Polycrystalline diamond materials formed from coarse-sized diamond grains

A polycrystalline diamond material prepared by the process of:

• combining substantially exclusively coarse-sized diamond grains with a catalyst/binder material to form a mixture, the diamond grains having a grain size of greater than about 20 micrometers and comprising 85 percent by volume or more of the total volume of the mixture, wherein diamond grains having a grain size of 20 micrometers or less are not intentionally added during the step of combining to form the polycrystalline diamond material;
• and
• pressurizing the mixture under elevated temperature conditions to form the polycrystalline diamond material;
• wherein the polycrystalline diamond material comprises at least one material phase of a polycrystalline diamond construction having a multi-phase material microstructure.

A polycrystalline diamond material that is prepared by:

• combining materials selected from the group consisting essentially of substantially exclusively coarse-sized diamond grains and a catalyst/binder material, without the intentional use of fine-sized diamond grains having a grain size of 20 micrometers of less, the coarse-sized diamond grains sized in the range of from 30 to 90 micrometers, and wherein the catalyst/binder material is selected from the group consisting of Co, Ni, Fe, and mixtures thereof;
• mixing together the coarse-sized diamond grains and the catalyst/binder material to form a mixture;
• processing the mixture into a desired green part;
• and
• pressurizing under elevated temperature conditions the green part to form the polycrystalline diamond material.

A rotary cone rock bit comprising:

• a bit body including at least one journal pin extending from a leg portion of the bit;
• a cutter cone rotatably mounted on the journal pin;
• and
• an insert disposed along a surface of the cutter cone, the insert comprising a carbide substrate and a polycrystalline diamond material disposed along a surface of the substrate, the polycrystalline diamond material being formed from a mixture consisting essentially of substantially exclusively coarse-sized diamond grains and catalyst/binder, the catalyst/binder selected from the group consisting of Co, Ni, Fe, and mixtures thereof, the mixture being formed without the intentional addition of fine-sized diamond grains having a grain size of 20 micrometers of less, the mixture comprising greater than 85 percent by volume diamond grains having a single average particle size distribution sized in the range of from 30 to 90 micrometers.