A method to produce a sintered metal carbide article containing diamond particles throughout said article is disclosed. In one embodiment, the method involves creating a mixture of metal carbide (MC) particles, metallic binder (MB) particles and coated diamond (D) particles is compacted into a desired shape and then heated at a temperature below the graphitization temperature of the D particles to produce an under sintered MC-MB-D article which is then rapidly heated in an induction heating device to surprisingly produce a sintered MC-MB-D article containing diamond particles throughout the article. The MC-MB-D article exhibits excellent drilling/cutting capacity and surprisingly high impact resistance. One useful MC-B-D article made according to the disclosed invention is a tungsten carbide-cobalt (WCCo) article containing diamonds WCCo-D throughout the article.

A polycrystalline diamond construction may be made by subjecting diamond grains to a high pressure/high temperature condition in the presence of a catalyst material to form a polycrystalline diamond material comprising a matrix phase of bonded together diamond grains and interstitial regions disposed between the diamond grains including the catalyst material, treating the polycrystalline diamond material to remove the catalyst material therefrom to form a diamond body that is substantially free of the catalyst material, and attaching a substrate to the diamond body with a layer of eruption minimization material having a thickness from about 2 m to 8 m on at least one attachment interface surface of the substrate and/or diamond body.

A polycrystalline diamond construction may be made by subjecting diamond grains to a high pressure/high temperature condition in the presence of a catalyst material to form a polycrystalline diamond material comprising a matrix phase of bonded together diamond grains and interstitial regions disposed between the diamond grains including the catalyst material, treating the polycrystalline diamond material to remove the catalyst material therefrom to form a diamond body that is substantially free of the catalyst material, and attaching a substrate to the diamond body with a layer of eruption minimization material having a thickness from about 2 m to 8 m on at least one attachment interface surface of the substrate and/or diamond body.

Cutting elements having accelerated leaching rates and methods of making the same are disclosed herein. In one embodiment, a method of forming a cutting element includes assembling a reaction cell having diamond particles, a non-catalyst material, a catalyst material, and a substrate within a refractory metal container, where the non-catalyst material is generally immiscible in the catalyst material at a sintering temperature and pressure. The method also includes subjecting the reaction cell and its contents to a high pressure high temperature sintering process to form a polycrystalline diamond body that is attached to the substrate. The method further includes contacting at least a portion of the polycrystalline diamond body with a leaching agent to remove catalyst material and non-catalyst material from the diamond body, where a leaching rate of the catalyst material and the non-catalyst material exceeds a conventional leaching rate profile by at least about 30%.

Cutting elements having accelerated leaching rates and methods of making the same are disclosed herein. In one embodiment, a method of forming a cutting element includes assembling a reaction cell having diamond particles, a non-catalyst material, a catalyst material, and a substrate within a refractory metal container, where the non-catalyst material is generally immiscible in the catalyst material at a sintering temperature and pressure. The method also includes subjecting the reaction cell and its contents to a high pressure high temperature sintering process to form a polycrystalline diamond body that is attached to the substrate. The method further includes contacting at least a portion of the polycrystalline diamond body with a leaching agent to remove catalyst material and non-catalyst material from the diamond body, where a leaching rate of the catalyst material and the non-catalyst material exceeds a conventional leaching rate profile by at least about 30%.

([Problem] To provide a diamond-containing brazing material that is used for easier bonding of diamond surfaces to a tool or the like upon having coated the diamond surfaces with a non-peeling metal and a diamond-bonded tool or the like that utilizes the brazing material.

[Solution] In order to solve the problem, the present invention provides: a diamond-containing brazing material characterized in that non-peeling metal-coated diamonds, the surfaces of which have been coated with a metal in a non-peeling manner, are mixed in a brazing material; a diamond-containing brazing material characterized in that the diamond-containing brazing material is formed into a drop-like or rod-like shape; and a diamond-bonded tool or the like characterized in that upon having formed the diamond-containing brazing material into a tool shape, the brazing material is fused so as to be metal-bonded to a surface of the tool.

([Problem] To provide a diamond-containing brazing material that is used for easier bonding of diamond surfaces to a tool or the like upon having coated the diamond surfaces with a non-peeling metal and a diamond-bonded tool or the like that utilizes the brazing material.

[Solution] In order to solve the problem, the present invention provides: a diamond-containing brazing material characterized in that non-peeling metal-coated diamonds, the surfaces of which have been coated with a metal in a non-peeling manner, are mixed in a brazing material; a diamond-containing brazing material characterized in that the diamond-containing brazing material is formed into a drop-like or rod-like shape; and a diamond-bonded tool or the like characterized in that upon having formed the diamond-containing brazing material into a tool shape, the brazing material is fused so as to be metal-bonded to a surface of the tool.