Wear resistant self-lubricating additive manufacturing parts and part features are disclosed in use with oilfield service operations.

Methods for preparing a layered metal nanocomposite and a layered metal nanocomposite. The method includes mixing a magnesium salt and a 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.

The inventive concept relates to a method for manufacturing a metal based component (100, 200) having a cavity (103, 203). The method comprises the steps of: providing a plurality of individual segments (110, 210) corresponding to different portions of the metal based component; arranging the plurality of segments in a stack (120, 220) in such a way that the shape of the stack corresponds to the shape of the metal based component, and that a void (130, 230) is formed in the stack, wherein the shape of at least a portion of the void corresponds to the shape of the cavity; filling at least the first 10 portion of the void with an incompressible filler (140, 240); removing gas from the stack; subjecting the stack to a hot pressing process to form the metal based component comprising the cavity; removing at least a part of the incompressible filler from the metal based component.

A method for coating a metal based component surface wherein said metal based component has an inner and/or outer surface portion that is to be coated, and which surface portion comprises a carbide forming composition. A cavity having one or more cavity walls, wherein said at least one inner and/or outer surface portion forms at least a portion of said one or more cavity walls is provided, and a portion of the cavity is filled with diamond powder. Thereafter gas is removed from the interface between said diamond powder and said at least one inner and/or outer surface portion, and the cavity is subjected to a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that said diamond powder diffusion bonds to said at least one one inner and/or outer surface portion. Finally at least a part of said diamond powder is removed from said at least one cavity.

A polycrystalline super hard construction has a body of polycrystalline diamond material with a working surface, a first region substantially free of a solvent/catalysing material extending a depth from the working surface into the body of PCD material, and a second region remote from the working surface that includes solvent/catalysing material. The first and second regions are joined along a boundary. A chamfer extends between the working surface and a peripheral side surface of the body of PCD material. The distance from the midpoint of the chamfer to the boundary of the first and second regions along a plane substantially perpendicular to the plane in which the chamfer extends is at least X divided by two, where X is 0.8 times the thickness of the body of PCD material.

The present disclosure relates to polycrystalline diamond covalently bonded to a substrate by spark plasma sintering and methods of covalently bonding polycrystalline diamond and a substrate. Spark plasma sintering produces plasma from a reactant gas found in the pores in the polycrystalline diamond and, optionally, also the substrate. The plasma forms carbide structures in the pores, which covalently bond to the substrate.

Methods of forming a polycrystalline compact using at least one metal salt as a sintering aid. Such methods may include forming a mixture of the at least one metal salt and a plurality of grains of hard material and sintering the mixture to form a hard polycrystalline material. During sintering, the metal salt may melt or react with another compound to form a liquid that acts as a lubricant to promote rearrangement and packing of the grains of hard material. The metal salt may, thus, enable formation of hard polycrystalline material having increased density, abrasion resistance, or strength. The metal salt may also act as a getter to remove impurities (e.g., catalyst material) during sintering. The methods may also be employed to form cutting elements and earth-boring tools.

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.

Methods of forming a polycrystalline compact using at least one metal salt as a sintering aid. Such methods may include forming a mixture of the at least one metal salt and a plurality of grains of hard material and sintering the mixture to form a hard polycrystalline material. During sintering, the metal salt may melt or react with another compound to form a liquid that acts as a lubricant to promote rearrangement and packing of the grains of hard material. The metal salt may, thus, enable formation of hard polycrystalline material having increased density, abrasion resistance, or strength. The metal salt may also act as a getter to remove impurities (e.g., catalyst material) during sintering. The methods may also be employed to form cutting elements and earth-boring tools.

A method for manufacturing a cutter includes: boring a passage into a polycrystalline superhard cutting head, the passage extending from a front face of the cutting head toward a side thereof; and introducing acid into the passage, thereby removing at least a portion of a metal from the cutting head.