Abstract: Disclosed is a drill bit for cutting formation comprises a bit body, a plurality of cutters, a plurality of blades with pockets to accommodate the cutters respectively. Each of the plurality of cutters has at least one alignment structure to align with at least one counter-alignment structure on each of the pockets to locate the rotary orientation between each of the plurality of cutters and each of the corresponding pockets.

Abstract: Embodiments disclosed herein are directed to a superabrasive compact including one or more superabrasive cutting portions or segments, rotary drill bits including one or more superabrasive compacts, and related methods (e.g., methods of fabricating and/or operating the superabrasive compacts). For example, the superabrasive compact may include polycrystalline diamond that may form at least a portion of a working surface of the superabrasive compact.

Abstract: A multi-layer friction reducing tape, including: a foil layer including a metal, polymer, or hybrid-metal-polymer; an under layer disposed on the foil layer; an adhesion promoting layer contiguous with a surface of the under layer; a functional layer that includes a fullerene based composite, a diamond based material, diamond-like-carbon (DLC), or combinations thereof, wherein the functional layer is contiguous with a surface of the adhesion promoting layer; and a tape, including an adhesive layer and a backing material, wherein the adhesive layer is attached to a surface of the foil layer opposite the under layer.

Abstract: Embodiments disclosed herein are directed to bearing assemblies, related bearing apparatuses, and related methods. An example of a bearing assembly disclosed herein may include a support structure having a first end and a second end. The bearing assembly also includes a superhard bearing element secured to the first end of the support structure. The superhard bearing element includes a superhard sealing surface that may be configured to contact a sealing surface of an opposing bearing element, a base surface contacting the support structure and opposing the superhard sealing surface, and at least one lateral surface extending between the superhard sealing surface and the base surface. The support structure and the superhard bearing element may both include at least one conduit extending therethrough through which a fluid may flow.

Abstract: A method of processing a superabrasive element includes providing a superabrasive element including a polycrystalline diamond table that includes a metallic material disposed in interstitial spaces defined within the polycrystalline diamond table. The polycrystalline diamond table includes a superabrasive face and a superabrasive side surface extending around an outer periphery of the superabrasive face. The method also includes leaching the metallic material from at least a volume of the polycrystalline diamond table to produce a leached volume in the polycrystalline diamond table by (1) exposing at least a portion of the polycrystalline diamond table to a processing solution, (2) exposing an electrode to the processing solution, and (3) applying a charge to the electrode such that a voltage is generated between the polycrystalline diamond table and the electrode and the voltage is applied to the processing solution.

Abstract: A cutting element includes a body, a non-planar cutting face formed on a first end of the body, and an edge formed around a perimeter of the cutting face. The cutting face includes a central raised portion, and the edge has an edge angle defined between the cutting face and a side surface of the body. The edge angle varies around the perimeter of the cutting face and includes an acute edge angle defined by a portion of the cutting face extending downwardly from the edge to a depth from the cutting angle. The portion of the edge defining the acute edge angle may be directly adjacent: a side surface of the cutting element; a bevel of the cutting element; or a flat region at the perimeter of the cutting element or bevel.

Abstract: A downhole cutting tool includes a tool body having a tool axis, and a blade extending from the tool body. The blade includes a cutting face, a trailing face, and a top face extending between the cutting face and the trailing face. Cutting elements are attached to the bade along the cutting face, with each having a cutting crest at a peak height and a reduced height extending laterally away from the cutting crest. In some cases, first cutting elements along the cutting face and second cutting elements along the top face and rearward from, and at the same radial position as, the first cutting elements have different size, orientation, geometry or material properties. In additional aspects, at least two cutting elements on the blade have differing material properties, sizes, orientations, or working surface geometries along a blade profile of the blade.

Abstract: A cutter for a drill bit includes: a substrate for mounting the cutter to the drill bit; and a cutting table. The cutting table: is made from a superhard material, is mounted to the substrate, has an interface with the substrate at a lower end thereof, and has a working face at an upper end thereof. The working face has a protruding center section and a plurality of protruding ribs. Each rib extends radially outward from the center section to a side of the cutting table. Each rib has a triangular profile formed by a pair of inclined side surfaces and a ridge connecting opposing ends of the side surfaces. The working face further has a plurality of recessed bases located between adjacent ribs and each extending inward from the side.

Abstract: A rotating cutter for a fixed cutter type bit includes an annular sleeve with a retainer having a plurality of inwardly extending tabs and a spindle cutter rotatably coupled to the annular sleeve. The spindle cutter includes a spindle extending into the annular sleeve and rotatable about a central axis of the annular sleeve, a base portion positioned between the retainer and a proximal end of the annular sleeve, and a cutter portion coupled to the spindle. The rotating cutter further includes at least one pin disposed between adjacent tabs of the plurality of tabs of the retainer to prevent axial movement of the base portion through the retainer.

Abstract: A drill bit includes a bit body having one or more blades extending therefrom, a plurality of cutters secured to the one or more blades, and a rolling element assembly positioned within a cavity defined on the bit body. The rolling element assembly includes a rolling element rotatable within the cavity about a rotational axis, and a retainer extendable within a retainer slot defined in the cavity to secure the rolling element within the cavity. The retainer and the cavity cooperatively encircle 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. The retainer includes a protruding portion thereon extendable into an offset region of the retainer slot when the first retainer piece is inserted into the retainer slot in a first direction and shifted within the retainer slot in a second direction.

Abstract: Polycrystalline diamond constructions comprise a diamond body attached with a substrate during high pressure/high temperature processing, and include a modified reaction zone interposed between the body and substrate that is engineered to minimize or eliminate unwanted back diffusion of carbon from the diamond body into the substrate during the high pressure/high temperature processing.

Abstract: In this diamond-coated cemented carbide cutting tool, (1) an average particle size of WC particles is 0.5 to 0.9 ?m, (2) (Rz) being 0.5 to 1.0 ?m, a maximum distance between the concave and convex (?) is 0.5 to 1.5 ?m, a length (Ye) is 0.5 to 2.0 ?m, (3) a sum of areas of WC particles, which satisfies (L1) being 0.4 to 0.8 ?m, (L2) being 0.2 to 0.4 ?m, and (L1)/(L2) being 1.5 to 2.5, is 70 area % or more, (4) an average grain size of diamond crystals in a region of 0.5 to 1.5 ?m from the body interface is 0.1 to 0.3 ?m, and (5) columnar crystals satisfying at least one of: a ratio of crystals, which has a growth direction shifted in 10 degrees or less from the diamond film thickness direction, being 90% or more; or an orientation ratio of <110> being 30 to 70%.

Abstract: A cutting element assembly includes a sleeve having a cutter-receiving aperture extending through the sleeve, a cutting element, and a rotation restriction element. The cutting element may include a first plurality of retention elements extending substantially radially from an outer surface of the cutting element and engaging the sleeve to retain the cutting element within the sleeve. The rotation restriction element may be coupled to the cutting element and may include a second plurality of retention elements extending axially from a bottom surface of the rotation restriction element and engaging the sleeve to restrict rotation of the cutting element within the sleeve.

Abstract: A cutter for a drill bit and method of manufacturing same is disclosed. The cutter has a non-leached polycrystalline diamond (PCD) table bonded to a substrate and a leached PCD table bonded to one or both of the substrate and non-leached PCD table. The leached PCD table may be ring-shaped and acts as the working surface of the cutting element. It may have a jagged inner surface which cooperates with complementary jagged-shaped outer surface of the non-leached PCD table to prevent rotation of the leached PCD table relative to the non-leached PCD table during a cutting operation. A surface of the leached PCD table may be tapered and fit together in a complementary manner with an oppositely tapered surface of the non-leached PCD table so as to mechanically lock the leached PCD table to the non-leached PCD table.

Abstract: Superabrasive compacts and methods of making superabrasive compacts are disclosed. A superabrasive compact includes a polycrystalline diamond table and a substrate attached to the polycrystalline diamond table. The substrate includes a hard metal carbide and a binder having a compound with a composition of AxByCz, where A and B are transition metals, where C is carbon, and where 0?x?7, 0?y?7, x+y=7, and 0?z?3.

Abstract: A cutting element comprises a cutting table of a polycrystalline hard material including a cutting face, a sidewall, and at least one peripheral cutting edge portion between the cutting face and the sidewall. A radius of curvature of the peripheral cutting edge portion is greater than a radius of curvature of at least another peripheral edge portion between the cutting face and the sidewall. An earth-boring tool may include one or more such cutting elements.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.

Abstract: Embodiments of the invention relate to liquid metal embrittlement (“LME”)-resistant superabrasive compacts, methods of making the same, and drill bits incorporating the same. The LME-resistant superabrasive compacts include a braze-resistant region on one or more portions of a substrate expected to be under residual tensile stress and susceptible to LME during brazing.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) that are less susceptible to liquid metal embrittlement damage due to the use of at least one transition layer between a polycrystalline diamond (“PCD”) layer and a substrate. In an embodiment, a PDC includes a PCD layer, a cemented carbide substrate, and at least one transition layer bonded to the substrate and the PCD layer. The at least one transition layer is formulated with a coefficient of thermal expansion (“CTE”) that is less than a CTE of the substrate and greater than a CTE of the PCD layer. At least a portion of the PCD layer includes diamond grains defining interstitial regions and a metal-solvent catalyst occupying at least a portion of the interstitial regions. The diamond grains and the catalyst collectively exhibit a coercivity of about 115 Oersteds or more and a specific magnetic saturation of about 15 Gauss·cm3/grams or less.

Abstract: In an embodiment, a polycrystalline diamond compact (“PDC”) includes a substrate and a polycrystalline diamond (“PCD”) table bonded to the substrate. The PCD table includes an upper surface. The PCD table includes a first PCD region including bonded-together diamond grains and exhibits a first diamond density. At least a portion of the first PCD region extending inwardly from the working surface is substantially free of metal-solvent catalyst. The PCD table includes an intermediate second PCD region bonded to the substrate, which is disposed between the first PCD region and the substrate. The second PCD region includes bonded-together diamond grains defining interstitial regions, with at least a portion of the interstitial regions including metal-solvent catalyst disposed therein. The second PCD region exhibits a second diamond density that is greater than that of the first diamond density of the first PCD region.

Abstract: In this novel PDC cutter, diamond powders of different composition and/or different grain size, are distributed, shaped, and compacted with a novel pressing tool, in multiple stages, spatially arranged into different regions of the PDC diamond body, then HPHT sintered to form one PDC body with spatially varying hardness, toughness and thermal resistance.

Abstract: A subterranean support-bolt drill bit includes a bit body rotatable about a central axis and at least one cutting element mounted to the bit body. The at least one cutting element has a cutting face, a cutting edge adjacent the cutting face, and a back surface opposite the cutting face. A first recess is defined in the bit body and positioned adjacent the at least one cutting element. A first opening extends through a portion of the bit body, the first opening extending from the first recess. A coupling projection extends from the back surface of the at least one cutting element, the coupling projection being positioned within the first recess and bonded to the coupling recess by brazing. A coupling attachment extends through the first opening and is attached to the coupling projection.

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

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability and/or wear resistance of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element such as phosphorous.

Abstract: A cutting element includes a sleeve, a rotatable cutting element, and at least one retaining ring. The sleeve has a first inner diameter and a second inner diameter, wherein the second inner diameter is larger than the first inner diameter and located at a lower axial position than the first inner diameter. The rotatable cutting element has an axis of rotation extending therethrough, a cutting face, a body extending axially downward from the cutting face, wherein the body has a shaft that is disposed within the sleeve, and a circumferential groove formed around an outer surface of the shaft. The at least one retaining ring is disposed in the circumferential groove and extends at least around the entire circumference of the shaft, wherein the at least one retaining ring protrudes from the circumferential groove, thereby retaining the rotatable cutting element within the sleeve.

Abstract: A method of forming a cutting element for an earth-boring tool includes forming a table of superabrasive material over a substrate in an HTHP environment such that the table of superabrasive material is bonded to the substrate. The table of superabrasive material and the substrate form a cutting element. The method includes removing the cutting element from the HTHP environment, ascertaining predictable residual stresses within the table of superabrasive material, and marking the cutting element with at least one mark. The at least one mark provides indication of a region of the table of superabrasive material having a maximum or minimum residual stress therein. An additional method includes obtaining such a marked cutting element and affixing the cutting element on an earth-boring tool in a preferential orientation as indicated at least partially by the mark.

Abstract: A unitary bit/holder assembly includes a reverse taper insert having a diamond coated tip mounted thereon that is received in an annular flange forwardmost portion of a holder body. In a modification, the diamond coated tip is received in a recess on a generally cylindrical forwardmost portion of the holder body.

Abstract: A cutting element may include a substrate and a volume of polycrystalline diamond material affixed to the substrate at an interface. The volume of polycrystalline diamond may include a front cutting face with at least one substantially planar portion and at least one recess. The at least one recess may extend from a plane defined by the at least one substantially planar portion a first depth into the volume of polycrystalline diamond material in an axial direction parallel to a central axis of the cutting element. The volume of polycrystalline diamond material may comprise a region including a catalyst material. At least one region substantially free of the catalyst material may extend from the at least one substantially planar portion of the front cutting face a second depth into the volume of polycrystalline diamond in the axial direction. Methods of forming cutting elements.

Abstract: Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.

Abstract: Disclosed are improved cutters for fixed-cutter rotating drill bits. One cutter includes a substrate defining a slot therein and being configured to be coupled to a middle portion of a blade of the drill bit, and a cutting element secured within the slot and having at least a portion of the cutting element extending out of the slot, the cutting element further having a first face and a second face, wherein portions of the first and second faces are supported by the substrate within the slot.

Abstract: A subterranean support-bolt drill bit includes a bit body rotatable about a central axis and at least one cutting element mounted to the bit body. The at least one cutting element has a cutting face, a cutting edge adjacent the cutting face, and a back surface opposite the cutting face. A first recess is defined in the bit body and positioned adjacent the at least one cutting element. A first opening extends through a portion of the bit body, the first opening extending from the first recess. A coupling projection extends from the back surface of the at least one cutting element, the coupling projection being positioned within the first recess. A coupling attachment extends through the first opening and is attached to the coupling projection.

Abstract: In one aspect of the invention, a high impact resistant tool includes a superhard material bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having a radius of curvature of 0.050 to 0.125 inches. The superhard material also has a thickness of 0.100 to 0.500 inches thickness from the apex to a central region of the cemented metal carbide substrate.

Abstract: Methods for forming cutting elements, methods for forming polycrystalline compacts, and related polycrystalline compacts are disclosed. Grains of a hard material are subjected to a high-pressure, high-temperature process to form a polycrystalline compact. Inclusion of at least one relatively quick spike in system pressure or temperature during an otherwise plateaued temperature or pressure stage accommodates formation of inter-granular bonds between the grains. The brevity of the peak stage may avoid undesirable grain growth. Embodiments of the methods may also include at least one of oscillating at least one system condition (e.g., pressure, temperature) and subjecting the grains to ultrasonic or mechanical vibrations.

Abstract: A method for hardfacing a drill bit includes applying a hardfacing material to a matrix metal forming the substrate of the drill bit. The hardfacing material is applied using a plasma arc welding process. A metallurgical bond is formed between the matrix metal and the hardfacing material. The matrix metal may include tungsten carbide and a braze filler metal.

Abstract: A superhard structure comprises a body of polycrystalline superhard material comprising a first region and a second region. The second region is adjacent an exposed surface of the superhard structure and comprises a diamond material or cubic boron nitride with a density greater than 3.4×103 kilograms per cubic meter when the second region comprises diamond material. The material(s) forming the first and second regions have a difference in coefficient of thermal expansion, the first and second regions being arranged such that this difference induces compression in the second region adjacent the exposed surface. The first/a further region has the highest coefficient of thermal expansion of the polycrystalline body and is separated in part from a peripheral free surface of the body by the second region or one or more further regions formed of a material(s) of a lower coefficient of thermal expansion. The regions comprise a plurality of grains of polycrystalline superhard material.

Abstract: In an embodiment, a superabrasive compact is disclosed in which a heat-absorbing material having a phase-transition temperature lower than a peak operating temperature of a superabrasive table of the superabrasive compact is positioned in the superabrasive compact. In some embodiments, the heat-absorbing material positioned between the substrate and the superabrasive table. In another embodiment, a rotary drill bit is also disclosed including a bit body and at least one cutting element including a substrate and a superabrasive table bonded to the substrate. At least one heat-absorbing material is positioned within the bit body at least proximate to the at least one cutting element.

Abstract: Polycrystalline ultra-hard constructions comprise a polycrystalline ultra-hard material body and two or more support members attached to the body by braze material. The support members include a backside support member and a side support member. The side support member is a one- or two-piece construction, and is positioned circumferentially around and extends axially along the body or both the body and the backside support member such that a working surface of the body remains exposed. The support members can be configured to provide a mechanical attachment or interlocking attachment with the body or another support member. The braze materials used in the construction can be different and selected to enhance the attachment and/or reduce the creation of thermal stress within the construction during assembly. The support members can be selected having different thermal expansion characteristics that also operate to reduce the thermal stress during construction assembly.

Abstract: A cutting element and a method of making the superabrasive cutter are disclosed. The cutting element has a substrate and a superabrasive layer. The substrate has an inner face and an annular face. The inner face may have a center. The annular face may have a periphery. A superabrasive layer attaches to the substrate along the inner face and the annular face, wherein the inner face slopes outwardly and upwardly from the center at an angle ranging from between about 1° and about 7° from horizontal.

Abstract: A superabrasive compact cutting element, for example, a insert utilized in shear cutter bits. The cutting elements include a layer of superabrasive materials that is provided with different shapes and positions relative to the substrate in order to enhance the abrasion resistance performance of the cutting element. The cutting element includes a top, bottom and peripheral surface. The cutting element further includes at least one superabrasive material portion comprising polycrystalline diamond (PCD) or cubic boron nitride (CBN), a substrate supporting the at least one superabrasive material portion, and an interface where the at least one superabrasive material portion and the substrate are joined. The interface slopes downwardly with a slope angle of less than about 40° and/or the cutting element has a longitudinal thickness of the at least one superabrasive material portion measured along a peripheral surface of the cutting element in a longitudinal direction greater than about 3 mm.

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 high diamond frame strength and methods for forming and evaluating such polycrystalline diamond bodies. A polycrystalline diamond body is provided, having a top surface, a cutting edge meeting the top surface, and a first region including at least a portion of the cutting edge. The first portion exhibits a diamond frame strength of about 1200 MPa or greater, or about 1300 MPa or greater.

Abstract: Earth-boring tools comprise a body comprising a plurality of radially extending blades. At least one blade of the plurality of radially extending blades comprises a blade support segment integral with the body. A blade frame segment is attached to a rotationally leading portion of the blade support segment. A plurality of cutting elements is attached to the blade frame segment. Methods of forming an earth-boring tool comprise forming a body including a blade support segment of at least one blade. At least one blade frame segment is attached to a rotationally leading portion the support segment of the at least one blade. A plurality of cutting elements is secured to the at least one blade segment.

Abstract: A cutting element for a drill bit includes an outer support element and an inner rotatable cutting element, a portion of which is disposed in the outer support element, where the inner rotatable cutting element has a body with a non-planar cutting face.

Abstract: A cutting element may include a substrate including a plurality of metal carbide particles and a first metal binder having a first metal binder content; an outer layer of polycrystalline diamond material at an end of the cutting element, the polycrystalline diamond material including a plurality of interconnected diamond particles; and a plurality of interstitial regions disposed among the interconnected diamond particles, the plurality of interstitial regions containing a second metal binder having a second metal binder content. The cutting element also includes at least one transition zone between the substrate and the outer layer, the at least one transition zone including a plurality of refractory metal carbide particles and a third metal binder having a third metal binder content, the third metal binder content being less than the first metal binder content and the second metal binder content.

Abstract: An earth-boring tool may comprise a body having at least one blade, and at least one cutting element recess may be formed in a surface of the at least one blade. At least one cutting element may be affixed within the at least one cutting element recess. The at least one cutting element may comprise a substantially cylindrical lateral side surface configured to allow the at least one cutting element to rotate about a longitudinal axis within the at least one cutting element recess when the at least one cutting element is partially inserted into the at least one cutting element recess. The at least one cutting element may also comprise a back face comprising alignment features configured to abut complementary alignment features disposed on a back surface of the at least one cutting element recess. Methods of forming earth-boring tool bodies.

Abstract: A cutting element for use in a drill bit for drilling subterranean formations includes a cutting body having a substrate including a rear surface, an upper surface, and a peripheral side surface extending between the rear surface and the upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further includes a sleeve surrounding the peripheral side surface of the cutting body and comprising a superabrasive layer bonded to an external surface of the sleeve.

Abstract: Cutting elements include a substrate, a polycrystalline table, and an asymmetric interface feature. The interface feature includes a shape that is reflectively asymmetric about at least two planes defined by x, y, and z axes of a Cartesian coordinate system defined to align a z axis of the coordinate system with the central axis of the substrate and to locate a center of the coordinate system at a midpoint along an axial height of the asymmetric interface feature. Methods of forming a cutting element involve: forming an asymmetric interface feature at an end of a substrate; distributing a plurality of superhard particles on the substrate over the asymmetric interface feature in a mold; and bonding the superhard particles in the mold to form a polycrystalline table attached to the substrate.

Abstract: Cutting elements for earth-boring tools may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed. The portion of the first substrate may exhibit a thickness less than a thickness of the first substrate before a remainder of the first substrate was removed to form the portion of the first substrate. Another substrate may be attached to the portion of the first substrate, the portion of the first substrate being interposed between the polycrystalline table and the other substrate. Earth-boring tools may include such cutting elements secured to bodies of the earth-boring tools. Bearings for earth-boring tools may include a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed, the polycrystalline table defining a contact surface.

Abstract: A superabrasive compact (e.g., a polycrystalline diamond compact) including a substrate pre-coated with at least one braze layer and an in-process drill bit assembly including at least one of such superabrasive compacts are disclosed. Pre-coating the substrate with at least one braze layer and dimensioning the pre-coated substrate to fit within the tolerances of a conventionally-sized cutter recess of a drill bit body enables a drill bit manufacture to easily and rapidly braze the disclosed superabrasive compacts into the conventionally-sized cutter recess without substantially decreasing the superabrasive volume of the superabrasive compact.

Abstract: A cutter for a fixed cutter drill bit including a substrate and an ultrahard material layer disposed on an end surface of the substrate, the ultra hard material layer having an upper surface opposite the substrate end surface and a peripheral surface such that the upper surface intersects the peripheral surface along a peripheral edge. The peripheral edge continuously increases and decreases in height as measured from a plane perpendicular to a longitudinal axis of the cutter.