Polycrystalline compacts for cutting elements, related earth-boring tools, and related methods

Abstract

Polycrystalline compact tables for cutting elements include regions of grains of super hard material. One region of grains ('first grains') and another region of grains ('second grains') have different properties, such as different average grain sizes, different super hard material volume densities, or both. The region of first grains and the region of second grains adjoin one another at grain interfaces that may include a curved portion in a vertical cross-section of the table. In some embodiments, discrete regions of the first grains may be vertically disposed between discrete regions of the second grains. As such, the tables have ordered grain regions of different properties that may inhibit delamination and crack propagation through the table when used in conjunction with a cutting element. Methods of forming the tables include forming the regions and subjecting the grains to a high-pressure, high-temperature process to sinter the grains.