Abstract: A cutting element includes a substrate configured to couple to a pocket formed in a blade of a downhole drill bit and a polycrystalline diamond portion secured to the substrate. The polycrystalline diamond portion includes a cutting face, a radial sidewall, and a cutting edge formed at a transition from the radial sidewall to the axial the cutting face. The cutting face includes a plow feature disposed at a center of the cutting face. The plow feature has a face portion and a shoulder portion. The shoulder portion extends radially outward from the face portion and axially downward toward the substrate. Additionally, the cutting face includes a recessed portion extending between the cutting edge and a radially outer edge of the shoulder portion.

Abstract: Cutting elements are installed on the outer surface of a drill bit body such that the surface profile supports the plurality of cutting elements in a desired orientation. Each cutting element has a substrate with a rear end, a leading end that carries a cutting portion, and a cylindrical surface therebetween. The cutting elements are installed within a cavity on the drill bit body such that a portion of the substrate is exposed and the leading end leads the cutting element in a direction of rotation of the drill bit body. The cutting elements are bound on the outer surface by applying a composite to the outer surface and to the portion of the substrate that is exposed. The composite is a mixture of a matrix and cutting fragments and is in direct contact with about 40-75% of the surface area of the substrate.

Abstract: An earth boring tool includes a tool body and a cutting element secured to the tool body. The tool body has at least one surface defining a cutting element recess where the cutting element is secured within the cutting element recess by a braze material. The cutting element includes a generally cylindrical substrate having at least one outer surface defining a braze recess. The braze material is disposed at an interface between the cutting element and the cutting element recess, including within the braze recess of the generally cylindrical substrate. The tool body does not include a surface defining a feature on the tool body complementary to the braze recess in the generally cylindrical substrate.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Abstract: A sensor system has a cutter element for a cutting tool, an interrogation transceiver operable to transmit a radio-frequency (RF) interrogation signal; and a sensor transceiver system operable to receive the RF interrogation signal and to transmit an RF response signal. The sensor transceiver system includes a signal guide medium configured to transduce between the RF interrogation signal, a guided signal in the signal guide medium, and the RF response signal. A characteristic of the RF response signal is dependent upon a condition of the signal guide medium. The cutter element includes the signal guide medium to allow the condition of the signal guide medium to depend upon a condition of the cutter element proximate the signal guide medium. A method of using the sensor system is also disclosed.

Abstract: A cutting element includes a substrate and a cutting table secure to the substrate. The cutting table includes a first surface, a cutting surface, a first transition surface, and a second transition surface. The cutting surface at least substantially surrounds an outer boundary of the first surface and is angled relative to a longitudinal centerline of the cutting table. The first and second transition surfaces are between the cutting surface and an outer lateral edge of the cutting table. The first and second transition surfaces are oriented at a first angle and a second different angle, respectively, relative to the longitudinal centerline of the cutting table. An earth-boring tool and method of forming an earth-boring tool are also described.

Abstract: Cutting elements include a carbonate diamond-bonded body that is sintered under HPHT conditions in the presence of a carbonate material, where the body includes a matrix phase of intercrystalline bonded diamond with interstitial regions including the carbonate material, where the diamond-bonded body is sintered without a substrate. A matrix casting is formed and mechanically coupled to the body after the body is sintered, and a portion of the body surface is exposed along a surface of the matrix casting. The exposed body surface is thereafter intentionally treated to induce a compressive residual surface stress that is greater than a remaining portion of the body. The compressive residual surface stress is less than about 500 MPa, and from about 100 to 500 MPa, and a remaining region the body may have a residual stress of less than about 300 MPa, and less than about 100 MPa.

Abstract: A method of forming a supporting substrate for a cutting element comprises forming a precursor composition comprising discrete WC particles, a binding agent, and discrete particles comprising Co, one or more of Al, Be, Ga, Ge, Si, and Sn, and one or more of C and W. The precursor composition is subjected to a consolidation process to form a consolidated structure including WC particles dispersed in a homogenized binder comprising Co, W, C, and one or more of Al, Be, Ga, Ge, Si, and Sn. A method of forming a cutting element, a cutting element, a related structure, and an earth-boring tool are also described.

Abstract: A bit for drilling a wellbore includes: a body; and a cutting face. The cutting face includes: an inner section and an outer section; a plurality of blades protruding from the body, and a row of superhard cutters mounted along each blade, the cutters in the inner section having a negative profile angle and the cutters in the outer section having a positive profile angle. At least one of: at least one inner cutter is oriented at a negative side rake angle to create a weight on bit (WOB) reducing effect, and at least one outer cutter is oriented at a positive side rake angle to create the WOB reducing effect. Each of the rest of the cutters are oriented at a side rake angle such that an overall effect of the side rake angles is the WOB reducing effect.

Abstract: In some examples, a method for additive manufacturing an article, the method including depositing a filament via a filament delivery device to form at least one track of the deposited filament, the at least one track of the deposited filament forming at least a portion of a preform article, wherein the filament includes a sacrificial binder and a powder, wherein the powder includes a plurality of elongated particles with each respective particle defining a longitudinal axis, wherein the longitudinal axes of the plurality of particles are substantially aligned with each other within the at least one track of the deposited filament; removing substantially all the binder from the at least one track of the preform article to form a powder article; and sintering the powder article to form a sintered article.

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a structure for enhancing at least one of abrasion resistance, thermal stability, or impact resistance. In an embodiment, a PDC includes a PCD table. The PCD table includes a lower region including a plurality of diamond grains exhibiting a lower average grain size and at least an upper region adjacent to the lower region and including a plurality of diamond grains exhibiting an upper average grain size. The lower average grain size may be at least two times greater than that of the upper average grain size. The PDC includes a substrate having an interfacial surface that is bonded to the lower region of the PCD table. Other embodiments are directed methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Abstract: A polycrystalline diamond is formed on a substrate to form a polycrystalline diamond compact (PDC) cutter for a tool. The polycrystalline diamond has a cross-sectional dimension of at least 4 millimeters. The substrate includes tungsten carbide. An outer surface of the PDC cutter is at least partially surrounded with at least a single layer of coating by atomic layer deposition. The single layer of coating is configured to protect the PDC cutter from thermal degradation in response to exposure to a temperature greater than 700 degrees Celsius (° C.) and less than about 1050° C.

Abstract: A system for improving drill bit performance, having processors and memory storing instructions to obtain a wear report for a drill bit, wherein the wear report includes wear characteristics of the drill bit and drill operating parameters under which the drill bit was used; compare the wear characteristics of the drill bit to a threshold for acceptable drill bit wear; and adjust drill operating parameters based on the wear characteristics of the drill bit. The instructions to obtain the wear report for the drill bit include instructions to analyze images of the drill bit to identify wear characteristics; identify wear patterns based on the wear characteristics of the drill bit; identify probable drilling conditions based on the wear patterns; and generate the wear report for the drill bit based on the images of the drill bit, the wear characteristics of the drill bit, and the probable drilling conditions.

Abstract: The present disclosure provides a sintering assembly and a polycrystalline diamond compact (PDC) including a acid-labile leach-enhancing material, a PDC including cavities formed by removal of an acid-labile leach-enhancing material, and a method of forming a leached PDC using an acid-labile leach-enhancing material. The present disclosure further includes drill bits using PDCs formed suing an acid-labile leach-enhancing material.

Abstract: A cutter element for an earth-boring tool, comprising a polycrystalline diamond (PCD) volume joined at an interface boundary to a cemented carbide substrate. The PCD volume includes a rake face opposite the interface boundary, an edge of the rake face being suitable as a cutting edge of the cutter element. The PCD volume comprises a plurality of strata directly joined to each other at inter-strata boundaries, in which each of a first plurality of the strata comprises PCD material having a first diamond content; each of a second plurality of the strata comprises PCD material having a second diamond content; the second diamond content being greater than the first diamond content; and the strata of the first and second pluralities disposed in an alternating arrangement with respect to each other.

Abstract: A drill bit for subterranean drilling operations is disclosed. The drill bit comprises a drill bit body with one or more blades. The drill bit further comprises a plurality of primary cutters, each primary cutter located on at least one blade, and a plurality of secondary cutters, each secondary cutter located on at least one blade other than the blade on which the primary cutters are located.

Abstract: A drilling tool for drilling a wellbore in a formation, where the drilling tool includes: a drill bit comprising a cutting element, a sensor array, and a controller. The sensor array includes: an acoustic emissions (AE) sensor configured to measure an acoustic signal generated during drilling of the formation by the cutting element and a load sensor configured to measure an applied load by the cutting element on the formation. The controller is communicably connected to the sensor array and configured to determine a toughness of the cutting element using the acoustic signal, the applied load, and a wear state.

Abstract: A downhole tool control apparatus includes a control assembly, a stroking assembly, and a pocket sleeve positioned in an outer sub. The control assembly and stroking assembly are independently slidable axially within the outer sub. The control assembly and stroking assembly slide depending on the flow rate of fluid through the downhole tool actuator. The stroking assembly includes a spline barrel having a spline projection positioned within a spline pocket formed in the pocket sleeve. The pocket sleeve and control assembly include one or more ratchet teeth positioned in the pocket sleeve such that as the flow rate is changed between a high and a low flow rate, the spline projection engages the ratchet teeth until an actuated cycle is completed, allowing the downhole tool actuator to move to an actuation position.

Abstract: A cutting element comprising a cylindrical substrate; a table bonded to the cylindrical substrate; at least one tooth with a reduced projected cutting area on a periphery of the table; and a plurality of undulating cutting ridges on a top of the table. The table can have a working surface and at least one lateral surface, and a chamfer formed therebetween. The working surface can be a non-planar working surface. For a given weight on the bit, the cutter will sink into the rock deeper which can lead to better stability and more effective rock removal.

Abstract: A method of forming a polycrystalline diamond compact includes forming a polycrystalline diamond material at a temperature and a pressure sufficient to form diamond-to-diamond bonds in the presence of a catalyst; substantially removing the catalyst from a volume of the polycrystalline diamond material from a first surface to a first leach depth; and substantially removing the catalyst from a volume of the polycrystalline diamond material from a second surface to a second, different leach depth. A polycrystalline diamond compact includes a polycrystalline diamond material having a first volume, a second volume, and a boundary between the first volume and the second volume. The first volume includes a catalyst disposed in interstitial spaces between diamond grains. The second volume is substantially free of the catalyst. The boundary's location is selected to control thermal stability and/or impact resistance.

Abstract: A cutter element includes a base portion having a central axis, a first end, and a second end. In addition, the cutter element includes a cutting layer fixably mounted to the first end of the base portion. The cutting layer includes a cutting face distal. The cutting face includes a planar central region centered relative to the central axis and disposed in a plane oriented perpendicular to the central axis. The cutting face also includes a plurality of circumferentially-spaced cutting regions disposed about the planar central region. Each cutting region extends from the planar central region to the radially outer surface of the cutting layer. Each cutting region slopes axially toward the base portion moving radially outward from the planar central region to the radially outer surface of the cutting layer. Further, the cutting face includes a plurality of circumferentially-spaced relief regions disposed about the planar central region.

Abstract: A method of producing a product includes a preparation step of preparing a member that constitutes a part of the product, a fixing step of positioning and fixing the member on a plate, a mounting step of positioning and mounting the plate on which the member has been fixed on an additive manufacturing apparatus, a shaping step of forming a shaped portion adhering to the upper surface of the member, a dismounting step of dismounting the plate on which the member bearing the shaped portion formed thereon is fixed from the additive manufacturing apparatus, and a separation step of separating the member bearing the shaped portion formed thereon from the plate.

Abstract: A drill bit for chiselling rock includes an impact face at an insertion end of the drill bit, a hollow shank, where a delivery passage is defined within the hollow shank, and a drill head, where the drill head has, at a front end of the drill head, a plurality of cutting faces, an intake opening, and an intake passage. The intake passage connects the intake opening to the delivery passage. The intake opening has a noncircular cross section.

Abstract: Oilfield tools having a metal-to-metal seal formed between a first metal surface and a second metal surface, wherein at least one of the first and second metal surfaces are at least partially coated by chemical bonding or physical deposition of a coating material that is more durable and has a lower coefficient of friction than either or both of the first and/or second metal surfaces to which the coating material is applied.

Abstract: Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a structure for enhancing at least one of abrasion resistance, thermal stability, or impact resistance. In an embodiment, a PDC includes a PCD table. The PCD table includes a lower region including a plurality of diamond grains exhibiting a lower average grain size and at least an upper region adjacent to the lower region and including a plurality of diamond grains exhibiting an upper average grain size. The lower average grain size may be at least two times greater than that of the upper average grain size. The PDC includes a substrate having an interfacial surface that is bonded to the lower region of the PCD table. Other embodiments are directed methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Abstract: A method of making a polycrystalline diamond compact includes forming a first layer of polycrystalline diamond precursor materials comprising diamond particles and a first concentration of catalyst, forming a second layer of polycrystalline diamond precursor materials comprising diamond particles and a second concentration of catalyst, and placing a layer of an infiltrant material in the proximity of the first or the second layer of polycrystalline diamond precursor materials. The second concentration of catalyst is greater than the first concentration of catalyst. The infiltrant material is a catalyst. The first layer and the second layer are sintered under high-pressure high-temperature conditions in the presence of the infiltrant material to form the polycrystalline diamond compact. At least a portion of the catalyst is leached from the polycrystalline diamond compact.

Abstract: Cutting elements include a diamond-bonded body attached with a substrate. The substrate has a coercivity of greater than about 200 Oe, and has a magnetic saturation of from about 73 to 90. The diamond-bonded body has a compressive stress at the surface of greater than about 0.9 GPa after heat treatment, and greater than about 1.2 GPa prior to heat treatment.

Abstract: A drill bit includes a bit body including one or more blades extending therefrom and a plurality of cutters secured to the one or more blades. A rolling element assembly is positioned within a cavity defined on the bit body and includes a housing, a rolling element rotatable within the housing about a rotational axis, and one or more bearing elements extendable into a corresponding one or more arcuate grooves defined in the cavity to secure the housing within the cavity. The housing encircles more than 180° but less than 360° of a circumference of the rolling element while leaving a full axial width of the rolling element exposed.

Abstract: Cutting elements for earth-boring tools may include a polycrystalline, superabrasive material secured to an end of a substrate. The polycrystalline, superabrasive material may include a first transition surface and a second transition surface. A waveform may extend around a circumference of the second transition surface, a surface of the waveform tapered toward from the substrate and extending radially from the second transition surface toward the central axis. The surface of the waveform may extend from the second transition surface to a planar surface of the polycrystalline located at a same distance from the substrate as troughs of the waveform surface, the planar surface oriented perpendicular, and located proximate, to the central axis.

Abstract: Polycrystalline diamond includes a working surface and a peripheral surface extending around an outer periphery of the working surface. The polycrystalline diamond includes a first volume including an interstitial material and a second volume having a leached region that includes boron and titanium. A method of fabricating a polycrystalline diamond element includes positioning a first volume of diamond particles adjacent to a substrate, the first volume of diamond particles including a material that includes a group 13 element, and positioning a second volume of diamond particles adjacent to the first volume of diamond particles such that the first volume of diamond particles is disposed between the second volume of diamond particles and the substrate, the second volume of diamond particles having a lower concentration of material including the group 13 element than the first volume of diamond particles. Various other articles, assemblies, and methods are also disclosed.

Abstract: A bit for drilling a wellbore includes: a body; and a cutting face forming a lower end of the bit. The cutting face includes: a blade protruding from the body and having a plurality of stud pockets formed in a bottom of the blade adjacent to a leading edge of the blade; a plurality of studs, each stud disposed in the respective pocket, mounted to the blade by a first braze material, and having a cutter pocket formed therein; a plurality of cutters, each cutter having a superhard cutting table attached to a cermet substrate, disposed in the respective cutter pocket, and mounted to the respective stud by a second braze material. An exposure of each cutter is greater than or equal to a diameter of the respective cutter.

Abstract: A method of fabricating an foam includes providing a foam comprising a base material. The base material is coated with an inorganic material using at least one of an atomic layer deposition (ALD), a molecular layer deposition (MLD), or sequential infiltration synthesis (SIS) process. The SIS process includes at least one cycle of exposing the foam to a first metal precursor for a first predetermined time and a first partial pressure. The first metal precursor infiltrates at least a portion of the base material and binds with the base material. The foam is exposed to a second co-reactant precursor for a second predetermined time and a second partial pressure. The second co-reactant precursor reacts with the first metal precursor, thereby forming the inorganic material on the base material. The inorganic material infiltrating at least the portion of the base material. The inorganic material is functionalized with a material.

Abstract: A polycrystalline diamond compact including a cemented carbide substrate and a polycrystalline diamond layer bonded to the cemented carbide substrate. The cemented carbide substrate is cylindrical and includes a circumferential wall. The polycrystalline diamond layer includes a central part including between 8 and 15 wt. % of cobalt and an outer part including between 0.5 and 2 wt. % of cobalt. The outer part is a columnar ring belt and includes a chamfer. The outer part includes an upper surface, a side surface connected to the circumferential wall of the cemented carbide substrate, and a chamfer surface connecting the upper surface and the side surface. The chamfer includes a first terminal connected to the upper surface of the outer part and a second terminal connected to the side surface of the outer part.

Abstract: A downhole cutting tool includes a body having a central axis extending therethrough, a plurality of blades extending outwardly from the body and converging towards a central region around the central axis, and at least one cutting element having a longitudinal axis, a non-cylindrical substrate, and an ultra-hard material body on the non-cylindrical substrate, the ultra-hard material body having a side surface extending around a cutting face and defining a cross-sectional shape of the ultra-hard material body, and the side surface comprising an edge having an inner angle of less than 180 degrees.

Abstract: A multi-layer downhole drilling tool designed for drilling a wellbore including a plurality of formations is disclosed. The drilling tool includes a bit body and a plurality of primary blades and secondary blades with respective leading surfaces on exterior portions of the bit body. The drilling tool further includes a plurality of first layer cutting elements and second layer cutting elements located on the leading surfaces of the primary blades and secondary blades, respectively. Each second layer cutting element is under-exposed with respect to the corresponding first layer cutting element. The amount of under-exposure is selected according to each second layer cutting element having an initial critical depth of cut greater than an actual depth of cut for a first drilling distance and a critical depth of cut equal to zero at a target drilling depth.

Abstract: A cutting tool has a tool body and at least one non-planar cutting element oriented at a forward rake angle on the top surface of the cutting tool. The at least one non-planar cutting element of the cutting tool has a grip region and a non-planar cutting end. A support of the cutting tool extends around at least a portion of a circumference of the grip region.

Abstract: The present disclosure relates to an industrial device, such as a drill bit that may be fabricated by performing a first coupling process that includes activating an attachment material between a first cutter element and a first recess of a bit body, monitoring a temperature associated with the first cutter element by a camera, and adjusting one or more parameters associated with the laser in response to output from the camera. The process may be repeated for a plurality of cutter elements. The disclosure further includes the process and a system to perform the process.

Abstract: Cutting elements for earth-boring tools may include a substrate and a polycrystalline superabrasive material secured to the substrate. The polycrystalline superabrasive material may include a first region including catalyst material in interstitial spaces among interbonded grains of the polycrystalline superabrasive material. A second region at least substantially free of catalyst material in the interstitial spaces among the interbonded grains of the polycrystalline superabrasive material may be located adjacent to the first region. An undulating boundary defined between the first region and the second region may include bumps and dimples formed by crests and troughs of a repeating pattern of concentric circles encircling a longitudinal axis of the cutting element.

Abstract: A polycrystalline diamond compact (PDC) cutting element includes a substrate and a polycrystalline diamond compact. The substrate comprises a ceramic-metal composite material including hard ceramic particles in a metal matrix. The polycrystalline diamond compact includes interbonded diamond particles. Interstitial material disposed within interstitial spaces between the interbonded diamond particles comprises aluminum and at least one element of the ceramic-metal composite material of the substrate. A method of manufacturing such a PDC cutting element includes forming a mixture including diamond particles and particles of aluminum, and subjecting the mixture and a substrate to a high pressure, high temperature (HPHT) sintering process.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table having a diamond grain size distribution selected for improving performance and/or leachability. In an embodiment, a PDC includes a PCD table bonded to a substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween. The plurality of diamond grains includes a first amount being about 5 weight % to about 65 weight % of the plurality of diamond grains and a second amount being about 18 weight % to about 95 weight % of the plurality of diamond grains. The first amount exhibits a first average grain size of about 0.5 ?m to about 30 ?m. The second amount exhibits a second average grain size that is greater than the first average grain size and is about 10 ?m to about 65 ?m. Other embodiments are directed to methods of forming PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.

Abstract: An earth-boring tool comprises a bit body and first and second depth of cut control (“DOCC”) features mounted thereon. The first and second DOCC features comprise a first rubbing surface having a first surface area and a second rubbing surface having a second surface area, respectively, for contacting a subterranean formation. The second surface area is different from the first surface area such that the first and second DOCC features distribute a load attributable to applied weight on bit over the first and second rubbing surfaces at different rates. Methods of forming an earth-boring tool include selecting first and second DOCC features having different rates of engagement with the subterranean formation and mounting the first and second DOCC features on a bit body.

Abstract: Polycrystalline diamond compacts (“PDCs”) include a polycrystalline diamond (“PCD”) table in which cobalt is alloyed with phosphorous to improve the thermal stability of the PCD table. The PDC includes a substrate and a PCD table including an upper surface spaced from an interfacial surface that is bonded to the substrate. The PCD table includes a plurality of diamond grains defining a plurality of interstitial regions. The PCD table further includes an alloy comprising at least one Group VIII metal and phosphorous. The alloy is disposed in at least a portion of the plurality of interstitial regions.

Abstract: Cutting elements for earth-boring tools may include a substrate and a polycrystalline, superabrasive material secured to an end of the substrate. The polycrystalline superabrasive material may include a first transition surface extending in a direction oblique to a central axis of the substrate, a second transition surface extending in a second direction oblique to the central axis, the second direction being different from the first direction, and a curved, stress-reduction feature located on the second transition surface.

Abstract: Cutters mounted on bits for advancing boreholes are subject to extreme forces that can separate the cutter from the bit. A cutter backing element with a rearward extending lug and forward face can provide support to the cutter. The backing element is attached to the back face of the cutter and the lug of the backing element is received in a recess of the bit. The backing element can be brazed to the bit and the cutter. The lug is offset from a longitudinal axis of the backing element. Forces applied to the front of the cutter during drilling operations are transferred through the cutter to the backing element and to the bit through the offset lug.

Abstract: In accordance with some embodiments of the present disclosure, a drill bit for drilling a wellbore in a subterranean formation comprises a plurality of cutters disposed at a contact face of the drill bit. Each of the cutters has a cutting face arranged to cut into the formation when the drill bit is rotated about an axis of rotation passing through the contact face during drilling of the wellbore. At least one of the cutters located inside a gauge portion of the drill bit is machine to form a substantially flat surface that intersects with the cutting face of the cutting and defines a cutting edge of the cutting face of the cutter.

Abstract: In accordance with some embodiments of the present disclosure, a method of configuring depth of cut controllers (DOCCs) of a drill bit comprises determining a primary depth of cut for a first radial swath. The first radial swath is associated with a first area of the bit face. The method further comprises configuring a primary DOCC for placement on the bit face within the first radial swath based on the primary depth of cut. In addition, the method comprises determining a back-up depth of cut for a second radial swath. The second radial swath is associated with a second area of the bit face that overlaps the first area of the bit face associated with the first radial swath. The method further comprises configuring a back-up DOCC for placement on the bit face within the second radial swath based on the back-up depth of cut.

Abstract: Cutting elements for earth-boring tools may include a superhard, polycrystalline material and a substrate adjacent to and secured to the superhard, polycrystalline material at an interface. The substrate may include a first region exhibiting a first coefficient of thermal expansion and a second region exhibiting a second, different coefficient of thermal expansion. The first region may be spaced from the superhard, polycrystalline material. The second region may extend from laterally adjacent to at least a portion of the first region to longitudinally between the first region and the superhard, polycrystalline material.

Abstract: A polycrystalline super hard construction has a body of PCD material and a plurality of interstitial regions between inter-bonded diamond grains forming the PCD material. The body also has a first region substantially free of a solvent/catalyzing material which extends a depth from a working surface into the body of PCD material. A second region remote from the working surface includes solvent/catalyzing material in a plurality of the interstitial regions. A chamfer extends between the working surface and a peripheral side surface of the body of PCD material. The chamfer has a height which is the length along a plane perpendicular to the plane along which the working surface extends between the point of intersection of the chamfer with the working surface and the point of intersection of the chamfer and the peripheral side surface of the body of PCD material. The depth of the first region is greater than the height of the chamfer.

Abstract: A cutting tool is provided. The cutting tool comprises a tip, a body and a shank. The tip has a tip radius and a tip length. The body has a body radius and a body length between the shank and a recess portion along a longitudinal axis of the body. The recess portion comprises a wall which forms a recess with a depth into the body for retaining a major part of the tip length within the recess. The body radius at half the depth of the recess does not exceed two tip radiuses. The tip is made of a hard metal alloy with a hardness of at least 1300 HV50 and the body is made of a steel alloy with a hardness of at least 450 HV30.

Abstract: A polycrystalline diamond abrasive cutting element consists generally of a layer of high grade polycrystalline diamond bonded to a cemented carbide substrate. The polycrystalline diamond layer has a working surface and an outer peripheral surface and is characterized by having an annular region or a portion thereof adjacent the peripheral surface that is lean in catalysing material. A region adjacent the working surface is also lean in catalysing material such that in use, as a wear scar develops, both the leading edge and the trailing edge thereof are located in a region lean in catalysing material.