Embodiments relate to polycrystalline diamond compacts (PDCs) and methods of manufacturing such PDCs in which an at least partially leached polycrystalline diamond (PCD) table is infiltrated with a low viscosity cobalt-based alloy infiltrant. In an embodiment, a method includes forming a PCD table in the presence of a metal-solvent catalyst in a first high-pressure/high-temperature (HPHT) process. The method includes at least partially leaching the PCD table to remove at least a portion of the metal-solvent catalyst therefrom to form an at least partially leached PCD table. The method includes subjecting the at least partially leached PCD table and a substrate to a second HPHT process effective to at least partially infiltrate the at least partially leached PCD table with a cobalt-based alloy infiltrant having a composition at or near a eutectic composition of the cobalt-based alloy infiltrant.

In an embodiment, a method of fabricating a leached polycrystalline diamond (PCD) body is disclosed. The PCD body includes bonded diamond grains defining interstitial regions at least a portion of which include at least one interstitial constituent disposed therein. The method includes leaching the PCD body with a leaching agent to remove at least a portion of the at least one interstitial constituent therefrom. The leaching agent includes a mixture having hydrofluoric acid in a first concentration of about 10 weight % to about 50 weight %, nitric acid in a second concentration of about 5 weight % to about 25 weight %, and water in a third concentration of about 25 weight % to about 85 weight %. Further embodiments relate to different leaching methods and different leaching agent compositions.

A support structure (40) for a PCD element (10) comprises a support (42) into which a PCD element (10) is locatable and a sealing element (48) for location in the support structure (40) and configured to protect a non-leached portion of a PCD element (10) during a leaching process. The support (42) is formed from or coated with a polyketone based plastics material.

Method of fabricating polycrystalline diamond include functionalizing surfaces of diamond nanoparticles with fluorine, combining the functionalized diamond nanoparticles with a polymer to form a mixture, and subjecting the mixture to high pressure and high temperature (HPHT) conditions to form inter-granular bonds between the diamond nanoparticles. A green body includes a plurality of diamond nanoparticles functionalized with fluorine, and a polymer material interspersed with the plurality of diamond nanoparticles. A method of forming cutting element includes functionalizing surfaces of diamond nanoparticles with fluorine, and combining the functionalized diamond nanoparticles with a polymer to form a mixture. The mixture is formed over a body, and the mixture and the body are subjected to HPHT conditions to form inter-granular bonds between the diamond nanoparticles and secure the bonded diamond nanoparticles to the body.

Disclosed herein is an apparatus and method for growing a diamond. The apparatus for growing a diamond comprises: a reaction cell that is configured to grow the diamond therein; a main heater including a main heating surface that is arranged along a first inner surface of the reaction cell; and a sub-heater including a sub-heating surface that is arranged along a second inner surface of the reaction cell, the second inner surface being non-parallel with the first inner surface.

A superabrasive compact and a method of making the superabrasive compact are disclosed. A method of making a superabrasive compact comprises steps of providing a plurality of superabrasive particles having a particle size distribution with a first ratio (d50)/(d50 principle particles) ranging from about 0.86 to about 0.92; providing a support to the plurality of superabrasive particles; and subjecting the support and the plurality of superabrasive particles to conditions of an elevated temperature and pressure suitable for producing the polycrystalline superabrasive compact.

Polycrystalline diamond compacts (PDCs) and methods of manufacturing such PDCs. In an embodiment, the PDC includes a polycrystalline diamond (PCD) table having at least a portion of a metal-solvent catalyst removed therefrom. Removing at least a portion of a metal-solvent catalyst from the PCD table may increase the porosity of the PCD table relative to a PCD table that has not been treated to remove the metal-solvent catalyst. Likewise, removing at least a portion of a metal-solvent catalyst from the PCD table may decrease the specific magnetic saturation and increase the coercivity of the PCD table relative to a PCD table that has not been treated to remove the metal-solvent catalyst.

A method of forming polycrystalline diamond includes encapsulating diamond particles, carbon monoxide, and carbon dioxide in a container. The encapsulated diamond particles, carbon monoxide, and carbon dioxide are subjected to a pressure of at least 4.5 GPa and a temperature of at least 1,400 C. to form inter-granular bonds between the diamond particles. A cutting element includes polycrystalline diamond material comprising inter-bonded grains of diamond. The polycrystalline diamond material is substantially free of graphitic carbon and metallic compounds. The polycrystalline diamond material exhibits a density of at least about 3.49 g/cm.sup.3 and a modulus of at least about 1,000 GPa. An earth-boring tool may include such a cutting element secured to a body.

Polycrystalline diamond constructions include a diamond body comprising a matrix phase of bonded together diamond crystals formed at high pressure/high temperature conditions with a catalyst material. The sintered body is treated remove the catalyst material disposed within interstitial regions, rendering it substantially free of the catalyst material used to initially sinter the body. Accelerating techniques can be used to remove the catalyst material. The body includes an infiltrant material disposed within interstitial regions in a first region of the construction. The body includes a second region adjacent the working surface and that is substantially free of the infiltrant material. The infiltrant material can be a Group VIII material not used to initially sinter the diamond body. A metallic substrate is attached to the diamond body, and can be the same or different from a substrate used as a source of the catalyst material used to initially sinter the diamond body.

Embodiments of the invention relate to polycrystalline diamond compacts (PDC) exhibiting enhanced diamond-to-diamond bonding. In an embodiment, PDC includes a sintered substantially single-phase polycrystalline diamond (PCD) body consisting essentially of bonded-together diamond grains exhibiting a morphology different than that of a PCD body formed by sintering diamond crystals. A substrate is bonded to the sintered substantially single-phase PCD body. Other embodiments are directed to methods of forming such PDCs, and various applications for such PDCs in rotary drill bits, bearing apparatuses, and wire-drawing dies.