Patent ID: 8505654

Claim:
A PCD composite compact comprising a PCD structure bonded at an interface to a substrate comprising cemented carbide material; the PCD structure comprising a mass of directly inter-bonded diamond grains having a mean size of at most about 4, microns, and the PCD structure comprising at least about 0.05, weight percent refractory metal or carbide of a refractory metal selected from the group comprising Ti, V, Cr, Zr, Nb, Mo, Hf and Ta; and at least the cemented carbide material proximate the interface having a content of metallic binder material of at most about 6, weight percent of the cemented carbide material; wherein the PCD structure contains sufficiently few large diamond grains having a dimension of at least double the D(99.99) value of the size distribution of the mass of grains, sufficiently sparsely dispersed therein, such that when a cross-section through the PCD structure, the substrate, and the interface is viewed, at most about 7, large diamond grains are evident at the cross-section along a length of at least about 10, mm of the interface.