultra-hard PCD material may be formed using a layer of insulative diamond grit feedstock that includes additives therein, then sintering to convert a plurality of the diamond crystals to include a semiconductive surface. In another embodiment, the ultra-hard PCD material is formed by sintering semiconductive diamond grit feedstock consisting of diamond crystals doped with an additive as for example Li, Al or Be. The ultra-hard semiconductive PCD cutting layer exhibits increased cuttability, especially in EDM and EDG cutting operations. A cutting element is provided having such a PCD layer. Furthermore, a bit is provided having a cutting element having such a PCD layer.

Abstract: A cutting element and bit incorporating the cutting element is provided, as well as a method for forming the same. The cutting element includes an ultra hard material layer including chromium and carbon and exhibiting increased abrasion resistance without sacrificing toughness. The method for manufacturing the cutting element includes providing a layer of ultra hard material particles and chromium carbide over the substrate, and then sintering to form the cutting element.