A superabrasive material and method of making the superabrasive material are provided. The superabrasive material may comprise a superabrasive crystal having an irregular surface. The superabrasive material further comprises a plurality of structure defects within the superabrasive crystal. The plurality of structure defects may cause micro-chipping when used as grinding materials.

Systems and methods include a computer-implemented method can be used to make drilling tools from new wurtzite boron nitride (w-BN) superhard material. An ultra-high-pressure, high-temperature operation is performed on pure w-BN powder to synthesize w-BN and cubic boron nitride (c-BN) compact having a first size greater than particles of the pure w-BN powder. The ultra-high-pressure, high-temperature operation includes pressurizing the w-BN powder to a pressure of approximately 20 Gigapascal, heating the w-BN powder at a heating rate of 100° C./minute and cooling the w-BN powder at a cooling rate of 50° C./minute. The compact is cut to a second size smaller than the first size using laser cutting tools. The cut compact is bonded metallurgically, mechanically, or both metallurgically and mechanically onto a tool substrate to form the drilling tool.

Polycrystalline compacts include a polycrystalline superabrasive material comprising a first plurality of grains of superabrasive material having a first average grain size and a second plurality of grains of superabrasive material having a second average grain size smaller than the first average grain size. The first plurality of grains is dispersed within a substantially continuous matrix of the second plurality of grains. Earth-boring tools may include a body and at least one polycrystalline compact attached thereto. Methods of forming polycrystalline compacts may include coating relatively larger grains of superabrasive material with relatively smaller grains of superabrasive material, forming a green structure comprising the coated grains, and sintering the green structure. Other methods include mixing diamond grains with a catalyst and subjecting the mixture to a pressure greater than about five gigapascals (5.0 GPa) and a temperature greater than about 1,300° C. to form a polycrystalline diamond compact.

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.

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.

Systems and methods include a computer-implemented method can be used to make milling tools from new wurtzite boron nitride (w-BN) superhard material. An ultra-high-pressure, high-temperature operation is performed on pure w-BN powder to synthesize w-BN and cubic boron nitride (c-BN) compact having a first size greater than particles of the pure w-BN powder. The ultra-high-pressure, high-temperature operation includes pressurizing the w-BN powder to a pressure of approximately 20 Gigapascal, heating the w-BN powder at a heating rate of 100 C./minute and cooling the w-BN powder at a cooling rate of 50 C./minute. The compact is cut to a second size smaller than the first size using laser cutting tools. The cut compact is turbulently mixed with additives in a mixer under vacuum. The cut compact mixed with the additives is thermally sprayed onto a tool substrate to form the tool.

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.

Polycrystalline compacts include a polycrystalline superabrasive material comprising a first plurality of grains of superabrasive material having a first average grain size and a second plurality of grains of superabrasive material having a second average grain size smaller than the first average grain size. The first plurality of grains is dispersed within a substantially continuous matrix of the second plurality of grains. Earth-boring tools may include a body and at least one polycrystalline compact attached thereto. Methods of forming polycrystalline compacts may include coating relatively larger grains of superabrasive material with relatively smaller grains of superabrasive material, forming a green structure comprising the coated grains, and sintering the green structure. Other methods include mixing diamond grains with a catalyst and subjecting the mixture to a pressure greater than about five gigapascals (5.0 GPa) and a temperature greater than about 1,300 C. to form a polycrystalline diamond compact.

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.

An assembly for High Pressure High Temperature (HPHT) synthesis of a superhard material. The assembly comprises a container comprising a first metal. A closure also comprising the first metal is sealed to the container using a sealant material. The sealant material comprises a second metal, the seal comprising a composition of the first and second metals formable below the melting point of the second metal. The container contains superhard material.