Abstract: The present invention relates to tungsten-rhenium coated compounds, materials formed from tungsten-rhenium coated compounds, and to methods of forming the same. In embodiments, tungsten and rhenium are coated on ultra hard material particles to form coated ultra hard material particles, and the coated ultra hard material particles are sintered at high temperature and high pressure.

Abstract: A method for making a diamond compact includes pre-heating a diamond body which includes a carbonate catalyst to convert at least a portion of the carbonate catalyst into an oxide, assembling the diamond body and a substrate, providing a braze material between the diamond body and the substrate to form a diamond compact, heating the braze material to melt the braze material and form a braze joint between the diamond body and the substrate, and cooling the braze material after increasing the pressure. A bit having a diamond compact including a carbonate catalyst and a metal oxide mounted thereon.

Abstract: The present invention relates to tungsten-rhenium coated compounds, materials formed from tungsten-rhenium coated compounds, and to methods of forming the same. In embodiments, tungsten and rhenium are coated on ultra hard material particles to form coated ultra hard material particles, and the coated ultra hard material particles are sintered at high temperature and high pressure.

Abstract: Methods for joining an ultra-hard body, such as a thermally stable polycrystalline diamond (TSP) body, to a substrate and mitigating the formation of high stress concentration regions between the ultra-hard body and the substrate. One method includes covering at least a portion of the ultra-hard body with an intermediate layer, placing the ultra-hard body and the intermediate layer in a mold, filling a remaining portion of mold with a substrate material including a matrix material and a binder material such that the intermediate layer is disposed between the ultra-hard body and the substrate material, and heating the mold to an infiltration temperature configured to melt the binder material and form the substrate.

Abstract: Polycrystalline diamond compacts for cutting tools and rock drilling tools, and more particularly to very fine polycrystalline diamond compacts with a grain growth inhibitor layer and reduced abnormal grain growth. A method of fabricating such polycrystalline diamond material includes placing a powder layer of nano-sized grain growth inhibitor particles next to a mixture of diamond particles having an average particle size of about 1 micron or less and sintering at high pressure and high temperature to create a polycrystalline structure of sintered diamond grains. The sintered diamond grains have an average size of about 1 micron or less.

Abstract: A method for treating a polycrystalline diamond material includes subjecting the polycrystalline diamond material to a leaching process and to a thermal decomposition process.

Abstract: A method of forming a cutting element may include subjecting a first press containing at least a diamond powder-containing container and a volume of a high melting temperature non-reactive material to a first high pressure high temperature sintering condition to form a sintered polycrystalline diamond wafer including a diamond matrix of diamond grains bonded together and a plurality of interstitial spaces between the bonded together diamond grains; and subjecting a second press containing the sintered polycrystalline diamond wafer and a substrate to a second high temperature high pressure condition, thereby attaching the wafer to the substrate to form a cutting element having a polycrystalline diamond layer on the substrate.

Abstract: The present disclosure relates to cubic boron nitride (cBN) cutting elements that have high cBN content and that are cuttable by electric discharge machining (EDM). A cutting element according to an embodiment includes a self-sintered polycrystalline cubic boron nitride (PCBN) compact, having a first phase of cubic boron nitride (cBN) particles and a ceramic binder phase with titanium compounds. The first phase occupies greater than 80% by volume of the self-sintered PCBN compact. The self-sintered PCBN compact has an electrical conductivity sufficient to be cuttable by electrical discharge machining.

Abstract: The present disclosure relates to cubic boron nitride (cBN) cutting elements that have high cBN content and that are cuttable by electric discharge machining (EDM). A cutting element according to an embodiment includes a self-sintered polycrystalline cubic boron nitride (PCBN) compact, having a first phase of cubic boron nitride (cBN) particles and a ceramic binder phase with titanium compounds. The first phase occupies greater than 80% by volume of the self-sintered PCBN compact. The self-sintered PCBN compact has an electrical conductivity sufficient to be cuttable by electrical discharge machining.

Abstract: A method of making a cutting element includes subjecting a mixture of diamond particles and a carbonate material to high-pressure high-temperature sintering conditions to form a sintered carbonate-polycrystalline diamond body having a diamond matrix of diamond grains bonded together and carbonates residing in the interstitial regions between the diamond grains, the carbonate material having a non-uniform distribution throughout the diamond matrix. The carbonate-polycrystalline diamond body is subjected to a controlled temperature, a controlled pressure condition or a combination thereof, to effect an at least partial decomposition of the carbonate material.

Abstract: A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.

Abstract: A method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond with a first quantity of magnesium carbonate to form a first layer for forming a working surface, and combining a second quantity of magnesium carbonate to form a second layer adjacent to the first layer, forming an assembly. The method includes placing a quantity of silicon or aluminum in or adjacent to at least a portion of the assembly and sintering the assembly including the silicon or aluminum at high pressure and high temperature, causing the silicon or aluminum to infiltrate at least one layer of the assembly.

Abstract: A method of making a polycrystalline diamond compact includes forming multiple layers of premised diamond particles and carbonate material, where the carbonate material includes an alkaline earth metal, carbonate, and where each layer has a weight percent ratio of diamond to carbonate that is different from adjacent layers. The layers are subjected to high pressure high temperature conditions to form polycrystalline diamond.

Abstract: A method of forming a polycrystalline diamond body includes mixing a sintering agent with diamond powder to form a premixed layer, the sintering agent including at least one alkaline eat mewl carbonate; forming an infiltration layer adjacent to the premixed layer, the infiltration layer including an infiltrant material including at least one alkaline earth metal carbonate; and subjecting the premixed layer and the infiltration layer to high pressure high temperature conditions.

Abstract: The present disclosure relates to cutting tools incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to a thermally stable polycrystalline diamond body joined to a substrate to form a cutting element. The thermally stable polycrystalline diamond body may be binderless polycrystalline diamond or a non-metal catalyst polycrystalline diamond. A polycrystalline cubic boron nitride layer is also provided, bonded on one side to the polycrystalline diamond body and on the other side to the substrate.

Abstract: A method for making a thermally stable cutting element may include forming an acid mixture containing two different acid species by combining an acid solution and at least one acid-forming compound, wherein the at least one acid-forming compound is provided in solid form, and wherein the at least one acid-forming compound produces an acid that is different than the acid solution; treating at least a portion of a sintered diamond body by placing the sintered diamond body in the acid mixture, wherein the sintered diamond body comprises: a matrix phase of bonded-together diamond grains; a plurality of interstitial regions dispersed within the matrix phase; and a metal material disposed within a plurality of the interstitial regions; wherein the treating removes the metal material from at least a portion of the plurality of interstitial regions; and removing the sintered diamond body from the acid mixture after a predetermined length of time, wherein at least a portion of the diamond body removed from the acid mi

Abstract: The present disclosure relates to cubic boron nitride (cBN) cutting elements that have high cBN content and that are cuttable by electric discharge machining (EDM). A cutting element according to an embodiment includes a self-sintered polycrystalline cubic boron nitride (PCBN) compact, having a first phase of cubic boron nitride (cBN) particles and a ceramic binder phase with titanium compounds. The first phase occupies greater than 80% by volume of the self-sintered PCBN compact. The self-sintered PCBN compact has an electrical conductivity sufficient to be cuttable by electrical discharge machining.

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 method for making a thermally stable cutting element may include forming an acid mixture containing two different acid species by combining an acid solution and at least one acid-forming compound, wherein the at least one acid-forming compound is provided in solid form, and wherein the at least one acid-forming compound produces an acid that is different than the acid solution; treating at least a portion of a sintered diamond body by placing the sintered diamond body in the acid mixture, wherein the sintered diamond body comprises: a matrix phase of bonded-together diamond grains; a plurality of interstitial regions dispersed within the matrix phase; and a metal material disposed within a plurality of the interstitial regions; wherein the treating removes the metal material from at least a portion of the plurality of interstitial regions; and removing the sintered diamond body from the acid mixture after a predetermined length of time, wherein at least a portion of the diamond body removed from the acid mi