Abstract

To prevent thermal stress from damaging a PCD or diamond, multilayer metal coatings for bonding polycrystalline diamond compacts and diamond crystals to a matrix comprise a first metal layer of a refractory metal, such as tungsten, a compliant metal layer of copper, and an outer metal layer of a refractory metal such as tungsten. Metallic bonding layers of a metal, such as nickel, are placed between the tungsten and copper layers for improved bonding. The method of manufacturing multilayer metal coatings comprises applying the inner metal layer by chemical vapor deposition, applying the first bonding layer metal by electrolytic deposition, applying the compliant layer metal by electrolytic deposition, applying the second bonding layer by electrolytic deposition and applying the outer layer by chemical vapor deposition. A superabrasive tool element comprises a coated diamond product bonded either to a matrix comprising tungsten carbide or iron powder or to a cemented tungsten carbide support.