Abstract: An improved cutter for fixed cutter drill bits includes a base portion with a longitudinal axis that extends through a center of the base portion and a cutting face which is generally centered with the base portion. The cutting face has a periphery edge geometry comprising a first arcuate segment and a second arcuate segment spaced apart and arranged opposite each other with linear edge segments disposed there between forming sides of the cutting face. The cutting face spans a maximum edge-to-edge dimension L in a first direction that corresponds to a major axis of the cutting face. The cutting face spans a maximum edge-to-edge dimension W in a second direction, which is perpendicular to the first direction, and W is less than L.

Abstract: A fixed cutter drill bit including a bit body having a plurality of primary blades extending radially from a bit center area, wherein the bit center area includes a partial connection between at least two of the plurality of primary blades. The fixed cutter drill bit further including at least one cutter disposed on at least one of the blades. Additionally, a method of designing a fixed cutter drill bit includes modeling the fixed cutter drill bit, the fixed cutter drill bit including a plurality of primary blades extending radially from a bit center area, wherein the plurality of primary blades includes a plurality of cutters. The method further including determining a center of an innermost cutter on each primary blade, creating a partial connection between the primary blades, and outputting the model of the fixed cutter drill bit.

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: A sintered polycrystalline composite for cutting tools that includes a plurality of diamond or cubic boron nitride particles; a plurality of nanotube materials; and a refractory or binder material is disclosed. Methods of forming such polycrystalline composites that include integrating or mixing a plurality of nanotube materials with diamond or cubic boron nitride particle and/or refractory or binder particles are also disclosed.

Abstract: A composite body for cutting tools that includes a ductile phase; a plurality of carbide particles dispersed the ductile phase; and a plurality of nanotubes integrated into the composite body is disclosed. Methods of making such composite bodies and drill bits formed of such material are also disclosed.

Abstract: A drill bit that includes a bit body; and at least one cutting element for engaging the formation disposed on the bit body, the at least one cutting element comprising: a ductile phase; a plurality of carbide particles dispersed in the ductile phase; and a plurality of nanotubes integrated into the cutting element is disclosed.

Abstract: Drill bit reinforcing members or blanks of this invention are formed from high-strength steels having a carbon content less than about 0.3 percent by weight, a yield strength of at least 55,000 psi, a tensile strength of at least 80,000 psi, a toughness of at least 40 CVN-L, Ft-lb, and a rate of expansion percentage change less than about 0.0025%/° F. during austenitic to ferritic phase transformation. In one embodiment, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.5 to 1.5 percent by weight manganese, up to about 0.8 percent by weight chromium, 0.05 to 4 percent by weight nickel, and 0.02 to 0.8 percent by weight molybdenum. In another example, such steel comprises in the range of from about 0.1 to 0.3 percent by weight carbon, 0.9 to 1.5 percent by weight manganese, 0.1 to 0.5 percent by weight silicon, and one or more microalloying element selected from the group consisting of vanadium, niobium, titanium, zirconium, aluminum and mixtures thereof.

Abstract: Thermally stable ultra-hard compact constructions comprise a polycrystalline diamond body substantially free of a catalyst material, and a substrate that is joined thereto. The substrate can be ceramic, metallic, cermet and combinations thereof, and can be joined to the body by a braze material or other material that forms an attachment bond at high pressure/high temperature conditions. The body and substrate are specially formed having complementary interfacing surface features to facilitate providing an improved degree of attachment therebetween. The complementary surface features can in the form of openings and projections, e.g., one of the body or substrate can comprise one or more openings, and the other of the body or substrate can comprise one or more projections, disposed within or extending from respective interfacing surfaces. The complementary surface features operate to resist unwanted delamination between the body and substrate, thereby extending effective service life of the construction.

Abstract: A sintered body for cutting tools that includes hard particle phase comprising a plurality of hard particles, wherein at least a portion of the hard phase particles comprise a coating deposited by atomic layer deposition disposed thereon; and a binder phase is disclosed. The hard particles that may be included in the sintered bodies may include tungsten carbide, diamond, and boron nitride particles.

Abstract: Polycrystalline diamond composites comprise a polycrystalline diamond body having a plurality of ultra-hard discrete regions dispersed within a polycrystalline diamond second region. The plurality of discrete regions has an density different from of the polycrystalline diamond second region. A metallic substrate can be joined to the body. The discrete regions can be relatively more thermal stable than, have a higher diamond density than, and/or may comprise a binder material that is different from the polycrystalline diamond second region. Polycrystalline diamond composites can be formed by combining already sintered granules with diamond grains to form a mixture, and subjecting the mixture to high pressure/high temperature conditions, wherein the granules form the plurality of discrete regions, or can be made by forming a plurality of unsintered granules, combining them with diamond grains to form a mixture, and then subjecting the mixture to first and second high pressure/high temperature conditions.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. 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 modified cutting element that includes a base portion, an ultrahard layer disposed on said base portion, and at least one modified region disposed adjacent to a cutting face of the cutter is described. In certain applications, the ultrahard layer comprises thermally stable polycrystalline diamond.

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 which is disposed in the outer support element, wherin 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 wherein 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 is disclosed.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. 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. A plurality of depressions are formed on the lands.

Abstract: A cutting element is provided having a substrate and an ultra hard material cutting layer over the substrate. The cutting layer includes a surface portion for making contact with a material to be cut by the cutting element. The surface portion in cross-section has a curvature that has a varying radius of curvature. A bit incorporating such a cutting element is also provided.

Abstract: A method for designing a drill bit including selecting a characteristic associated with a failure mode. A first value of the characteristic of a first cutting element and a second value for the characteristic of a second cutting element are determined. The method also includes determining whether a difference between the first value and the second value is within a predetermined range. A cutting element design parameter for the first cutting element is adjusted if the difference is outside the predetermined range. The determining first and second values, determining the difference, and adjusting a cutting element design parameter are repeated until the difference is within the predetermined range.

Abstract: A method for forming a drill bit body is disclosed which comprises infiltrating powdered tungsten carbide with a binder alloy in a mold. The mold has therein at least one displacement adapted to form a mounting pad for a cutting element. The displacement comprises a substantially cylindrical body having a diameter selected to substantially conform to a radius of the cutting element and a projection adapted to form a relief groove under a position of a diamond table in the cutting element when the cutting element is mounted on the pad. The width of the relief groove is selected so that the relief groove extends back from an outer surface of the bit body at least about 40 percent of that portion of a thickness of the diamond table which does not extend past the outer surface.

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: 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: A cutter comprising a base portion, an ultrahard layer disposed on said base portion, and at least one recessed region on an outer surface of the cutter. A start of the recessed region disposed a selected distance behind a cutting face.