Polycrystalline Diamond Abrasive Compact

A PCD composite structure comprising a first portion having a first skeletal diamond structure formed of intergrown diamond grains and defining interstitial regions between the diamond grains and a second portion having a second skeletal diamond structure formed of intergrown diamond grains and defining interstitial regions between the diamond grains, the first skeletal structure containing metal carbide structures or particles that are occluded from the interstitial regions of the first portion by diamond, and the second skeletal structure being substantially devoid of metal carbide structures or particles that are occluded from the interstitial regions of the second portion by diamond.

A method of manufacturing a PCD compact, the method including introducing a metal carbide former, in the form of a metal compound comprising a metal that is capable of reacting with carbon to form a metal carbide, and boron and/or nitrogen, into an aggregated plurality of diamond grains to form a pre-sinter mass, and sintering the pre-sinter mass in the presence of a solvent/catalyst material for diamond at a pressure and a temperature at which diamond is thermodynamically stable in order to form PCD.