Patent ID: 8764862

Claim:
A method of forming a super abrasive element comprising: assembling an assembly comprising: a mold having a bottom; a thermally stable polycrystalline diamond (TSP) body having pores and a contact surface and located in the bottom of the mold; a matrix powder disposed adjacent the contact surface and above the TSP body in the mold, the matrix powder operable to form a base after heating; and an infiltrant material disposed in the matrix powder in the mold; heating the assembly to a temperature up to 1200° C. at a pressure and for a time sufficient for the infiltrant material to infiltrate the matrix powder to form a base and pores of the TSP body at the contact surface to form an infiltrant material-containing region, while leaving an infiltrant-free region at a working surface of the TSP body, wherein the infiltrant material infiltrates the pores of the TSP body to a depth from the contact surface of 100 μm or less; and cooling the assembly to form a super abrasive element, wherein the matrix powder comprises a carbide-containing or carbide-forming powder.