Abstract: In one aspect of the invention, a tool has a working portion with a least one impact tip brazed to a carbide extension. The carbide extension has a cavity formed in a base end and is adapted to interlock with a shank assembly of the cutting element assembly. The shank assembly has a locking mechanism adapted to interlock a first end of the shank assembly within the cavity. The locking mechanism has a radially extending catch formed in the first end of the shank assembly. The shank assembly has an outer surface at a second end of the shank assembly adapted to be press-fitted within a recess of a driving mechanism. The outer surface of the shank assembly has a coefficient of thermal expansion of 110 percent or more than a coefficient of thermal expansion of a material of the driving mechanism.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and to a bit incorporating such cutting element. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

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: Cutting elements having a slanted top surface for an improved cutter to blade transition, the slanted top surface being integratable into a receiving pocket of a bit blade such that the slanted top surface and the perimeter of the receiving pocket are relatively contiguous when the slanted cutter is mounted within the receiving pocket. Also, a bit with slanted cutters as well as a method of manufacturing a bit having slanted cutters.

Abstract: A method for forming an ultra hard material layer is provided. The method includes disposing a metallic liner inside the periphery of a refractory metal enclosure, introducing ultra hard material feed stock into the enclosure, and sintering using HPHT processing and cooling to form the ultra hard material layer, substantially free of peripheral cracking, chipping and fracturing.

Abstract: In one aspect of the invention, a superhard insert has a carbide substrate bonded to ceramic layer at an interface. The substrate has a generally frusto-conical end at the interface with a tapered portion leading to a flat portion. The central section of the ceramic layer may have a first thickness immediately over the flat portion of the substrate. The peripheral section of the ceramic layer has a second thickness being less than the first thickness covering the tapered portion of the substrate. The ceramic layer may be formed using HPHT technology.

Abstract: A rotary drill bit is disclosed, including at least one cutting element affixed thereto and configured to form a distinct borehole surface in response to drilling a subterranean formation. At least one substantially helically extending feature associated with the at least one cutting element may be formed upon the leading end of the rotary drill bit. Alternatively, a rotary drill bit may include a plurality of substantially helically extending features. Methods of operating a rotary drill bit are also disclosed. Specifically, a subterranean formation may be drilled with a rotary drill bit to form an on-center bottomhole pattern, which may be at least partially contacted by at least one substantially helically extending feature of the rotary drill bit. Alternatively, a subterranean formation may be contacted with at least one substantially helically extending feature of the rotary drill bit. A method of designing a rotary drill bit is disclosed.

Abstract: A drill bit that includes a steel bit body having at least one blade thereon, at least one cutter pocket disposed on the at least one blade; at least one cutter disposed in the at least one cutter pocket; at least one recess formed in at least a portion of the surface of the at least one cutter pocket, wherein the recess is adjacent a leading face of the at least one blade; and an erosion resistant material in the at least one recess is disclosed.

Abstract: A cutting element including a shank portion and a conical cutting portion. The conical cutting portion has a narrow end and a broad end connected to the shank portion. The conical cutting portion narrow end has an insert receiving recess, and an insert is secured in the insert receiving recess. The insert has an outer layer made of tungsten carbide, and an inner core made of a material with a greater hardness than the outer layer.

Abstract: A polycrystalline superabrasive composite tool can be produced using high pressure high temperature processes allowing for increased thermal resistance, wear resistance and toughness of abrasive tools, and additionally allowing for increased effective thickness of abrasive tools. A polycrystalline superabrasive compact can include a support substrate and a superabrasive polycrystalline layer having a diffusion bridge embedded therein that includes a carbide former. Additionally, a working layer can be attached adjacent to the superabrasive polycrystalline layer and opposite the support substrate to form a drill bit sandwich segment. The diffusion bridge matrix of the present invention allows for a new welding phase at each interface between the superabrasive polycrystalline layer and support substrate and between the polycrystalline layer and the metal working layer, thus eliminating delamination failure at the interfaces.

Abstract: A cutting element includes a layer of integrally bonded superabrasive particles disposed over a substrate. The layer has an outer circumference comprising at least one trough having a distinct cutting point on either side of the trough. A rock drilling drag bit incorporating the cutting element and a method of cutting a material using the cutting element are also disclosed.

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: The present invention includes an improved cutting element substrate for cutting elements. The cutting element substrate includes non-planar, non-linear interfaces with an abrasive layer of superhard material affixed thereto often using a high pressure high temperature press apparatus. The cutting element substrate includes a cant intersecting a first and second interfacial surface. A plurality of truncated nodules intersects the first surface and extends towards the second surface. Arcuate segments protrude out of the second surface and are radially positioned along the surface. The truncated nodules are ill-aligned with the arcuate segments proximate the truncated nodules.

Abstract: Cutting elements and bits incorporating such cutting elements are provided. The cutting elements have a substrate, a first ultra hard material layer formed over the substrate, and a second ultra hard material layer formed over the first ultra hard material layer. The second ultra hard material layer has a thickness in the range of 0.05 mm to 2 mm.

Abstract: A cutting element for a rotary drill bit that has a superabrasive member joined to a substrate at a three-dimensional interface is disclosed. The interface of the cutting element preferably incorporates a first ring pattern comprising a plurality of circumferentially arranged raised sections which are separated by a plurality of radially extending grooves. Also, the interface configuration may include at least a second ring pattern comprising a plurality of circumferentially arranged raised sections which are separated by a plurality of radially extending grooves. Radially adjacent ring patterns may substantially circumferentially overlap with one another. An interface of a cutting element including at least one ring pattern having an odd number of sections is also disclosed. Further, rotary drill bits including at least one such cutting element are disclosed.

Abstract: An insert for a drill bit which includes a diamond impregnated body, and a shearing portion disposed on said body is shown. In addition, a method for forming a drill bit that includes (a) forming a shearing portion on a diamond-impregnated insert body to form a cutting insert, (b) forming a bit body having a plurality of sockets sized to receive a plurality of the cutting inserts, and (c) mounting the plurality of cutting inserts in the bit body and affixing the plurality of cutting inserts to the bit body; wherein steps (a)–(c) are carried out such that a total exposure of the diamond-impregnated insert to temperatures above 1000° F. is greater than a total exposure of the shearing portion to temperatures above 1000° F.

Abstract: A percussion drill bit for drilling a bore includes a drill body having a connecting section at a rear end thereof for connection to a percussive unit, and a plurality of cemented carbide buttons embedded in a front end of the drill body. Each button comprises a cemented carbide body having a rear mounting portion embedded in the drill body, and a front end protruding from the drill body. The front end of the cemented carbide button is substantially semi-spherically curved and defined by a radius whose origin is disposed axially rearwardly of a plane through the largest diameter of the button. The button projects from the drill bit body a distance which is not less than 50% of the button diameter. A conical intermediate surface forms, in cross-section, an acute angle of about 13–19° with an envelope surface of the rear mounting portion.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and a method of forming the same. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

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: Compacts are oriented in certain places on roller cones of an earth boring bit to increase the number of compacts in certain rows. The compacts that are pressed into holes in rows on the cones. The compacts are of tungsten carbide and have a cutting end axis and a barrel axis. The barrel axis intersects the cutting end axis at an obtuse angle. In one of the cones, the barrel axis of at least some of the compacts is rotated to have less inclination than the barrel axis of the compact nearest to it. The nearest compact may be in the same row or an adjacent row. Also, at least some of the compacts may be asymmetrical, with a cutting end axis that diverges from a barrel axis.

Abstract: A steel body rotary drag bit for drilling a subterranean formation includes a plurality of support elements affixed to the bit body, each forming at least a portion of a cutting element pocket. Each of a plurality of cutting elements has a substantially cylindrical body and is at least partially disposed within a cutter pocket. At least a portion of the substantially cylindrical body of each cutting element is directly secured to at least a portion of a substantially arcuate surface of the bit body. At least a portion of a substantially planar surface of each cutting element matingly engages at least a portion of a substantially planar surface of a support element.

Abstract: Asymmetrical compacts are utilized in certain places on roller cones of an earth boring bit to increase the number of compacts in certain rows. The compacts that are pressed into holes in rows on the cones. The compacts are of tungsten carbide and have a cutting end axis and a barrel axis. The barrel axis intersects the cutting end axis at an obtuse angle. In the heel row, the barrel axis of at least some of the compacts is rotated to have less inclination than the cutting end axis. In an adjacent row to the heel row, each of the compacts has a barrel axis that is rotated to have more inclination than its cutting end axis and more inclination than the barrel axes of the heel row.

Abstract: Disclosed is a rolling cone cutter and drill bit employing multiple inserts retained as a cluster in an aperture in the cone cutter. Apertures in which the insert clusters are retained are multilobed apertures formed by intersecting bores formed in the cone steel. The apertures may also be created by forming spaced apart bores and milling regions of the cone steel that extends between the bores. The inserts in a cluster may be retained within the aperture to differing depths, may extend above the cone steel to differing extension lengths, and may have cutting portions having a variety of shapes. The inserts in a cluster may be made of different materials in order to optimize cutting duty.

Abstract: A roller cone body defines a circumferential channel or race into which a plurality of cutter or wear segments are mounted. The wear segments may be of any appropriate contour or shape, such as for example chisel, spherical, or even flat face and are preferably made or carbide. The wear elements may be all the same within a channel or race, or they may be varied within a race as needed for a particular application.

Abstract: An earth boring bit has rolling cones rotatably mounted to the bit legs. Each cone has conical bands extending around the exterior. Holes are formed in each of the bands. Compacts are press-fitted into the holes, each having a cutting tip that projects from the conical band. Flats are formed in the conical bands, each flat extending between adjacent compacts.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed an ultra hard material layer and a method of forming the same. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: Cutting elements having a non-planar substrate interface surface including a band and an ultra hard material layer over the interface surface are provided. Also provided are earth boring bits incorporating such cutting elements.

Abstract: A center vacuum rotary drill bit including a rotary drill bit body and an insert. The bottom surface of the slot has a projecting key that cooperates with a depression keyway of the insert. Generally vertical sidewall surfaces of a depression keyway and vertical surfaces of a projection key provide mechanical resistance against lateral movement of the cutting insert. This mechanical resistance reduces displacement of the insert with respect to the bit body during brazing and thus a high quality, accurately aligned drill bit assembly is provided by applicants' invention. The depression keyway is designed so as to minimize the effect of the axial load on the insert by avoiding sharp corners which tend to amplify nominal stress and provides an insert of a proper carbide density after pressing. Integral bit body protuberance means adequately separate the insert within the slot and permit braze flow between the insert and slot.

Abstract: Cutter elements including pointed contact structures and elements, and rock tools or bits for carrying those elements, for chipping, cutting, and breaking non-ductile materials are disclosed. The cutter elements, the ends of which directly contact and cut through rock and other materials, have tapered contact structure ends which are flatter than those known to the prior art, obtaining increased durability. The contact elements which may be part of the contact structures are selected of materials having hardness and other characteristics in relation to those of the mounting structures, including the tapered and projecting portions, which also add durability and wear-resistance to the elements. Fixed, replaceable, and rotatable cutter elements are disclosed. Rock tools including bits are also disclosed for carrying the cutter elements, having sockets for threaded or rotatable cutter elements arranged in straight or curved rows on the head opposite the drill-string-engaging base of the tool.

Abstract: The present invention addresses this need in the art by providing a cutter insert comprising a plug section and a cutter pedestal. The cutter insert is preferably formed of tungsten carbide, except for two exterior surfaces covered with PDC. The plug section may be circular or oval in cross section perpendicular to the axis of the insert. The plug section and the pedestal each defines a shoulder which is coated with a PDC layer. In this way, two cutting surfaces are applied to the formation, enhancing the cutting ability of the insert.

Abstract: A non-uniform interface is formed between a polycrystalline ultra hard material layer and a cemented tungsten carbide substrate, or a polycrystalline ultra hard material layer and a transition layer, or a transition layer and a substrate of a cutting element. A first sheet made from an intermediate material is formed and embossed on one face forming a non-uniform pattern raised in relief on the face. The embossed sheet is placed on a face of a presintered substrate. An ultra hard material sheet is formed and embossed, forming a non-uniform face complementary to the non-uniform face on the sheet of intermediate material. The ultra hard material sheet is placed over the intermediate material sheet so that the complementary faces are adjacent to each other. The assembly of substrate and sheets is sintered in a HPHT process.

Abstract: Cutting elements having a non-planar substrate interface surface including a band and an ultra hard material layer over the interface surface are provided. Also provided are earth boring bits incorporating such cutting elements.

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: A rotary drag bit and method for drilling subterranean formations including a bit body being provided with at least one cutter thereon exhibiting reduced, or limited, exposure to the formation so as to control the depth-of-cut of the at least one cutter, so as to control the volume of formation material cut per bit rotation, as well as to control the amount of torque experienced by the bit and an optionally associated bottomhole assembly regardless of the effective weight-on-bit. The exterior of the bit preferably includes a plurality of blade structures carrying at least one such cutter thereon and including a sufficient amount of bearing surface area to contact the formation so as to generally distribute an additional weight applied to the bit against the bottom of the borehole without exceeding the compressive strength of the formation rock.

Abstract: An insert for a drill bit which includes a diamond impregnated body, and a shearing portion disposed on said body is shown. In addition, a method for forming a drill bit that includes (a) forming a shearing portion on a diamond-impregnated insert body to form a cutting insert, (b) forming a bit body having a plurality of sockets sized to receive a plurality of the cutting inserts, and (c) mounting the plurality of cutting inserts in the bit body and affixing the plurality of cutting inserts to the bit body; wherein steps (a)-(c) are carried out such that a total exposure of the diamond-impregnated insert to temperatures above 1000° F. is greater than a total exposure of the shearing portion to temperatures above 1000° F.

Abstract: The present invention provides a bit with cutting structures or inserts that include diamond particles, in which the diamond-impregnated inserts are surrounded by substantially diamond-free support members. The diamond-impregnated inserts are manufactured separately from the bit body. Once formed, the diamond-impregnated inserts are affixed to the substantially diamond-free support members on bit body by brazing or other means of attachment. The total thermal exposure of the diamond particles during manufacture in accordance with the present invention is significantly lower than the total manufacturing-related thermal exposure in previously known diamond-impregnated cutting structures. Furthermore, the substantially diamond-free support members allow the bit to continue cutting through a formation without an increased contact area, as experienced by bits with diamond-impregnated ribs. Thus, the operating life of the cutting structures, and therefore the life of the bit itself, is increased.

Abstract: A cutter for drilling subterranean formations including a superabrasive table formed on an end face of a supporting substrate, there being an interface between the table and the end face defined by at least one annular surface centered about the centerline of the cutter in a location adjacent the side periphery of the substrate, the annular surface having an arcuate topography of an orientation and radial width sufficient to accommodate resultant loading of the cutting edge of the cutter throughout a variety of angles with vectors normal to the surface at a variety of angles such that at least one normal vector is aligned substantially parallel to the resultant loading on the cutting edge.

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: A cutter for a drill bit has a superabrasive member joined to a substrate at a three-dimensional interface. The three-dimensional interface comprises a protrusive pattern of interconnected elements comprising projections of the superabrasive member into the substrate and vice versa. The protrusive pattern comprises at least one generally annular member intersected by a series of generally radially extending members for distributing stresses along the interface, enhancing compressive strength, and enabling optimization of the magnitudes and locations of beneficial residual stresses in the superabrasive member and in the vicinity of the substrate.

Abstract: A cutting tip for a drilling tool includes a cemented carbide cutting base 11, a diamond element 12 supported by the cutting base 11, and a bonding layer formed between the cutting base 11 and the diamond element 12 in order to bond them. The bonding layer 13 includes diffusion layers S1 and S2 in which one or two or more metals selected from a group consisting of Fe, Ni, Co, Ti, Zr, W, V, Nb, Ta, Cr, Mo, and Hf diffuses into at least one of the cemented carbide or the diamond.

Abstract: A center vacuum rotary drill bit including a rotary drill bit body and an insert. The bottom surface of the slot has a projecting key that cooperates with a depression keyway of the insert. Generally vertical sidewall surfaces of a depression keyway and vertical surfaces of a projection key provide mechanical resistance against lateral movement of the cutting insert. This mechanical resistance reduces displacement of the insert with respect to the bit body during brazing and thus a high quality, accurately aligned drill bit assembly is provided by applicants' invention. The depression keyway is designed so as to minimize the effect of the axial load on the insert by avoiding sharp corners which tend to amplify nominal stress and provides an insert of a proper carbide density after pressing. Integral bit body protuberances adequately separate the insert within the slot and permit braze flow between the insert and slot.

Abstract: A cutter for a drill bit has a superabrasive member joined to a substrate at a three-dimensional interface. The three-dimensional interface comprises a protrusive pattern of interconnected elements comprising projections of the superabrasive member into the substrate and vice versa. The protrusive pattern comprises at least one generally annular member intersected by a series of generally radially extending members for distributing stresses along the interface, enhancing compressive strength, and enabling optimization of the magnitudes and locations of beneficial residual stresses in the superabrasive member and in the vicinity of the substrate.

Abstract: A cutter for a drill bit has a superabrasive member joined to a substrate at a three-dimensional interface. The three-dimensional interface comprises a protrusive pattern of interconnected elements comprising projections of the superabrasive member into the substrate and vice versa. The protrusive pattern comprises at least one generally annular member intersected by a series of generally radially extending members for distributing stresses along the interface, enhancing compressive strength, and enabling optimization of the magnitudes and locations of beneficial residual stresses in the superabrasive member and in the vicinity of the substrate.

Abstract: The present invention provides a cutting element having a cylindrical body having a canted end face on which is formed a ultra hard material layer and a method of forming the same. One or a plurality of transition layers may be provided between the ultra hard material layer and the cutting element body.

Abstract: A cutter and a drill bit having such cutters for drilling subterranean formations including a superabrasive table formed on an end face of a supporting substrate, there being an interface between the table and the end face including a topographic configuration including at least one, and preferably a plurality of, annular arcuate surfaces centered about the centerline of the cutter and at least one recessed region or groove extending across a substantial portion of the end face. The topographic configuration of the end face is of an orientation and radial width sufficient to accommodate resultant loading of the cutting edge of the cutter throughout a variety of angles with vectors normal to the surface at a variety of angles such that at least one normal vector is aligned substantially parallel to the resultant loading on the cutting edge.

Abstract: A superabrasive cutter-equipped rotary drag bit especially suitable for directional drilling in subterranean formations. The bit may employ PDC cutters in an engineered cutter placement profile exhibiting optimal aggressiveness in relation to where the cutters are positioned along the profile of the bit extending from a cone region laterally, or radially, outward toward a gage region thereof. The engineered cutter placement profile may include cutters exhibiting differing degrees of aggressiveness positioned in order to maximize rate-of-penetration and minimize torque-on-bit while maintaining side cutting capability and steerability.

Abstract: A cutting element for an earth boring bit comprises a cutting compact of a superabrasive material layer bonded to a supporting substrate. The superabrasive material layer has a pattern of radially extending ribs, the ribs extending from the peripheral surface of the layer, and a second pattern of circular ribs radially spaced from the peripheral surface and intersecting the first pattern of radially extending ribs. The supporting substrate comprises a first pattern of radially extending grooves for mating with the first pattern of radially extending ribs. In addition, the supporting substrate comprises a second pattern of circular grooves for mating with the first pattern of circular ribs. The interface between the substrate and the superabrasive material has a dome-shaped configuration.

Abstract: A cutting element for use on a rotary-type earth boring drill bit for drilling subterranean formations including a segment and a support member. The support member is preferably fabricated from a tough and ductile material, such as iron, an iron-based alloy, nickel, a nickel-based alloy, copper, a copper-based alloy, titanium, a titanium-based alloy, zirconium, a zirconium-based alloy, silver, or a silver-based alloy. A bit attachment portion of the support member is securable to a bit body. A segment-receiving portion of the support member is disposable within a recess formed in the segment to secure the segment to the bit body and support the segment during use of the drill bit. Preferably, the segment is fabricated from a hard continuous phase material that is impregnated with a particulate abrasive material, such as natural diamond, synthetic diamond, or cubic boron nitride.

Abstract: A cutter for drilling subterranean formations including a superabrasive table formed on an end face of a supporting substrate, there being an interface between the table and the end face defined by at least one annular surface centered about the centerline of the cutter in a location adjacent the side periphery of the substrate, the annular surface having an arcuate topography of an orientation and radial width sufficient to accommodate resultant loading of the cutting edge of the cutter throughout a variety of angles with vectors normal to the surface at a variety of angles such that at least one normal vector is aligned substantially parallel to the resultant loading on the cutting edge.