Cemented and cemented/sintered superabrasive polycrystalline bodies and methods of manufacture thereof

A backed superabrasive compact comprising a plurality of metal coated superabrasive particles, said superabrasive particles having a hardness at least equal to that of diamond or cubic boron nitride, said metal being selected from Groups IVA, VA, VIA or an alloy thereof, said coating being chemically bonded to said superabrasive particles and to the coatings of adjacent superabrasive particle, said coating forming a matrix cementing said superabrasive particles together into a coherent mass of high structural strength having a predetermined configuration;

• said matrix further comprising a binding aid which wets said metal coatings and is located essentially between said metal coated particles;
• and a backing bonded to said matrix and said superabrasive particles.

A method for manufacturing a cemented superabrasive cutting element comprising the steps of;

• placing a plurality of metal coated superabrasive particles in a mold, said superabrasive particles having a hardness at least equal to that of diamond or cubic boron nitride, said metal being chosen from the Groups IVA, VA, VIA, or an alloy therof;
• and subjecting the contents of said mold to high pressure and high temperature conditions characteristic of the diamond stable region for bonding said metal coatings of said coated particles to the metal coatings of adjacent coated particles, and forming a coherent mass of superabrasive particles having high structural strength and a predetermined configuration.

A method of manufacturing a free standing cutting element comprising the steps of placing diamond particles coated with tungsten in a mold;

• placing a silicon disc in contact with said coated particles in said mold;
• and exposing said container to high pressure and high temperature conditions characteristic of the diamond stable region for a sufficient time to form a cemented structure of high structural strength.

A thermally stable cutting element comprising:

• a plurality of diamond particles coated with tungsten, wherein said tungsten coatings of said diamond particles are chemically bonded to said diamond and to the tungsten coatings of adjacent coated particles, said coatings forming a matrix of high structural strength cementing said particles together;
• said matrix further comprising silicon.