Superabrasive materials and compacts, methods of fabricating same, and applications using same

A superabrasive compact, comprising:

• a superabrasive table including a superabrasive material comprising:
• a plurality of first superabrasive regions characteristic of being formed at least partially from a plurality of agglomerates, each first superabrasive region including a plurality of first superabrasive grains exhibiting a first average grain size;
• a matrix through which the plurality of first superabrasive regions is dispersed, the matrix including a plurality of second superabrasive grains exhibiting a second average grain size;
• and
• wherein the superabrasive table exhibits at least one characteristic selected from the group consisting of:
• the first average grain size being less than that of the second average grain size;
• and a thermal stability of the plurality of first superabrasive regions being greater than that of the matrix;
• and
• a substrate bonded to the superabrasive table.

A rotary drill bit, comprising:

• a bit body including a leading end having generally radially extending blades configured to facilitate drilling a subterranean formation;
• and
• a plurality of cutting elements mounted to the blades, at least one of the cutting elements including a superabrasive material comprising:
• a plurality of first superabrasive regions characteristic of being formed at least partially from a plurality of agglomerates, each first superabrasive region including a plurality of first superabrasive grains exhibiting a first average grain size;
• a matrix through which the plurality of first superabrasive regions is dispersed, the matrix including a plurality of second superabrasive grains exhibiting a second average grain size;
• and
• wherein the superabrasive material exhibits at least one characteristic selected from the group consisting of:
• the first average grain size being less than that of the second average grain size;
• and a thermal stability of the plurality of first superabrasive regions being greater than that of the matrix.

A method, comprising:

• sintering a mixture to form a superabrasive material, wherein the mixture comprises:
• a plurality of first agglomerates exhibiting a first average agglomerate size, each first agglomerate including a plurality of first superabrasive particles exhibiting a first average particle size;
• and
• a plurality of second agglomerates exhibiting a second average agglomerate size that is approximately equal to the first average agglomerate size, each second agglomerate including a plurality of second superabrasive particles exhibiting a second average particle size that is greater than that of the first average particle size.

A method, comprising:

• sintering a mixture to form a superabrasive material, wherein the mixture comprises:
• a plurality of first agglomerates, each of the first agglomerates including a plurality of first superabrasive particles;
• and
• a plurality of second agglomerates, each second agglomerate including a plurality of second superabrasive particles, with the plurality of second superabrasive particles having a composition that is different than that of the plurality of first superabrasive particles.

A method, comprising:

• providing a mixture comprising:
• a plurality of first agglomerates, each agglomerate including a plurality of first superabrasive particles;
• and
• a plurality of second agglomerates, each second agglomerate including a plurality of second superabrasive particles;
• and
• sintering the mixture to form a superabrasive material including a plurality of first superabrasive regions formed at least partially from the plurality of first agglomerates and a plurality of second superabrasive regions formed at least partially from the plurality of second agglomerates, the plurality of first superabrasive regions exhibiting a thermal stability greater than that of the plurality of second superabrasive regions.

A superabrasive material fabricated according to a method, the method comprising:

• sintering a mixture including:
• a plurality of first agglomerates exhibiting a first average agglomerate size, each first agglomerate including a plurality of first superabrasive particles exhibiting a first average particle size;
• and
• a plurality of second agglomerates exhibiting a second average agglomerate size that is approximately equal to the first average agglomerate size, each second agglomerate including a plurality of second superabrasive particles exhibiting a second average particle size that is greater than that of the first average particle size.