A superabrasive fracture resistant compact is formed by depositing
successive layers of ceramic throughout the network of open pores in a
thermally stable self-bonded polycrystalline diamond or cubic boron
nitride preform. The void volume in the preform is from approximately 2
to 10 percent of the volume of the preform, and the average pore size is
below approximately 3000 nanometers. The preform is evacuated and
infiltrated under at least about 1500 pounds per square inch pressure
with a liquid pre-ceramic polymerizable precursor. The precursor is
infiltrated into the preform at or below the boiling point of the
precursor. The precursor is polymerized into a solid phase material. The
excess is removed from the outside of the preform, and the polymer is
pyrolized to form a ceramic. The process is repeated at least once more
so as to achieve upwards of 90 percent filling of the original void
volume. When the remaining void volume drops below about 1 percent the
physical properties of the compact, such as fracture resistance, improve
substantially. Multiple infiltration cycles result in the deposition of
sufficient ceramic to reduce the void volume to below 0.5 percent. The
fracture resistance of the compacts in which the pores are lined with
formed in situ ceramic is generally at least one and one-half times that
of the starting preforms.