A method of making a thermally stable polycrystalline super hard construction having a plurality of interbonded super hard grains and interstitial regions disposed therebetween to form a polycrystalline super hard construction having a first thermally stable region and a second region, the first thermally stable region forming at least part of a working surface of the construction, comprises treating the polycrystalline super hard material with a leaching mixture to remove non-super hard phase material from a number of interstitial regions in the first region. The step of treating comprises masking the polycrystalline super hard construction along at least a portion of the peripheral side surface up to and/or at the working surface to inhibit penetration of the leaching mixture into the super hard construction through a peripheral side surface of the super hard construction.

A polycrystalline diamond structure comprises a first region and a second region adjacent the first region, the second region being bonded to the first region by intergrowth of diamond grains. The first region comprises a plurality of alternating strata or layers, each or one or more strata or layers in the first region having a thickness in the range of around 5 to 300 microns. The polycrystalline diamond (PCD) structure has a diamond content of at most about 95 percent of the volume of the PCD material, a binder content of at least about 5 percent of the volume of the PCD material, and one or more of the layers or strata in the first region comprise and/or the second region comprises diamond grains having a mean diamond grain contiguity of greater than about 60 percent and a standard deviation of less than about 2.2 percent. There is also disclosed a method of making such a polycrystalline diamond structure.

A diamond polycrystal includes diamond grains, the diamond polycrystal including a cubic diamond and a 6H type hexagonal diamond, wherein the cubic diamond and the 6H type hexagonal diamond exist in the same or different diamond grains, and a ratio Ab.sub.1/Ab.sub.2 is more than or equal to 0.4 and less than or equal to 1, Ab.sub.1 representing a maximum value of absorption in a range of more than or equal to 1200 cm.sup.1 and less than or equal to 1300 cm.sup.1 in an infrared absorption spectrum, Ab.sub.2 representing a maximum value of absorption in a range of more than or equal to 1900 cm.sup.1 and less than or equal to 2100 cm.sup.1.

Systems and methods include a computer-implemented method for manufacturing a binder for spraying onto tools. A binder is manufactured for binding compacts onto a tool substrate. The binder is designed to provide a coating strength on the tool substrate. The binder includes: a metal selected from iron (Fe), cobalt (Co), and nickel (Ni); an alloy including the metal selected from Fe, Co, and Ni; or a refractory alloy selected from tungsten, tantalum (Ta), molybdenum (Mo), and niobium (Nb). An ultra-high-pressure, high-temperature operation is performed on pure wurtzite boron nitride (w-BN) powder to synthesize w-BN and cubic boron nitride (c-BN) compact. A binder-compact mixture is produced by turbulently mixing the binder with the compact in a mixer within a vacuum. The binder-compact mixture is thermally sprayed onto a tool substrate to coat the tool.

A polycrystalline diamond construction comprising a body of polycrystalline diamond material formed of a mass of diamond grains exhibiting inter-granular bonding, wherein between around 50 wt % to around 99 wt % of the diamond grains in a cross-section of the body of polycrystalline diamond material taken at any orientation have a sectorial growth structure. A method of making the polycrystalline diamond construction is also disclosed.

A method of making a thermally stable polycrystalline super hard construction having a plurality of interbonded super hard grains and interstitial regions disposed therebetween to form a polycrystalline super hard construction having a first thermally stable region and a second region, the first thermally stable region forming at least part of a working surface of the construction, comprises treating the polycrystalline super hard material with a leaching mixture to remove non-super hard phase material from a number of interstitial regions in the first region. The step of treating comprises masking the polycrystalline super hard construction along at least a portion of the peripheral side surface up to and/or at the working surface to inhibit penetration of the leaching mixture into the super hard construction through a peripheral side surface of the super hard construction.

A polycrystalline diamond construction comprising a body of polycrystalline diamond material formed of a mass of diamond grains exhibiting inter-granular bonding, wherein between around 50 wt % to around 99 wt % of the diamond grains in a cross-section of the body of polycrystalline diamond material taken at any orientation have a sectorial growth structure. A method of making the polycrystalline diamond construction is also disclosed.

The present disclosure relates to cutting elements incorporating polycrystalline diamond bodies used for subterranean drilling applications, and more particularly, to polycrystalline diamond bodies having a high diamond content which are configured to provide improved properties of thermal stability and wear resistance, while maintaining a desired degree of impact resistance, when compared to prior polycrystalline diamond bodies. In various embodiments disclosed herein, a cutting element with high diamond content includes a modified PCD structure and/or a modified interface (between the PCD body and a substrate), to provide superior performance.

A method of forming polycrystalline diamond comprised placing a plurality of graphene nano-platelets into a capsule; and subjecting the platelets to a pressure of around 10 GPa to around 20 GPa and a temperature of around 1600 degrees Celsius to around 3000 degrees Celcius to convert the graphene platelets to nano-polycrystalline diamond. There is also disclosed a polycrystalline super hard construction comprising a polycrystalline diamond region comprising polycrystalline diamond material formed according to said method.

A composite polycrystal contains polycrystalline diamond formed of diamond grains that are directly bonded mutually, and compressed graphite dispersed in the polycrystalline diamond.