Patent application number | Description | Published |
20080202814 | Earth-boring tools and cutter assemblies having a cutting element co-sintered with a cone structure, methods of using the same - Methods of forming cutter assemblies for use on earth-boring tools include sintering a cone structure to fuse one or more cutting elements thereto. In some embodiments, one or more green, brown, or fully sintered cutting elements may be positioned on a green or brown cone structure prior to sintering the cone structure to a final density. Cutter assemblies may be formed by such methods, and such cutter assemblies may be used in earth-boring tools such as, for example, earth-boring rotary drill bits and hole openers. | 08-28-2008 |
20090031863 | BONDING AGENTS FOR IMPROVED SINTERING OF EARTH-BORING TOOLS, METHODS OF FORMING EARTH-BORING TOOLS AND RESULTING STRUCTURES - Methods for forming earth-boring tools include providing a metal or metal alloy bonding agent at an interface between a first element and a second element and sintering the first element, the second element, and the boding agent to form a bond between the first element and the second element at the interface. The methods may be used, for example, to bond together portions of a body of an earth-boring tool (which may facilitate, for example, the formation of cutting element pockets) or to bond cutting elements to a body of an earth-boring tool (e.g., a bit body of a fixed-cutter earth-boring drill bit or a cone of a roller cone earth-boring drill bit). At least partially formed earth-boring tools include a metal or metal alloy bonding agent at an interface between two or more elements, at least one of which may comprise a green or brown structure. | 02-05-2009 |
20090044663 | EARTH-BORING TOOLS HAVING POCKETS FOR RECEIVING CUTTING ELEMENTS AND METHODS FOR FORMING EARTH-BORING TOOLS INCLUDING SUCH POCKETS - Methods of forming cutting element pockets in blades of earth-boring tools include forming a first recess and a second recess intersecting at a location defining the a back of the pocket using a cutter oriented in a manner so as to avoid tool path interference with adjacent blades. A filler material is disposed in the second recess to the location of the back of the pocket. Earth-boring tools having such cutting element pockets are also disclosed. | 02-19-2009 |
20090078470 | SYSTEM, METHOD, AND APPARATUS FOR REACTIVE FOIL BRAZING OF CUTTER COMPONENTS FOR FIXED CUTTER BIT - A reactive foil is used to assemble the components of rock bit cutters and to affix cutting elements to rock bit bodies. A small pulse of localized energy ignites the foil in a fraction of second to deliver the necessary amount of heat energy to flow solder or braze and form a strong, true metallic joint. The reaction in the foil may be activated using optical, electrical, or thermal sources. | 03-26-2009 |
20090301786 | METHODS OF FORMING EARTH-BORING TOOLS USING GEOMETRIC COMPENSATION AND TOOLS FORMED BY SUCH METHODS - Geometric compensation techniques are used to improve the accuracy by which features may be located on drill bits formed using particle compaction and sintering processes. In some embodiments, a positional error to be exhibited by at least one feature in a less than fully sintered bit body upon fully sintering the bit body is predicted and the at least one feature is formed on the less than fully sintered bit body at a location at least partially determined by the predicted positional error. In other embodiments, bit bodies of earth-boring rotary drill bits are designed to include a design drilling profile and a less than fully sintered bit body is formed including a drilling profile having a shape differing from a shape of the design drilling profile. Less than fully sintered bit bodies of earth-boring rotary drill bits are formed using such methods. | 12-10-2009 |
20090301789 | METHODS OF FORMING EARTH-BORING TOOLS INCLUDING SINTERBONDED COMPONENTS AND TOOLS FORMED BY SUCH METHODS - Methods of forming earth-boring rotary drill bits by forming and joining two less than fully sintered components, by forming and joining a first fully sintered component with a first shrink rate and forming a second less than fully sintered component with a second sinter-shrink rate greater that that of the first shrink rate of the first fully sintered component, by forming and joining a first less than fully sintered component with a first sinter-shrink rate and by forming and joining at least a second less than fully sintered component with a second sinter-shrink rate less than the first sinter-shrink rate. The methods include co-sintering a first less than fully sintered component and a second less than fully sintered component to a desired final density to form at least a portion of an earth-boring rotary drill bit which may either cause the first less than fully sintered component and the second less than fully sintered component to join or may cause one of the first less than fully sintered component and the second less than fully sintered component to shrink around and at least partially capture the other less than fully sintered component. Earth-boring rotary drill bits are formed using such methods. | 12-10-2009 |
20090308662 | METHOD OF SELECTIVELY ADAPTING MATERIAL PROPERTIES ACROSS A ROCK BIT CONE - Methods of forming cutter assemblies for use on earth-boring tools include sintering a cone structure to fuse one or more cutting elements thereto and having a hardened land area. In some embodiments, one or more green, brown, or fully sintered cutting elements may be positioned on a green or brown cone structure prior to sintering the cone structure to a final density. Cutter assemblies may be formed by such methods, and such cutter assemblies may be used in earth-boring tools such as, for example, earth-boring rotary drill bits and hole openers. | 12-17-2009 |
20090311124 | METHODS FOR SINTERING BODIES OF EARTH-BORING TOOLS AND STRUCTURES FORMED DURING THE SAME - A first green or brown object is sintered while being supported by a second green or brown object in a furnace, and a body of an earth-boring tool is formed from the first object. An object is sectioned to form first and second structures, and the first structure is sintered within a furnace while it is supported by (e.g., resting on) the second structure. A layer of powder material is provided on a green or brown object, another green or brown object is rested on the powder material over the first green or brown object, and the first and second green or brown objects are sintered with the powder material therebetween. Intermediate structures formed during fabrication of a body of an earth-boring tool include a layer of powder between a green or brown tool body precursor and a green or brown structure supporting the green or brown tool body. | 12-17-2009 |
20090320584 | ROTARY DRILL BITS AND SYSTEMS FOR INSPECTING ROTARY DRILL BITS - A method for conducting nondestructive internal inspection of a rotary drill bit used for drilling subterranean formations comprises communicating ultrasonic waves into a drill bit and detecting ultrasonic waves that are reflected by at least a portion of the drill bit. In some embodiments, the waves may be directed into the drill bit from within a longitudinal bore thereof. Reflected waves also may be detected from within the bore. The methods may be used to develop threshold acceptance criteria for classifying drill bits as acceptable or unacceptable to prevent catastrophic failures of drill bits during use. Systems and apparatuses are disclosed for conducting nondestructive ultrasonic inspection of a drill bit used for drilling subterranean formations. The systems and apparatuses may comprise an ultrasonic probe configured for insertion within an internal longitudinal bore of a drill bit. Drill bits are disclosed that are configured to facilitate nondestructive ultrasonic inspection thereof. | 12-31-2009 |
20100108397 | EARTH-BORING TOOLS HAVING THREADS FOR AFFIXING A BODY AND SHANK TOGETHER AND METHODS OF MANUFACTURE AND USE OF SAME - Earth-boring tools comprise a shank comprising a distal connector including a set of threads thereon and a bit body comprising a shank connector, also comprising at least one set of threads thereon. The set of threads on the distal connector and the at least one set of threads on the shank connector are at least substantially bound together. Methods of forming such earth-boring tools are also disclosed, as well as methods of securing a bit body of an earth-boring tool to a shank. | 05-06-2010 |
20100263935 | EARTH BORING ROTARY DRILL BITS AND METHODS OF MANUFACTURING EARTH BORING ROTARY DRILL BITS HAVING PARTICLE MATRIX COMPOSITE BIT BODIES - Methods of forming bit bodies for earth-boring bits include assembling green components, brown components, or fully sintered components, and sintering the assembled components. Other methods include isostatically pressing a powder to form a green body substantially composed of a particle-matrix composite material, and sintering the green body to provide a bit body having a desired final density. Methods of forming earth-boring bits include providing a bit body substantially formed of a particle-matrix composite material and attaching a shank to the body. The body is provided by pressing a powder to form a green body and sintering the green body. Earth-boring bits include a unitary structure substantially formed of a particle-matrix composite material. The unitary structure includes a first region configured to carry cutters and a second region that includes a threaded pin. Earth-boring bits include a shank attached directly to a body substantially formed of a particle-matrix composite material. | 10-21-2010 |
20100276205 | METHODS OF FORMING EARTH-BORING ROTARY DRILL BITS - Methods of forming earth-boring rotary drill bits include providing a bit body, providing a shank that is configured for attachment to a drill string, and attaching the shank to the bit body. Providing a bit body includes providing a green powder component having a first region having a first composition and a second region having a second, different composition, and at least partially sintering the green powder component. Other methods include providing a powder mixture, pressing the powder mixture to form a green component, and sintering the green component to a final density. A shank is provided that includes an aperture, and a feature is machined in a surface of the bit body. The aperture is aligned with the feature, and a retaining member is inserted through the aperture. An earth-boring bit includes a bit body comprising a particle-matrix composite material including a plurality of hard particles dispersed throughout a matrix material. A shank is attached to the bit body using a retaining member. | 11-04-2010 |
20100288564 | CUTTING ELEMENT FOR USE IN A DRILL BIT FOR DRILLING SUBTERRANEAN FORMATIONS - A cutting element for use in a drill bit for drilling subterranean formations including a substrate having a body including an upper surface extending transversely to a longitudinal axis of the body, a superabrasive layer overlying the upper surface of the substrate, wherein the superabrasive layer includes an annular shape having a central opening defined by an inner surface. The cutting element further includes an abrasive insert overlying the upper surface of the substrate and disposed within the central opening of the superabrasive layer, wherein the abrasive insert has an upper surface having a surface roughness (R | 11-18-2010 |
20110000715 | HARDFACING MATERIALS INCLUDING PCD PARTICLES, WELDING RODS AND EARTH-BORING TOOLS INCLUDING SUCH MATERIALS, AND METHODS OF FORMING AND USING SAME - Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to form diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material. | 01-06-2011 |
20110017517 | DIAMOND-ENHANCED CUTTING ELEMENTS, EARTH-BORING TOOLS EMPLOYING DIAMOND-ENHANCED CUTTING ELEMENTS, AND METHODS OF MAKING DIAMOND-ENHANCED CUTTING ELEMENTS - Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles. | 01-27-2011 |
20110024200 | CUTTING ELEMENT AND METHOD OF FORMING THEREOF - A cutting element for use in a drilling bit and/or milling bit having a cutter body made of a substrate having an upper surface, and a superabrasive layer overlying the upper surface of the substrate. The cutting element further including a sleeve extending around a portion of a side surface of the superabrasive layer and a side surface of the substrate, wherein the sleeve exerts a radially compressive force on the superabrasive layer. | 02-03-2011 |
20110030509 | METHODS FOR FORMING EARTH BORING TOOLS HAVING POCKETS FOR RECEIVING CUTTING ELEMENTS - Methods of forming cutting element pockets in earth-boring tools may include forming a first recess and a second recess. A filler material is disposed in the second recess to the form at least a portion of a back surface of the pocket. Methods of forming cutting element pockets in earth-boring tools may include orienting a rotating cutter generally parallel to a longitudinal axis of a cutting element pocket to be formed in a body of an earth-boring tool and machining the cutting element pocket in the earth-boring tool. Methods of forming earth-boring tools include forming a body comprising at least one blade and forming at least one cutting element pocket in the at least one blade. | 02-10-2011 |
20110031031 | CUTTING ELEMENT FOR A DRILL BIT USED IN DRILLING SUBTERRANEAN FORMATIONS - 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. | 02-10-2011 |
20110036641 | METHODS OF FORMING POLYCRYSTALLINE DIAMOND CUTTING ELEMENTS, CUTTING ELEMENTS, AND EARTH-BORING TOOLS CARRYING CUTTING ELEMENTS - Methods of forming polycrystalline diamond elements include forming a polycrystalline diamond compact comprising a cavity in a surface thereof. A catalyst is at least substantially removed from the polycrystalline diamond compact, and the polycrystalline diamond compact is secured to a supporting substrate. Cutting elements include a diamond table formed with a cavity in a back side surface thereof and a supporting substrate secured to the back side surface of the diamond table. Earth-boring tools comprise a bit body carrying one or more cutting elements including a diamond table, a supporting substrate and an adhesion layer comprising a superhard material between and bonding the cutting table and the supporting substrate. | 02-17-2011 |
20110073379 | CUTTING ELEMENT AND METHOD OF FORMING THEREOF - A cutting element comprising a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface. The cutting element further includes a superabrasive layer comprising a rear surface, an upper surface, and a side surface connected to and extending between the rear surface and upper surface, wherein the rear surface of the superabrasive layer overlies the upper surface of the substrate. The cutting element is also formed to include a jacket overlying the side surface of the substrate and abutting a portion of the rear surface of the superabrasive layer, wherein the jacket comprises a flange extending along a portion of the side surface of the superabrasive layer. | 03-31-2011 |
20110155472 | EARTH-BORING TOOLS HAVING DIFFERING CUTTING ELEMENTS ON A BLADE AND RELATED METHODS - Earth-boring tools include combinations of shearing cutting elements and gouging cutting elements on a blade of the earth-boring tools. In some embodiments, a gouging cutting element may be disposed adjacent to a shearing cutting element on a blade of an earth-boring tool. Methods of forming earth-boring tools include providing such combination of at least one shearing cutting element and at least one gouging cutting element on a blade of an earth-boring tool. | 06-30-2011 |
20110192651 | SHAPED CUTTING ELEMENTS ON DRILL BITS AND OTHER EARTH-BORING TOOLS, AND METHODS OF FORMING SAME - Earth-boring tools include a body, one or more blades projecting outwardly from the body, and cutting elements carried by the blade. The cutting elements include at least one shearing cutting element and at least one gouging cutting element. Methods of forming an earth-boring tool include mounting a shearing cutting element comprising an at least substantially planar cutting face to a body of an earth-boring tool, and mounting a gouging cutting element comprising a non-planar cutting face to the body of the earth-boring tool. The gouging cutting element may be positioned on the body of the earth-boring tool such that the gouging cutting element will gouge formation material within a kerf cut in the formation material by the shearing cutting element, or between kerfs cut in the formation material by a plurality of shearing cutting elements. | 08-11-2011 |
20110259642 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS AND RELATED METHODS - Cutting elements, earth-boring drill bits having such cutting elements and related methods are described herein. In some embodiments, a cutting element for an earth-boring tool may include a diamond table having an indentation in a cutting face thereof and a shaped feature in a substrate at the interface between the diamond table and the substrate, the shaped feature corresponding to the indentation in the cutting face of the diamond table. In further embodiments, a cutting element for an earth-boring tool may include a sacrificial structure positioned within an indentation in a diamond table. In additional embodiments, a method of forming a cutting element may include positioning a sacrificial structure in a mold, positioning a powdered precursor material over the sacrificial structure, and pressing and sintering the powdered precursor material to form a diamond table having an indentation in a cutting face formed by the sacrificial structure. | 10-27-2011 |
20110266070 | CUTTING ELEMENTS, EARTH-BORING TOOLS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS AND TOOLS - Cutting elements include a volume of superabrasive material. The volume of superabrasive material comprises a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. An earth-boring tool may comprise a bit body and at least one cutting element attached to the bit body. Methods of forming cutting elements comprise forming a volume of superabrasive material comprising forming a front-cutting surface, an end-cutting surface, a cutting edge, and lateral side surfaces extending between and intersecting each of the front-cutting surface and the end-cutting surface. Methods of forming earth-boring tools comprise forming a cutting element and attaching the cutting element to an earth-boring tool. | 11-03-2011 |
20110315456 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING CUTTING ELEMENTS FOR EARTH-BORING TOOLS - Cutting elements for use with earth-boring tools include a cutting table having a base surface and a substrate having a support surface. An intermediate structure and an adhesion layer extend between the base surface of the cutting table and the support surface of the substrate. Earth-boring tools include such cutting elements. Methods for fabricating cutting elements for use with earth-boring tools include forming an intermediate structure on and extending from a support surface of a substrate and adhering a cutting table comprising a superabrasive material to the support surface of the substrate. | 12-29-2011 |
20120031674 | SHAPED CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - A cutting element for an earth-boring tool. The cutting element comprises a substrate base, and a volume of polycrystalline diamond material on an end of the substrate base. The volume of polycrystalline diamond material comprises a generally conical surface, an apex centered about a longitudinal axis extending through a center of the substrate base, a flat cutting surface extending from a first point at least substantially proximate the apex to a second point on the cutting element more proximate a lateral side surface of the substrate base. Another cutting element is disclosed, as are a method of manufacturing and a method of using such cutting elements. | 02-09-2012 |
20120056022 | METHODS OF FORMING HARDFACING MATERIALS INCLUDING PCD PARTICLES, AND WELDING RODS INCLUDING SUCH PCD PARTICLES - Hardfacing materials include particles of polycrystalline diamond (PCD) material embedded within a matrix material. The PCD particles comprise a plurality of inter-bonded diamond grains. Material compositions and structures used to apply a hardfacing material to an earth-boring tool (e.g., welding rods) include PCD particles. Earth-boring tools include a hardfacing material comprising PCD particles embedded within a matrix material on at least a portion of a surface of a body of the tools. Methods of forming a hardfacing material include subjecting diamond grains to elevated temperatures and pressures to diamond-to-diamond bonds between the diamond grains and form a PCD material. The PCD material is broken down to form PCD particles that include a plurality of inter-bonded diamond grains. Methods of hardfacing tools include bonding PCD particles to surfaces of the tools using a metal matrix material. | 03-08-2012 |
20120080239 | CUTTING ELEMENTS, EARTH-BORING TOOLS INCORPORATING SUCH CUTTING ELEMENTS, AND METHODS OF FORMING SUCH CUTTING ELEMENTS - Cutting elements include a substrate, a thermally stable polycrystalline table comprising a superhard material secured to the substrate, and a layer of metal interposed between, and attaching the substrate and the thermally stable polycrystalline table. Methods of forming a cutting element include providing a thermally stable polycrystalline table in a mold, providing a layer of metal on the thermally stable polycrystalline table, distributing a mixture of particles comprising a plurality of hard particles and a plurality of particles comprising a matrix material on the layer of metal, and heating the mold while applying pressure to the mixture of particles to cause the mixture of particles to coalesce and form a substrate and at least partially melt the layer of metal to flow and wet the thermally stable polycrystalline table and the substrate to form an attachment therebetween. | 04-05-2012 |
20120080240 | DIAMOND IMPREGNATED CUTTING STRUCTURES, EARTH-BORING DRILL BITS AND OTHER TOOLS INCLUDING DIAMOND IMPREGNATED CUTTING STRUCTURES, AND RELATED METHODS - An earth-boring tool includes a bit body, a plurality of first cutting elements, and a plurality of second cutting elements. Each of the first cutting elements includes a discontinuous phase dispersed within a continuous matrix phase. The discontinuous phase includes a plurality of particles of superabrasive material. Each of the second cutting elements includes a polycrystalline diamond compact or tungsten carbide. A method of forming an earth-boring tool includes disposing a plurality of first cutting elements on a bit body and disposing a second plurality of second cutting elements on the bit body. Another method of foaming an earth-boring tool includes forming a body having a plurality of first cutting elements and a plurality of cutting element pockets and securing each of a plurality of second cutting elements within each of the cutting element pockets. | 04-05-2012 |
20120222363 | METHODS OF FORMING POLYCRYSTALLINE TABLES AND POLYCRYSTALLINE ELEMENTS AND RELATED STRUCTURES - Methods of forming a polycrystalline table comprise disposing a plurality of particles comprising a superabrasive material, a substrate comprising a hard material, and a catalyst material in a mold. The plurality of particles is partially sintered in the presence of the catalyst material to form a brown polycrystalline table having a first permeability attached to an end of the substrate. The substrate is removed from the brown polycrystalline table and catalyst material is removed from the brown polycrystalline table. The brown polycrystalline table is then fully sintered to form a polycrystalline table having a reduced, second permeability. Intermediate structures formed during a process of attaching a polycrystalline table to a substrate comprising a substantially fully leached brown polycrystalline table. The substantially fully leached brown polycrystalline table comprises a plurality of interbonded grains of a superabrasive material. | 09-06-2012 |
20120222364 | POLYCRYSTALLINE TABLES, POLYCRYSTALLINE ELEMENTS, AND RELATED METHODS - Polycrystalline elements comprise a substrate and a polycrystalline table attached to an end of the substrate. The polycrystalline table comprises a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability, the at least second region being interposed between the substrate and the first region. Methods of forming a polycrystalline element comprise attaching a polycrystalline table comprising a first region of superabrasive material having a first permeability and at least a second region of superabrasive material having a second, lesser permeability to an end of a substrate, the at least a second region being interposed between the first region and the substrate. Catalyst material is removed from at least the first region of the polycrystalline table. | 09-06-2012 |
20120225253 | METHODS OF FORMING POLYCRYSTALLINE ELEMENTS AND STRUCTURES FORMED BY SUCH METHODS - Methods of forming a polycrystalline element comprise forming a polycrystalline table on a first substrate. Catalyst material may be removed from at least a portion of the polycrystalline table. The polycrystalline table and a portion of a first substrate attached to the polycrystalline table may be removed from a remainder of the first substrate. The portion of the first substrate may be attached to another substrate. Polycrystalline elements comprise a polycrystalline table attached to a portion of a first substrate on which the polycrystalline table was formed another substrate attached to the portion of the first substrate. | 09-06-2012 |
20120279785 | EARTH-BORING TOOLS AND METHODS OF FORMING SUCH EARTH-BORING TOOLS - Earth-boring drill bits comprise a bit body having a plurality of radially extending blades and a plurality of cutting elements attached to the plurality of radially extending blades. Only gouging cutting elements are attached to at least one blade of the plurality of radially extending blades. Only shearing cutting elements are attached to at least another blade of the plurality of radially extending blades. Only shearing cutting elements are attached to a number of blades of the plurality of radially extending blades that is different from a number of blades of the plurality of radially extending blades to which only gouging cutting elements are attached. Methods of forming an earth-boring drill bit comprise forming a bit body including a plurality of radially extending blades. Only shearing cutting elements are attached to a number of blades different from a number of blades to which only gouging cutting elements are attached. | 11-08-2012 |
20120325562 | DIAMOND ENHANCED CUTTING ELEMENTS, EARTH-BORING TOOLS EMPLOYING DIAMOND-ENHANCED CUTTING ELEMENTS, AND METHODS OF MAKING DIAMOND-ENHANCED CUTTING ELEMENTS - Cutting elements for use in earth-boring applications include a substrate, a transition layer, and a working layer. The transition layer and the working layer comprise a continuous matrix phase and a discontinuous diamond phase dispersed throughout the matrix phase. The concentration of diamond in the working layer is higher than in the transition layer. Earth-boring tools include at least one such cutting element. Methods of making cutting elements and earth-boring tools include mixing diamond crystals with matrix particles to form a mixture. The mixture is formulated in such a manner as cause the diamond crystals to comprise about 50% or more by volume of the solid matter in the mixture. The mixture is sintered to form a working layer of a cutting element that is at least substantially free of polycrystalline diamond material and that includes the diamond crystals dispersed within a continuous matrix phase formed from the matrix particles. | 12-27-2012 |
20130068538 | CUTTING ELEMENTS FOR EARTH-BORING TOOLS, EARTH-BORING TOOLS INCLUDING SUCH CUTTING ELEMENTS, AND RELATED METHODS - Cutting elements for earth-boring tools include one or more recesses and/or one or more protrusions in a cutting face of a volume of superabrasive material. The superabrasive material may be disposed on a substrate. The cutting face may be non-planar. The recesses and/or protrusions may include one or more linear segments. The recesses and/or protrusions may comprise discrete features that are laterally isolated from one another. The recesses and/or protrusions may have a helical configuration. The volume of superabrasive material may comprise a plurality of thin layers, at least two of which may differ in at least one characteristic. Methods of forming cutting elements include the formation of such recesses and/or protrusions in and/or on a cutting face of a volume of superabrasive material. Earth-boring tools include such cutting elements, and methods of forming earth-boring tools include attaching such a cutting element to a tool body. | 03-21-2013 |