Abstract: A modified cutting element that includes a base portion, an ultrahard layer disposed on the base portion, and at least one modified region disposed adjacent to a cutting face of the cutter. In certain applications, the ultrahard layer includes thermally stable polycrystalline diamond.

Abstract: A bottom hole assembly containing a drill bit. The drill bit additionally has a plurality of primary cutter elements mounted thereto. The plurality of cutter elements comprise one or more first cutter elements and one or more second cutter elements. The second cutter element differs from the first cutter element in at least one cutter element property. The first cutter element has a diamond body containing a first region comprising an infiltrant material disposed within the interstitial regions. The first region is located remote from the working surface of the diamond body. The first cutter element also contains a second region comprising interstitial regions that are substantially free of the infiltrant material. The second region is located along at least the working surface of the diamond body. Also included are a cutter element, method of designing a bottom hole assembly as well as method of designing a drill bit.

Abstract: A cutter having a base portion, an ultrahard layer disposed on the base portion, and at least one relief groove formed on an outer surface of the cutter. The at least one relief groove is configured to form a relief gap between the ultrahard layer and an inside surface of a cutter pocket.

Abstract: A cutter for a drill bit used for drilling wells in a geological formation includes an ultra hard working surface and a chamfer along an edge of the working surface, wherein the chamfer has a varied geometry along the edge. The average geometry of the chamfer varies with cutting depth. A depression in the shaped working surface is oriented with the varied chamfer and facilitates forming the varied chamfer. A non-planar interface has depressions oriented with depressions in the shaped working surface to provide support to loads on the working surface of the cutter when used.

Abstract: Cutting elements and bits incorporating such cutting elements. The cutting elements include a substrate having an interface surface over which is formed an ultra hard material layer. A plurality of lands are formed on the interface surface including a land surrounded by spaced-apart lands extending to a periphery of the substrate.

Abstract: A drill bit may include a bit body having a plurality of blades extending radially therefrom, the bit body comprising a first matrix region and a second matrix region, wherein the first matrix region is formed from a moldable matrix material having carbide particles with a unimodal particle size distribution; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades.

Abstract: A cutting element for a drill bit that includes an outer support element having at least a bottom portion and a side portion; and an inner rotatable cutting element. A portion of the inner rotatable cutting element is disposed in the outer support element, where the inner rotatable cutting element includes a substrate and a diamond cutting face having a thickness of at least 0.050 inches disposed on an upper surface of the substrate; and where a distance from an upper surface of the diamond cutting face to a bearing surface between the inner rotatable cutting element and the outer support element ranges from 0 to about 0.300 inches.

Abstract: A method for forming a cutting element that includes forming at least one cavity in at least one surface of a polycrystalline abrasive body; placing the polycrystalline abrasive body adjacent a substrate such that an opening of at least one cavity is adjacent the substrate at an interface, wherein an interface surface of the substrate is non-mating with the polycrystalline abrasive body; and subjecting the polycrystalline abrasive body and substrate to high pressure/high temperature conditions is disclosed.

Abstract: The present invention relates to ultra-hard cutting elements, and in particular cutting elements or compacts formed by a pulsed electrical field assisted HPHT sintering process or a spark plasma HPHT sintering process. In an embodiment, a method of forming a polycrystalline ultra-hard material includes providing a mixture of ultra-hard particles, placing the mixture of ultra-hard particles into an enclosure, placing the enclosure into a press cell assembly having a heater, applying a repeated high-energy pulse of direct current to the heater to heat the ultra-hard particles, and pressing the enclosure at sufficient pressure to form a polycrystalline ultra-hard material.

Abstract: A method for forming a thermally stable cutting element that includes forming at least one acid infusion pathway in a polycrystalline abrasive body containing a catalyzing material to be leached; and contacting at least a portion of the at least one acid infusion pathway in the polycrystalline abrasive body with a leaching agent is disclosed.

Abstract: A drill bit that includes a bit body having a plurality of blades extending radially therefrom, the bit body comprising a first matrix region and a second matrix region, wherein the first matrix region is formed from a moldable matrix material; and at least one cutting element for engaging a formation disposed on at least one of the plurality of blades is disclosed.

Abstract: Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided.

Abstract: Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided.

Abstract: Polycrystalline diamond constructions include a diamond body comprising a matrix phase of bonded together diamond crystals formed at high pressure/high temperature conditions with a catalyst material. The sintered body is treated remove the catalyst material disposed within interstitial regions, rendering it substantially free of the catalyst material used to initially sinter the body. Accelerating techniques can be used to remove the catalyst material. The body includes an infiltrant material disposed within interstitial regions in a first region of the construction. The body includes a second region adjacent the working surface and that is substantially free of the infiltrant material. The infiltrant material can be a Group VIII material not used to initially sinter the diamond body. A metallic substrate is attached to the diamond body, and can be the same or different from a substrate used as a source of the catalyst material used to initially sinter the diamond body.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.

Abstract: Polycrystalline diamond constructions comprises a diamond body attached to a metallic substrate, and having an engineered metal content. The body comprises bonded together diamond crystals with a metal material disposed interstitially between the crystals. A body working surface has metal content of 2 to 8 percent that increases moving away therefrom. A transition region between the body and substrate includes metal rich and metal depleted regions having controlled metal content that provides improved thermal expansion matching/reduced residual stress. A point in the body adjacent the metal rich zone has a metal content that is at least about 3 percent by weight greater than that at a body/substrate interface. The metal depleted zone metal content increases gradually moving from the body, and has a thickness greater than 1.25 mm. Metal depleted zone metal content changes less about 4 percent per millimeter moving along the substrate.

Abstract: Cutting elements are provided having substrates including end surfaces. TSP material layers extend over only a portion of the end surfaces or extend into the substrates below the end surfaces. Bits incorporating such cutting elements are also provided.

Abstract: Cutting elements include an ultra-hard body, e.g., comprising diamond, that is attached to substrate, e.g., comprising a cermet. An interface exists between the body and the substrate, and an angle of departure as measured between the interface and a free edge of the cutting element within one or both of the body and substrate, is less than about 90 degrees to provide a desired stress reduction along the interface. The angle of departure can be from about 3 to 87 degrees. The desired reduced angle of departure is provided by a surface feature disposed along an outer side surface of the cutting element adjacent a free edge of the interface. The surface feature can in the form of a groove disposed circumferentially around the body and/or substrate outer side surface, that is configured to provide the desired reduced angle of departure within the body and/or substrate.

Abstract: A drill bit comprises a bit body and a plurality of cutting blades extending radially from the bit body, the plurality of cutting blades further comprising cutting elements disposed thereon. The drill bit also comprises a plurality of utility blades extending radially from the bit body, the plurality of utility blades being free of cutting elements.

Abstract: PCD materials comprise a diamond body having bonded diamond crystals and interstitial regions disposed among the crystals. The diamond body is formed from diamond grains and a catalyst material at high pressure/high temperature conditions. The diamond grains have an average particle size of about 0.03 mm or greater. At least a portion of the diamond body has a high diamond volume content of greater than about 93 percent by volume. The entire diamond body can comprise high volume content diamond or a region of the diamond body can comprise the high volume content diamond. The diamond body includes a working surface, a first region substantially free of the catalyst material, and a second region that includes the catalyst material. At least a portion of the first region extends from the working surface to depth of from about 0.01 to about 0.1 mm.