Abstract: An ultra-hard cutting element for use in a drill bit, such as a percussion drill bit, a rotary cone drill bit, a drag bit, or a reamer. The ultra-hard cutting element includes a base portion, an extension portion on an end of the base portion, and a lip on an outer surface of the extension portion. At least a portion of the outer surface of the extension portion includes an ultra-hard abrasive material. The ultra-hard abrasive material may be polycrystalline diamond or polycrystalline cubic boron nitride.

Abstract: A container assembly for use in a high-pressure press having a central pressure cell and a method of sealing a central pressure cell. The container assembly includes a container that receives a sample to be pressed, and a gasket distinct from the container, the gasket meeting the container at an interface. The container and the gasket are dimensioned to locate the interface within the central pressure cell.

Abstract: HPHT press system includes a thermal insulation layer. The thermal insulation layer includes CsCl, CsBr, CsI, or a combination thereof, and the thermal insulation layer is electrically insulating. The thermal insulation layer may include a thermal insulation sleeve and/or a thermal insulation button for an HPHT cell.

Abstract: HPHT press system includes a thermal insulation layer. The thermal insulation layer includes CsCl, CsBr, CsI, or a combination thereof, and the thermal insulation layer is electrically insulating. The thermal insulation layer may include a thermal insulation sleeve and/or a thermal insulation button for an HPHT cell.

Abstract: An ultra-hard cutting element for use in a drill bit, such as a percussion drill bit, a rotary cone drill bit, a drag bit, or a reamer. The ultra-hard cutting element includes a base portion, an extension portion on an end of the base portion, and a lip on an outer surface of the extension portion. At least a portion of the outer surface of the extension portion includes an ultra-hard abrasive material. The ultra-hard abrasive material may be polycrystalline diamond or polycrystalline cubic boron nitride.

Abstract: A container assembly for use in a high-pressure press having a central pressure cell and a method of sealing a central pressure cell. The container assembly includes a container that receives a sample to be pressed, and a gasket distinct from the container, the gasket meeting the container at an interface. The container and the gasket are dimensioned to locate the interface within the central pressure cell.

Abstract: A high-pressure high-temperature cell including two or more thermal insulation layers is described. A high-pressure high-temperature cell including a current path through a thermal insulation layer, the current path being electrically connected to a heating element and having an indirect path through the thermal insulation layer, is also described. High-pressure high-temperature press systems including the foregoing high-pressure high-temperature cells alone or in combination are also disclosed.

Abstract: A container assembly for use in a high-pressure press having a central pressure cell and a method of sealing a central pressure cell. The container assembly includes a container that receives a sample to be pressed, and a gasket distinct from the container, the gasket meeting the container at an interface. The container and the gasket are dimensioned to locate the interface within the central pressure cell.

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: Thermally-stable polycrystalline diamond materials 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.

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: A thermal insulation layer for an HPHT cell, the thermal insulation layer including CsCl, CsBr, CsI, or a combination thereof, and the thermal insulation layer being electrically insulating; the thermal insulation layer including a thermal insulation sleeve and/or a thermal insulation button for an HPHT cell; a pressure transfer medium for an HPHT cell, the pressure transfer medium including CsBr, CsI or a combination thereof; and a pressure transfer medium for an HPHT cell, the pressure transfer medium including CsCl and additive, with the proviso that the additive does not include ZrO2 are disclosed. HPHT press systems that include a thermal insulation layer or a pressure transfer medium according to embodiments of the present disclosure are also disclosed.

Abstract: A high-pressure high-temperature cell including two or more thermal insulation layers is described. A high-pressure high-temperature cell including a current path through a thermal insulation layer, the current path being electrically connected to a heating element and having an indirect path through the thermal insulation layer, is also described. High-pressure high-temperature press systems including the foregoing the high-pressure high-temperature cells alone or in combination are also disclosed.

Abstract: A container assembly for use in a high-pressure press having a central pressure cell and a method of sealing a central pressure cell. The container assembly includes a container that receives a sample to be pressed, and a gasket distinct from the container, the gasket meeting the container at an interface. The container and the gasket are dimensioned to locate the interface within the central pressure cell.

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: 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: 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 mat results in the forming of an ultrahard compact including an ultrahard layer integrally bonded with a substrate.

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: 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: 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.