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.

A base material according to an aspect of the present disclosure is made of a cemented carbide. The cemented carbide includes a first hard phase and a binder phase. The first hard phase consists of WC particles. The binder phase includes at least one element selected from Co and Ni. The base material includes a body portion, and a surface portion provided on a surface of the body portion. The surface portion has a thickness less than or equal to an average particle size in the first hard phase. A ratio (B/A) of an area proportion (B) of the binder phase in a surface of the surface portion to an area proportion (A) of the binder phase in a cross section of the body portion is not less than 1.2 and not more than 2.0.

A base material according to an aspect of the present disclosure is made of a cemented carbide. The cemented carbide includes a first hard phase and a binder phase. The first hard phase consists of WC particles. The binder phase includes at least one element selected from Co and Ni. The base material includes a body portion, and a surface portion provided on a surface of the body portion. The surface portion has a thickness less than or equal to an average particle size in the first hard phase. A ratio (B/A) of an area proportion (B) of the binder phase in a surface of the surface portion to an area proportion (A) of the binder phase in a cross section of the body portion is not less than 1.2 and not more than 2.0.

The invention concerns pre-alloyed powders useful for the manufacture of metal-bonded diamond tools. A process for the synthesis of such powders is presented, characterized in that at least a major part of the phosphor is introduced by adding an aqueous solution of a phosphorus salt to one or more of the metal-bearing compounds. The powder can have a low cobalt content, or even be cobalt-free, yet remain suitable for the production of diamond-loaded segments having harness and bending characteristics approaching or exceeding that of cobalt.

A sensor element for a cutting tool (100) has a hard portion (110) having a sensing surface (112), first and second electrodes (120, 130), first and second sets of thermocouple wires (122, 132) and an electrically insulating portion. The first and second electrodes (120, 130) are arranged to allow electric current to flow when the sensing surface (112) contacts external material in response to the cutting tool engaging the external material. A first thermocouple junction (124) is operable to indicate a temperature of the first electrode and a second thermocouple junction (134) is operable to measure temperature of the second electrode.

A polycrystalline super hard construction is disclosed having a first region comprising a body of thermally stable polycrystalline super hard material having an exposed surface forming a working surface, and a peripheral side edge, the polycrystalline super hard material comprising a plurality of grains of super hard material; a second region forming a substrate to the first region; and a third region interposed between the first and second regions. The third region extends across a surface of the second region along an interface, the interface comprising a portion having an uneven topology and a substantially planar portion, the third region comprising a composite material including a first phase comprising a plurality of non-intergrown diamond grains, and a matrix material.

A drilling tool includes a drive assembly with a shank that is configured to couple to a power tool and a step drill bit. The step drill bit includes a body having a proximal end adjacent the shank, a distal end opposite the proximal end, and a bit axis extending centrally through the body between the proximal end and the distal end. The body is defined by a wall extending around the bit axis to define a hollow interior cavity of the body. The step drill bit also includes a plurality of axially stacked, progressively sized steps with a first step at the proximal end and a terminal step at the distal end and a flute extending from the proximal end to the distal end. The flute defines a cutting edge.

A drilling tool includes a drive assembly with a shank that is configured to couple to a power tool and a step drill bit. The step drill bit includes a body having a proximal end adjacent the shank, a distal end opposite the proximal end, and a bit axis extending centrally through the body between the proximal end and the distal end. The body is defined by a wall extending around the bit axis to define a hollow interior cavity of the body. The step drill bit also includes a plurality of axially stacked, progressively sized steps with a first step at the proximal end and a terminal step at the distal end and a flute extending from the proximal end to the distal end. The flute defines a cutting edge.

A tool main body to which an insert is attachable, in which the tool main body is made of sintered metal material, and the sintered metal material includes a parent phase made of a metal and a plurality of pores present in the parent phase.

An anvil for a cutting tool includes an anvil body. A curved passage extends from an inlet opening in the anvil body to an outlet opening in the anvil body. The anvil body can be made by an additive manufacturing process.