Methods of forming cutting elements

A method of forming a cutting element, comprising:

• providing a diamond-containing material comprising discrete diamond particles over a substrate;
• sintering the diamond-containing material in the presence of a liquid phase of a homogenized alloy comprising at least one first element selected from Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U, and at least one second element selected from Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P to inter-bond the discrete diamond particles;
• and
• converting portions of the homogenized alloy within interstitial spaces between the inter-bonded diamond particles into a thermally stable material substantially free of Co, the thermally stable material comprising one or more carbide precipitates having the general chemical formula:
• A3XZ1-n,
• where A comprises the at least one first element;
• X comprises the at least one second element;
• Z comprises C;
• and
• n is greater than or equal to 0 and less than or equal to 0.75.

A method of forming a cutting element, comprising:

• providing a diamond-containing material comprising discrete diamond particles over a substrate;
• sintering the diamond-containing material in the presence of a liquid phase of a homogenized alloy to inter-bond the discrete diamond particles, the homogenized alloy comprising:
• one first element selected from Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U;
• and
• two second elements selected from Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P;
• and
• converting portions of the homogenized alloy within interstitial spaces between the inter-bonded diamond particles into a thermally stable material comprising a quaternary κ-carbide having the general chemical formula:
• A3XZ1-n,
• where A comprises the one first element;
• X comprises the two second elements;
• Z comprises C;
• and
• n is greater than or equal to 0 and less than or equal to 0.75.