A method of making shaped abrasive particles including forming an abrasive flake comprising a plurality of precursor shaped abrasive particles and a frangible support joining the precursor shaped abrasive particles together; transporting the abrasive flake through a rotary kiln to sinter the abrasive flake; and breaking the sintered abrasive flake into individual shaped abrasive particles. The method is useful to make small shaped abrasive particles having insufficient mass to be efficiently individually sintered in a rotary kiln without joining two or more of the shaped abrasive particles together.

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 m) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 m). During high pressurehigh temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations.

A cutting element for an earth-boring tool includes a substrate and volume of superabrasive material positioned on the substrate. The volume of superabrasive material includes a cutting face having at least one recess extending into the volume of superabrasive material and/or at least one protrusion extending outward from the volume of superabrasive material. The volume of superabrasive material includes a first chamfer surface having a peripheral edge and a radially innermost edge. The peripheral edge of the first chamfer surface is located proximate a cutting edge of the volume of superabrasive material. A radial width of the first chamfer surface is between about 0.002 inch and about 0.045 inch. The volume of superabrasive material also includes a second chamfer surface having a peripheral edge and a radially innermost edge. The peripheral edge of the second chamfer surface is located adjacent the radially innermost edge of the first chamfer surface.

An abrasive article comprising: a first body comprising a first bond material having abrasive particles contained within the first bond material, wherein the first body comprising the first bond material comprises a ratio of V.sub.AG(1)/V.sub.BM(1) of at least about 1.3; a second body comprising a second bond material having abrasive particles contained within the second bond material, wherein the second body comprising the second bond material comprises a ratio of V.sub.AG(2)/V.sub.BM(2) of less than about 1.3, and wherein V.sub.AG is a volume percent of abrasive particles within a total volume of the first or second body respectively and V.sub.BM is a volume percent of the first or second bond material within the total volume of the first or second body respectively.

A PCD 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 comprising a plurality of alternating strata or layers, each stratum or layer having a thickness in the range of around 5 to 300 microns. The second region comprises a plurality of strata or layers, one or more strata or layers in the second region having a thickness greater than the thicknesses of the individual strata or layers in the first region. The alternating layers or strata in the first region comprise first layers or strata alternating with second layers or strata, the first layers or strata being in a state of residual compressive stress and the second layers or strata being in a state of residual tensile stress.

The present invention relates to a powder for three-dimensional printing of a cermet or a cemented carbide body. The powder has 30-70 vol % of the particles that are <10 m in diameter. The present invention also relates to a method of making a cermet or cemented carbide body. The method includes the steps of forming the powder, 3D printing a body using the powder together with a printing binder to form a 3D printed cermet or cemented carbide green body and subsequently sintering the green body to form a cermet or cemented carbide body.

The present invention relates to a powder mixture for three-dimensional (3D) printing of a cermet or a cemented carbide body. The powder mixture includes 65-85 wt % of porous cemented carbide or cermet particles of a median particle size (D50) of 10-35 m, and 15-35 wt % of a dense cemented carbide or cermet particles of a median particle size (D50) of 3-10 m. The present invention also relates to a method of making a cermet or cemented carbide body, the method including the steps of forming the powder mixture, 3D printing a body using the powder mixture and a printing binder and thereby forming a 3D printed cermet or cemented carbide green body and sintering the green body and to form a cermet or cemented carbide body.

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.

Diamond bodies and methods of manufacture are disclosed. Diamond bodies are formed from at least a bimodal, alternatively a tri-modal or higher modal, feedstock having at least one fraction of modified diamond particles with a fine particle size (0.5-3.0 m) and at least one fraction of diamond particles with coarse particle size (15.0 to 30 m). During high pressurehigh temperature processing, fine particle sized, modified diamond particles in the first fraction preferentially fracture to smaller sizes while preserving the morphology of coarse particle sized diamond particles in the second fraction. Diamond bodies incorporating the two fractions have a microstructure including second fraction diamond particles dispersed in a continuous matrix of first fraction modified diamond particles and exhibit improved wear characteristics, particularly for wear associated with drilling of geological formations.

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.