Cutting elements including non-planar interfaces, earth-boring tools including such cutting elements, and methods of forming cutting elements

• Main Authors: FUSELIER DANIELLE M, DOSTER MICHAEL L, NELMS DEREK L, DEGEORGE JAROD
• Format: Patent
• Language: English
• Published: 22.09.2015
• Subjects: EARTH DRILLING; EARTH DRILLING, e.g. DEEP DRILLING; FIXED CONSTRUCTIONS; MINING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR ASLURRY OF MINERALS FROM WELLS

Cutting elements for earth-boring tools may comprise a substrate, a polycrystalline table comprising superhard material secured to the substrate at an end of the substrate, and a non-planar interface defined between the polycrystalline table and the substrate. The non-planar interface may comprise a cross-shaped groove extending into one of the substrate and the polycrystalline table and L-shaped grooves extending into the other of the substrate and the polycrystalline table proximate corners of the cross-shaped groove. Transitions between surfaces defining the non-planar interface may be rounded. Methods of forming cutting elements for earth-boring tools may comprise forming a substrate to have a non-planar end. The non-planar end of the substrate may be provided adjacent particles of superhard material to impart an inverse shape to the particles. The particles may be sintered to form a polycrystalline table, with a non-planar interface defined between the substrate and the polycrystalline table.