Cutting element and method of forming thereof

Abstract

A cutting element comprising a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface. The cutting element further includes a superabrasive layer comprising a rear surface, an upper surface, and a side surface connected to and extending between the rear surface and upper surface, wherein the rear surface of the superabrasive layer overlies the upper surface of the substrate. The cutting element is also formed to include a jacket overlying the side surface of the substrate and abutting a portion of the rear surface of the superabrasive layer, wherein the jacket comprises a flange extending along a portion of the side surface of the superabrasive layer.

1 . A cutting element comprising:
 a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface;   a superabrasive layer comprising a rear surface, an upper surface, and a side surface connected to and extending between the rear surface and upper surface, wherein the rear surface of the superabrasive layer overlies the upper surface of the substrate; and   a jacket overlying the side surface of the substrate and abutting a portion of the rear surface of the superabrasive layer, wherein the jacket comprises a flange extending along a portion of the side surface of the superabrasive layer.   
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . The cutting element of  claim 1 , wherein the jacket comprises an average thickness as measured in a radial direction of not greater than about 5 mm. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The cutting element of  claim 4 , wherein the jacket comprises an average thickness within a range between about 0.1 mm and about 5 mm. 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . The cutting element of  claim 1 , wherein the jacket comprises a radially varying thickness. 
     
     
         11 . The cutting element of  claim 1 , wherein the jacket comprises an axially varying thickness. 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . The cutting element of  claim 1 , wherein the jacket comprises an inorganic material selected from the group of materials consisting of metal, ceramic, cermet, and a combination thereof. 
     
     
         15 . (canceled) 
     
     
         16 . The cutting element of  claim 15 , wherein the jacket comprises a metal element selected from the group of elements consisting of titanium, chromium, nickel, tungsten, cobalt, iron, molybdenum, vanadium, and a combination thereof. 
     
     
         17 . (canceled) 
     
     
         18 . The cutting element of  claim 1 , wherein the jacket comprises a contoured inner surface for complementary engagement with a contoured region along the side surface of the substrate. 
     
     
         19 . (canceled) 
     
     
         20 . The cutting element of  claim 1 , wherein the jacket is mechanically interlocked with the substrate. 
     
     
         21 - 28 . (canceled) 
     
     
         29 . A cutting element comprising:
 a cutter body comprising:
 a substrate having an upper surface, a rear surface spaced apart from the upper surface, and a side surface connected to the rear surface and upper surface; 
 a superabrasive layer comprising a rear surface overlying the upper surface of the substrate at a substrate/superabrasive layer interface; and 
   a jacket comprising an erosion-resistant material overlying a periphery of the substrate/superabrasive layer interface at a side surface of the substrate, wherein the jacket extends for a fraction of a total length of the cutter body.   
     
     
         30 . The cutting element of  claim 29 , wherein the jacket comprises a collar extending peripherally around the side surface of the substrate and around a side surface of the superabrasive layer. 
     
     
         31 - 37 . (canceled) 
     
     
         38 . The cutting element of  claim 29 , wherein the jacket is releasably attached to the cutter body. 
     
     
         39 . The cutting element of  claim 29 , wherein the jacket is fixably attached to the cutter body. 
     
     
         40 - 56 . (canceled) 
     
     
         57 . The cutting element of  claim 29 , wherein the jacket comprises an axially varying composition, wherein the composition of the jacket at a first axial position is different than a composition of the jacket at a second axial position, the first and second axial positions spaced apart from each other along a length of the jacket. 
     
     
         58 . The cutting element of  claim 57 , wherein the axially varying composition comprises a gradient of cobalt content along the length of the jacket, wherein the cobalt content of the jacket at the first axial position is different than a cobalt content of the jacket at the second axial position. 
     
     
         59 . The cutting element of  claim 58 , wherein the first axial position is closer to the superabrasive layer than the second axial position, and wherein the cobalt content of the jacket at the first axial position is less than the cobalt content of the jacket at the second axial position. 
     
     
         60 . The cutting element of  claim 29 , wherein the jacket comprises a radially varying composition, wherein the composition of the jacket at a first radial position is different than a composition of the jacket at a second radial position, the first and second radial positions spaced apart from each other along a thickness of the jacket. 
     
     
         61 . The cutting element of  claim 60 , wherein the radial varying composition comprises a gradient of cobalt content along the thickness of the jacket, wherein the cobalt content of the jacket at the first radial position is different than a cobalt content of the jacket at the second radial position. 
     
     
         62 . The cutting element of  claim 61 , wherein the first radial position is closer to the substrate than the second radial position, and wherein the cobalt content of the jacket at the first radial position is greater than the cobalt content of the jacket at the second radial position. 
     
     
         63 - 70 . (canceled) 
     
     
         71 . A cutting element comprising:
 a substrate having an upper surface;   a superabrasive layer comprising a rear surface overlying the upper surface of the substrate at a substrate/superabrasive layer interface; and   a jacket overlying a periphery of the substrate/superabrasive layer interface, wherein the jacket comprises a coating including an erosion-resistant material.   
     
     
         72 - 116 . (canceled)