Embodiments of the invention relate generally to protective leaching masks, and methods of manufacturing and using the same for leaching superabrasive elements such as polycrystalline diamond elements. In an embodiment, a protective leaching mask assembly includes a superabrasive element including a central axis and a superabrasive table, and a protective mask formed to protect at least a portion of the superabrasive element. The protective mask includes a base portion and at least one sidewall extending from the base portion and defining an opening generally opposite the base portion. The at least one sidewall includes an inner surface configured to abut with a selected portion of the superabrasive element being chemically resistant to a leaching agent and an outer surface sloping at an oblique angle relative to the central axis.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

A method of making a cutting element for use on an earth-boring tool may include forming the cutting element including a cutting table formed from a superabrasive polycrystalline material. The method may further include polishing a cutting surface of the cutting table by pulsing a laser onto the cutting surface of the cutting table. The cutting element may include a superabrasive polycrystalline cutting table including a cutting surface substantially free of micro-anomalies in the superabrasive material.

A method of making a cutting element for use on an earth-boring tool may include forming the cutting element including a cutting table formed from a superabrasive polycrystalline material. The method may further include polishing a cutting surface of the cutting table by pulsing a laser onto the cutting surface of the cutting table. The cutting element may include a superabrasive polycrystalline cutting table including a cutting surface substantially free of micro-anomalies in the superabrasive material.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the inter-bonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises a first region and a second region. The first region comprising inter-bonded diamond particles and is substantially free of at least highly catalytic metallic compounds, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and voids within interstitial spaces between the inter-bonded diamond particles. The second region comprising inter-bonded diamond particles, one or more non-catalytic compounds within interstitial spaces between the inter-bonded diamond particles, and one or more metallic phases within interstitial spaces between the inter-bonded diamond particles. The first region of the cutting table has a content of elemental metal of at least about 2.6 wt %. A method of forming a cutting element, and an earth-boring tool are also described.

A cutter element for a drill bit includes a base portion having a central axis, a first end, and a second end. In addition, the cutter element includes a cutting layer fixably mounted to the first end of the base portion. The cutting layer includes a cutting face distal the base portion. The cutting face includes an elongate raised ridge having a first end at a radially outer surface of the cutting layer and a second end at the radially outer surface of the cutting layer. The raised ridge defines a maximum height of the cutter element measured axially from the second end of the base portion to the cutting face. The cutting face also includes a first planar lateral side surface and a second planar lateral side surface. Each planar lateral side surface extends from the raised ridge to the radially outer surface of the cutting layer.

A cutter element for a drill bit includes a base portion having a central axis, a first end, and a second end. In addition, the cutter element includes a cutting layer fixably mounted to the first end of the base portion. The cutting layer includes a cutting face distal the base portion. The cutting face includes an elongate raised ridge having a first end at a radially outer surface of the cutting layer and a second end at the radially outer surface of the cutting layer. The raised ridge defines a maximum height of the cutter element measured axially from the second end of the base portion to the cutting face. The cutting face also includes a first planar lateral side surface and a second planar lateral side surface. Each planar lateral side surface extends from the raised ridge to the radially outer surface of the cutting layer.

A polycrystalline composite tool component and associated methods are disclosed. In one example plurality of diamond particles are coated with a conforming catalyst metal coating and a plurality of graphene particles. Various asymmetric distributions of graphene particles are shown that provide a variety of material properties.