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

The inventive concept relates to method for manufacturing a metal based component comprising at least one protrusion. The method comprises: providing a metal based substrate comprising a surface having at least one cavity; providing a metal based protrusion element comprising a first portion and a second portion, wherein said first portion has a shape that conforms to a shape of the cavity; arranging the first portion of the protrusion element in said cavity such that at least the second portion of the protrusion element protrudes at least 5 mm from a surface of the metal based substrate, to form a substrate comprising a protrusion; placing said substrate comprising a protrusion in a canister such that a void is formed between the canister and the surface of the substrate comprising the protrusion; filling at least a portion of the void with a diamond powder such that the surface of the substrate comprising the protrusion is covered by the inert filler material; removing gas from the interface between said diamond powder and said substrate comprising the protrusion; subjecting said substrate comprising the protrusion to a hot isostatic pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that said substrate and protrusion element bond metallurgically to each other to form said metal based component comprising said at least one protrusion; removing at least a part of said diamond powder from said metal based component having a protrusion, wherein a melting point of the diamond powder at said predetermined temperature is higher than said predetermined temperature.

The present disclosure relates to a polycrystalline diamond compact (PDC) with a fiber-reinforces substrate. The disclosure further relates to method of forming such a PDC.

In the area of rocket engines, regeneratively cooled rocket engines currently undergo long manufacturing time frames. This deters the speed of the development process resulting in a longer time to get to the market with a proven new design. There is a need to create methods that can manufacture regeneratively cooled rocket engines faster with a quick time to the market. This disclosure relates to faster methods for manufacturing regeneratively cooled rocket thrust chamber nozzles that use rocket propellant fluids to cool the chamber walls of the nozzle itself before being injected and burned. Furthermore, the new methods lead to enhanced designs that could enable reusable rocket engines by limiting overall fatigue with novel materials.

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 method of forming a polycrystalline diamond cutting element includes assembling a diamond material, a substrate, and a source of catalyst material or infiltrant material distinct from the substrate, the source of catalyst material or infiltrant material being adjacent to the diamond material to form an assembly. The substrate includes an attachment material including a refractory metal. The assembly is subjected to a first high-pressure/high temperature condition to cause the catalyst material or infiltrant material to melt and infiltrate into the diamond material and subjected to a second high-pressure/high temperature condition to cause the attachment material to melt and infiltrate a portion of the infiltrated diamond material to bond the infiltrated diamond material to the substrate.

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.

Provided is an aluminum-diamond-based composite which can be processed with high dimensional accuracy. The flat-plate-shaped aluminum-diamond-based composite is coated with a surface layer of which the entire surface has an average film thickness of 0.01-0.2 mm and which contains not less than 80 volume % of a metal containing an aluminum.

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.

Embodiments disclosed herein relate to polycrystalline diamond compacts that have a substrate including a cementing constituent constituting less than 13 weight percent (wt %) of the substrate, the cementing constituent including a cobalt alloy having and at least one alloying element, wherein the at least one alloying element constitutes less than 12 wt % of the substrate and wherein the cobalt constitutes less than 12 wt % of the substrate; and methods of making the same.