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: A method of manufacturing a drill bit having a bit body and a plurality of blades extending radially from the bit body is disclosed, wherein the method includes adhering a first matrix material to at least a portion of a mold cavity corresponding to an outer surface of the bit body, loading a second matrix material into the other portions of the mold cavity, and heating the mold contents to form a matrix body drill bit.

Abstract: Diamond bonded construction comprise a diamond body attached to a support. In one embodiment, an initial substrate used to sinter the body is interposed between the body and support, and is thinned to less than 5 times the body thickness, or to less than the body thickness, prior to attachment to the support to relieve stress in the body. In another embodiment, the substrate is removed after sintering, and the body is attached to the support. The support has a material construction different from that of the initial substrate, wherein the initial substrate is selected for infiltration and the support for end use properties. The substrate and support include a hard material with a volume content that may be the same or different. Interfaces between the body, substrate, and/or support may be nonplanar. The body may be thermally stable, and may include a replacement material disposed therein.

Abstract: A cutter assembly may include a multi-piece split sleeve, an inner cutting element having a groove or protrusion formed in a side surface thereof and disposed in the multi-piece split sleeve, and at least one component interfacing at least a portion of the groove or the protrusion to limit axial movement of the inner cutting element with respect to the multi-piece split sleeve, in which the multiple pieces of the split sleeve are joined together at an overlapping joint.

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, wherein 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: A cutting element assembly includes a cutting element partially disposed within a support and a retention mechanism disposed between the cutting element and the support, both the axial and radial dimensions of the retention mechanism being deformable.

Abstract: A cutting tool having a tool body with a plurality of blades extending radially therefrom and a plurality of rotatable cutting elements mounted on at least one of the plurality of blades is disclosed, wherein the plurality of rotatable cutting elements are mounted on the at least one blade utilizing multiple side rake angles.

Abstract: A cutter assembly may include a sleeve having at least one passageway extending through the sleeve from a outer surface thereof into an inner surface thereof; at least one rotatable cutting element disposed in the sleeve, wherein the at least one rotatable cutting element has a circumferential groove formed in a side surface thereof, wherein when the inner rotatable cutting element is disposed in the sleeve, the circumferential groove is aligned with the passageway; and a retention element disposed in at least a portion of the passageway and the circumferential groove to retain the at least one rotatable cutting element in the sleeve, wherein the retention element has an axis that is parallel to a tangent of the rotatable cutting element side surface at least one point of contact with the rotatable cutting element.

Abstract: A drill bit has a bit body, a plurality of blades extending radially from the bit body, at least one rolling cutter pocket disposed on the plurality of blades, and at least one rolling cutter, wherein each rolling cutter is disposed in one of the rolling cutter pockets, and wherein a side surface of the rolling cutter pocket and an outer circumferential surface of the rolling cutter have at least one mating lip and channel formed therein. Further, the rolling cutter may include a cavity extending at least partially along a rotational axis through the rolling cutter, from a bottom surface of the rolling cutter, and a retention pin disposed within the cavity.

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: A drill bit may have a bit body, a plurality of cutting blades extending radially from the bit body and having cutting elements disposed thereon, the plurality of cutting blades forming a cutting blade gage pad diameter configured to contact a formation, and a plurality of raised volumes of material extending from the bit body and devoid of cutting elements, the plurality of raised volumes of material forming a gage pad diameter configured to contact the formation, wherein the plurality of cutting blades and the plurality of raised volume of material are circumferentially spaced having fluid courses that extend therebetween.

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: A cutting element may include a polycrystalline diamond layer and a reduced-CTE substrate comprising diamond particles disposed in a matrix material, wherein the diamond particles have a contiguity of 15% or less. Also, a cutting element may include a polycrystalline diamond layer and a reduced-CTE substrate comprising a matrix material, at least one diamond-filled region, and embedded diamond particles.

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, wherein 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: Cutter assemblies include an outer support and a cutting element disposed therein. The cutting element is immovably attached to the outer support element. Also disclosed is downhole tools incorporating such cutter assemblies and methods of making such downhole tools.

Abstract: A cutting element assembly includes a sleeve, a lining extending a distance axially from an end of the sleeve, and an inner cutter. The inner cutter has a cutting end, wherein the cutting end extends a depth from a cutting face, a side surface, and a body, wherein the body is at least partially disposed within the sleeve, and wherein the side surface of the cutting end interfaces with an interfacing surface of the lining.

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: Cutter assemblies comprising an outer support element and a cutting element disposed therein. The cutting element is immovably attached to the outer support element. Also provided are downhole tools incorporating such cutter assemblies and methods of making such downhole tools.

Abstract: The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance.

Abstract: A cutting tool cutting tool may include a tool body having a plurality of blades extending radially therefrom, a plurality of rotatable cutting elements having a first chamfer mounted on at least one of the plurality of blades, and a plurality of non-rotatable cutting elements having a second, distinct chamfer mounted on at least one the plurality of blades.