Polycrystalline diamond compacts having parting compound within the interstitial volumes are disclosed herein. In one embodiment, a polycrystalline diamond compact includes a polycrystalline diamond body having a plurality of diamond grains bonded together in diamond-to-diamond bonds, interstitial volumes positioned between the adjacent diamond grains, and a parting compound positioned in at least a portion of the interstitial volumes of the polycrystalline diamond body.

The invention relates to a method for producing a cutting tool comprising the following steps: a) providing a starting material for use in an additive manufacturing method in a plurality of material layers; and b) bonding each material layer of the starting material in the form of an indexable insert, wherein the material layers are arranged such that a recess is formed in the cutting tool for securing the cutting tool with a fastener to a tool base body in order to secure the cutting tool with a tool reference level that is parallel to a support plane of a tool base body.

Cutters for a downhole drill bit can be formed by providing a catalyst-free synthesized polycrystalline diamond (PCD) having a cross-sectional dimension of at least 8 millimeters; providing a substrate comprising tungsten carbide; and attaching the synthesized PCD to the substrate comprising tungsten carbide to form a PDC cutter.

Methods for preparing a layered metal nanocomposite and a layered metal nanocomposite. The method includes mixing a magnesium salt and an aluminum salt to form a Mg.sup.2+/Al.sup.3+ solution. The Mg/Al has a molar ratio of between 0.5:1 to 6:1. Then a diamondoid compound is added to the Mg.sup.2+/Al.sup.3+ solution to form a reactant mixture. The diamondoid compound has at least one carboxylic acid moiety. The reactant mixture is heated at a reaction temperature for a reaction time to form a Mg/Al-diamondoid intercalated layered double hydroxide. The Mg/Al-diamondoid intercalated layered double hydroxide is thermally decomposed under a reducing atmosphere for a decomposition time at a decomposition temperature to form the layered metal nanocomposite.

A cutting element comprises a supporting substrate, a cutting table comprising a hard material attached to the supporting substrate, and a fluid flow pathway extending through the supporting substrate and the cutting table. The fluid flow pathway is configured to direct fluid delivered to an outermost boundary of the supporting substrate through internal regions of the supporting substrate and the cutting table. A method of forming a cutting element and an earth-boring tool are also described.

Polycrystalline diamond cutting elements having enhanced thermal stability, drill bits incorporating the same, and methods of making the same are disclosed herein. In one embodiment, a cutting element includes a substrate having a metal carbide and a polycrystalline diamond body bonded to the substrate. The polycrystalline diamond body includes a plurality of diamond grains bonded to adjacent diamond grains by diamond-to-diamond bonds and a plurality of interstitial regions positioned between adjacent diamond grains. At least a portion of the plurality of interstitial regions comprise lead or lead alloy, a catalyst material, metal carbide, or combinations thereof. At least a portion of the plurality of interstitial regions comprise lead or lead alloy that coat portions of the adjacent diamond grains such that the lead or lead alloy reduces contact between the diamond and the catalyst.

Polycrystalline diamond constructions are formed from a mixture of diamond grains including a first volume of fine-sized diamond grains, and a second volume of coarse-sized diamond grains. The fine-sized diamond grains are partially graphitized, and the coarse-sized diamond grains are not graphitized. The mixture of diamond grains is subjected to high pressure/high temperature sintering process conditions in the presence of a sintering aid thereby forming polycrystalline diamond. Contact areas between coarse-sized diamond grains in the polycrystalline diamond construction are substantially free of graphite.

A manufacturing method for a three-dimensional structure includes forming unit layers using at least one of a first flowable composition including first powder and a second flowable composition including second powder and solidifying at least one of the first flowable composition including the first powder and the second flowable composition including the second powder in the unit layers. In the forming the unit layers, both of the first flowable composition and the second flowable composition are caused to be present in plane directions crossing a thickness direction of the unit layers.

A composition for making a composite polycrystalline diamond includes a plurality of diamond particles, a plurality of boron-doped diamond particles, and an additive which is selected from the group consisting of boron oxide powder, nano-carbon material and a combination thereof. Based on the total weight of the composition, the diamond particles are present in an amount that ranges from 0.5 wt % to 99.4 wt %, the boron-doped diamond particles are present in an amount that ranges from 0.5 wt % to 99.4 wt %, and the additive is present in an amount that ranges from 0.1 wt % to 20 wt %. A method for making the composite polycrystalline diamond and a composite polycrystalline diamond made thereby are also disclosed.

Processes produce a compound material structure by producing a composite material which extends along an axis of elongation from carbon nanostructures anchored in a matrix of a first metal extending along the axis of elongation of the composite material. The processes comprise dividing the composite material into segments of the composite material, arranging the segments in a plane of a die matrix, filling free spaces in the die matrix with a filler material and subsequently sintering in the die matrix to form a compound material structure or squeeze casting in the die matrix, and exposing the carbon nanostructures of the composite material on at least one surface of the compound material structure such that the carbon nanostructures protrude out of this surface. Compound material structures and uses thereof as a heat conductor and/or a heat exchanger are also provided.