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.

It is an object of the present invention to provide an abrasive material which enables: processing efficiency and finished planarity of a substrate material to be simultaneously improved at a high level; polishing costs to be reduced; and a difficult-to-process substrate composed of sapphire or silicon carbide to be polished efficiently and precisely. An abrasive material comprises a substrate and an abrasive layer laminated on a front face side of the substrate, wherein the abrasive layer includes a binder containing an inorganic substance as a principal component, and abrasive particles dispersed in the binder, wherein a front face of the abrasive layer comprises a plurality of regions provided through dividing by grooves, and wherein a maximum peak height (Rp) on the front face of the abrasive layer is no less than 2.5 m and no greater than 70 m.

It is an object of the present invention to provide an abrasive material which enables: processing efficiency and finished planarity of a substrate material to be simultaneously improved at a high level; polishing costs to be reduced; and a difficult-to-process substrate composed of sapphire or silicon carbide to be polished efficiently and precisely. An abrasive material comprises a substrate and an abrasive layer laminated on a front face side of the substrate, wherein the abrasive layer includes a binder containing an inorganic substance as a principal component, and abrasive particles dispersed in the binder, wherein a front face of the abrasive layer comprises a plurality of regions provided through dividing by grooves, and wherein a maximum peak height (Rp) on the front face of the abrasive layer is no less than 2.5 m and no greater than 70 m.

A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.

A polycrystalline diamond body, and a method for making a carbonate polycrystalline diamond body includes combining a first quantity of diamond particles with a first quantity of magnesium carbonate to form a first layer in an enclosure, the first layer having a working surface, and placing a second quantity of magnesium carbonate in the enclosure forming a second layer, the first layer and the second layer forming an assembly. A quantity of at least one of silicon or aluminum is mixed in with or placed adjacent to at least one of the first layer or the second layer. The assembly, including the at least one of silicon or aluminum, is sintered at high pressure and high temperature, causing the at least one of silicon or aluminum to infiltrate at least one layer of the assembly, forming a polycrystalline diamond body.

A polycrystalline diamond construction comprising a body of polycrystalline diamond material is formed of a mass of diamond grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween, and a non-diamond phase at least partially filling a plurality of the interstitial regions to form non-diamond phase pools, the non-diamond phase pools each having an individual cross-sectional area. The percentage of non-diamond phase in the total area of a cross-section of the body of polycrystalline diamond material and the mean of the individual cross-sectional areas of the non-diamond phase pools in the image analysed using an image analysis technique at a selected magnification is less than 0.7, or less than 0.340 microns squared, or between around 0.005 to 0.340 microns squared depending on the percentage of non-diamond phase in the total area of the cross-section of the polycrystalline diamond construction. The body of polycrystalline material in the construction has a cutting surface having a surface topology comprising one or more indentations therein and/or projections therefrom. There is also disclosed a method of making such a construction.

A polycrystalline diamond construction comprising a body of polycrystalline diamond material is formed of a mass of diamond grains exhibiting inter-granular bonding and defining a plurality of interstitial regions therebetween, and a non-diamond phase at least partially filling a plurality of the interstitial regions to form non-diamond phase pools, the non-diamond phase pools each having an individual cross-sectional area. The percentage of non-diamond phase in the total area of a cross-section of the body of polycrystalline diamond material and the mean of the individual cross-sectional areas of the non-diamond phase pools in the image analysed using an image analysis technique at a selected magnification is less than 0.7, or less than 0.340 microns squared, or between around 0.005 to 0.340 microns squared depending on the percentage of non-diamond phase in the total area of the cross-section of the polycrystalline diamond construction. The body of polycrystalline material in the construction has a cutting surface having a surface topology comprising one or more indentations therein and/or projections therefrom. There is also disclosed a method of making such a construction.

Disclosed are an additive raw material composition and an additive for superhard material product, a method for preparing the additive, a composite binding agent, a superhard material product, a self-sharpening diamond grinding wheel and a method for manufacturing the same. The raw material composition consisting of components in following mass percentage: Bi2O3 25%40%, B2O3 25%40%, ZnO 5%25%, SiO2 2%10%, Al2O3 2%10%, Na2CO3 1%5%, Li2CO3 1%5%, MgCO3 0%5%, and CaF2 1%5%. The composite binding agent is prepared from the additive and a metal composite binding agent. The self-sharpening diamond grinding wheel prepared from the composite binding agent has high self-sharpness, high strength, and fine texture, is uniformly consumed during the grinding process, does not need to be trimmed during the process of being used, and maintains good grinding force all the time, fundamentally solving the problems of long trimming time and high trimming cost of the diamond grinding wheel.

Disclosed are an additive raw material composition and an additive for superhard material product, a method for preparing the additive, a composite binding agent, a superhard material product, a self-sharpening diamond grinding wheel and a method for manufacturing the same. The raw material composition consisting of components in following mass percentage: Bi2O3 25%40%, B2O3 25%40%, ZnO 5%25%, SiO2 2%10%, Al2O3 2%10%, Na2CO3 1%5%, Li2CO3 1%5%, MgCO3 0%5%, and CaF2 1%5%. The composite binding agent is prepared from the additive and a metal composite binding agent. The self-sharpening diamond grinding wheel prepared from the composite binding agent has high self-sharpness, high strength, and fine texture, is uniformly consumed during the grinding process, does not need to be trimmed during the process of being used, and maintains good grinding force all the time, fundamentally solving the problems of long trimming time and high trimming cost of the diamond grinding wheel.

A method of making a polycrystalline diamond compact includes forming multiple layers of premixed diamond particles and carbonate material, where the carbonate material includes an alkaline earth metal carbonate, and where each layer has a weight percent ratio of diamond to carbonate that is different from adjacent layers. The layers are subjected to high pressure high temperature conditions to form polycrystalline diamond.