INTRODUCTION
[0001] The present invention relates to picks comprising a shank, a substrate and an impact
resistant tip bonded to the substrate and exposed to perform a cutting action in a
forward direction in use. The invention further relates to high impact resistant tools
including such picks, and to use of such tools in methods of formation degradation.
BACKGROUND OF THE INVENTION
[0002] Picks are used as cutting tools in machinery for formation degradation applications
such as the mining of coal, the tunneling through of rock, surface mining and in road
surfacing, road milling and trenching. The term "pick" typically means a pointed or
chisel shaped rock cutting tool which cuts rock by penetrating and scraping along
the surface of the rock, asphalt or concrete. Picks typically consist of a steel shank
with a tapered front end with a pointed tungsten carbide-cobalt tool forming the cutting
tip.
[0003] An array of picks is typically mounted onto a rotating barrel or drum or mining machine
which engages the picks with the material to be removed. Picks are generally axi-symmetric
and mounted such that they themselves can rotate around their own axis. Pick rotation
is typically facilitated by mounting the pick into a cylindrical aperture of a mounting
block which in turn is permanently attached to the drum or mining machine. Load is
transmitted onto the tool via an annular flange which mates with the planar front
surface of the mounting block.
[0004] As the picks engage the working surface of the material to be removed they are subject
to a range of wear modes which include severe impact and loading in various directions
often resulting in bending moments, as well as severe abrasive and thermal wear due
to the removed material being hard, inhomogeneous and abrasive and scraping continuously
along the tip and body of the pick.
[0005] The severe and rapid wear of the carbide tip and pick body is the prime reason for
introducing rotating picks. The rotational action allows the tip and pick body to
wear symmetrically around the axis and a degree of self sharpening is induced. As
a result undermining and one-sided wear are avoided. This increases the overall lifetime
of the pick avoiding premature failure through breakage or bluntening of the tip to
a point where no further cutting action is achieved.
[0006] Whilst being significantly more wear resistant than hard metals, polycrystalline
diamond (PCD), also known as a diamond abrasive compact, tends to be brittle. In use
such materials are frequently bonded to a cemented carbide substrate to afford support.
Such supported abrasive compacts are known in the art as composite diamond abrasive
compacts. Composite diamond abrasive compacts may be used as such in a working surface
of an abrasive tool.
[0007] Polycrystalline cubic boron nitride (PCBN), also known as a cubic boron nitride abrasive
compact, is another superhard abrasive material which can, in use, be bonded to a
substrate such as a cemented carbide substrate.
[0008] Abrasive compacts bonded to a cemented carbide substrate made at HPHT conditions
are brought into or close to an equilibrium state at those conditions. Bringing the
compacts to conditions of normal temperature and normal pressure induces large stresses
in the abrasive compact due to the different thermal and mechanical/elastic properties
of the abrasive layer and the substrate. The combined effect is to place the abrasive
layer in a highly stressed state. Finite element analysis shows that the abrasive
layer may be in tension in some regions whilst being in compression elsewhere. The
nature of the stresses is a complex interaction of the conditions of manufacture,
the nature of the materials of the abrasive layer and the substrate, and the nature
of the interface between the abrasive layer and the substrate, amongst others. In
service, such a stressed abrasive compact is predisposed to premature failure by spalling,
delamination and other mechanisms. That is to say, the abrasive compact fails prematurely
due to separation and loss of all or part of the abrasive layer from the cutting surface
of the abrasive compact, and the higher the residual stresses, the greater is the
probability of premature failure.
[0009] This problem is well recognised in the industry and there have been a number of techniques
applied in an attempt to solve it.
[0010] Various abrasive compact structures have been proposed in which the interface between
the abrasive layer and the supporting substrate contains a number of ridges, grooves,
indentations or asperities of one type or another aimed at reducing the susceptibility
of the interface to mechanical and thermal stresses. Such structures are taught, for
example, in
U.S. Pat. Nos. 4,784,203,
5,011,515,
5,486,137,
5,564,511,
5,906,246 and
6,148,937. In effect, these patents focus on distributing the residual stresses over the largest
possible area. Further examples of composite abrasive compacts which have non-planar
interfaces can be found described in
US Pat. Nos. 5,154,245,
5,248,006,
5,743,346,
5,758,733,
5,848,657,
5,871,060,
5,890,552,
6,098,730,
6,102,143 and
6,105,694.
[0011] Another method applied in attempting to solve the problem of a highly stressed composite
abrasive compact is to provide one or more interlayers of a different material with
properties, particularly thermal and mechanical/elastic properties, intermediate between
the properties of the substrate and the abrasive layer. The purpose of such interlayers
is to accommodate some of the stresses in the interlayers and thereby reduce the residual
stresses in the abrasive layer.
[0012] This method is exemplified by
U.S. Pat. No. 5,510,913 which provides for an interlayer of sintered polycrystalline cubic boron nitride.
Another example is
U.S. Pat. No. 5,037,704 which allows the interlayer to comprise cubic boron nitride with aluminium or silicon
and at least one other component selected from the group comprising the carbides,
nitrides and carbonitrides of the elements of Groups 4A, 5A and 6A of the Periodic
Table of the Elements. A further example,
U.S. Pat. No. 4,959,929, teaches that the interlayer may comprise 40% to 60% by volume cubic boron nitride
together with tungsten carbide and cobalt.
[0013] In yet another approach,
U.S. Pat. No. 5,469,927 teaches that the combination of a non-planar interface and transition layers may
be used. In particular, this patent describes the use of a transition layer of milled
polycrystalline diamond with tungsten carbide in the form of both particles of tungsten
carbide alone and precemented tungsten carbide particles. Furthermore, there is provision
for tungsten metal to be mixed into the transition layer to enable excess metal to
react to form tungsten carbide
in situ.
[0014] Further examples of composite diamond abrasive compacts having one or more interlayers
can be found described in
US Pat. Nos. 3,745,623,
4,403,015,
4,604,106,
4,694,918,
4,729,440,
4,807,402,
5,370,195,
5,469,927,
6,258,139 and
6,315,065 and
US patent publication no. 2006/0166615 A1.
[0015] Finally, improvements in impact resistance have been demonstrated by employing a
solid self-supporting PCD layer where the yield strength of the layer is at least
as high as the yield strength of the hard metal substrate (
US Pat. No. 5,890,552).
[0016] The prior art on improving impact resistance has been established primarily in the
context of shear bit drilling, roller cone drilling and to a lesser degree for percussive
hard rock drill bits. Little is known as to what is the optimum design for PCD cutters
for pick applications.
[0017] The following patents and patent applications describe picks with composite diamond
compact tips:
US 4,944,559,
US 6,051,079,
US 6,733,087,
US 2003/0209366,
US 2004/0026983,
US 2004/0065484. The picks described in these documents are all of the rotatably mounted type. The
PCD tips are not described in great detail.
[0018] An alternative concept of a non-rotating plough-type pick with a planar cylindrical
PCD cutter as cutting element has been disclosed in
US Pat Nos. US 4,733,987,
US 4,902,073,
US 5,722,733 and
US 6,283,844. In this arrangement the shank is mounted non-rotatably in the mounting block.
[0019] Whilst there is a strong need to extend the lifetime of picks in application, all
the published PCD pick solutions have significant drawbacks:-
- The moving parts associated with rotating picks become the weak link once the lifetime
of the pick is extended by using a PCD tip. Significant wear and ultimately failure
is seen through the actions of shank moving against and within the mounting block
aperture together with sleeve and washer. Fragments of rock or asphalt cause significant
erosion and failure of joints well before the PCD tip is worn out. At the same time,
the dramatically increased wear resistance of PCD over carbide results in a tip that
does not blunt appreciably over the lifetime of the pick and eliminates the need to
generate a symmetrical wear pattern in the tip through rotation.
- The only PCD-tipped non-rotating pick reported in the prior art uses a planar cutter
with a PCD layer having a planar or stepped planar interface. This solution is very
susceptible to impact damage. Particular weaknesses are firstly the brittle sharp
corner presented as the cutting edge to the rock, and secondly the high directional
dependence of impact resistance. Good impact resistance is only seen if the impact
is normal to the top PCD surface. Any side impact is likely to cause the PCD table
to shear off from the substrate due to lack of carbide support and the residual stresses
between substrate and PCD layer.
[0020] There is therefore a need for optimized wear and impact resistant pick bodies for
mining and road working applications.
SUMMARY OF THE INVENTION
[0021] According to a first aspect to the present invention there is provided a pick body
comprising a shank, a substrate and an impact resistant tip bonded to the substrate
and exposed to perform a cutting action in a forward direction in use, the impact
resistant tip having an exposed layer of superhard material selected from PCD, PCBN,
single crystal diamond and cBN composite materials, wherein the impact resistant tip
is of conical, frustoconical, ballistic, hemispherical, chisel or wedge shaped including
a rounded top and wherein a thickness of the layer of superhard material is from about
0.05mm to about 2.3mm from an apex of the tip of the conical, frustoconical, ballistic,
hemispherical, chisel or wedge shape to the substrate.
[0022] The superhard material may be selected from polycrystalline diamond (PCD), vapour
deposited diamond, natural diamond, cubic boron nitride, infiltrated diamond, layered
diamond, diamond impregnated carbide, diamond impregnated matrix, silicon bonded diamond
or combinations thereof.
[0023] The shank of the pick body is preferably adapted to be received non-rotatably in
use in a tool holder or mounting block. As such, the pick body may include a base
with the shank extending from the base wherein the shank is threaded to engage with
corresponding threading in a mounting block or tool holder bore. Alternatively or
in conjunction with the above, the shank may be eccentric with respect to the base,
preferably in the forward direction. The pick body is receivable in the tool holder
or mounting block by brazing, press fit, adhesive or other means of attachment known
in the art.
[0024] Preferably the superhard material is PCD.
[0025] The PCD may comprise an impact resistant grade of diamond with an average grain size
range greater than 10 um. The grain size is preferably less than 30 um.
[0026] The superhard layer preferably includes an average cobalt content greater than 15
% by weight. The cobalt content is preferably less than 20 wt.%. Other material which
may be included in the superhard layer and/or substrate include iron, nickel, ruthenium,
rhodium, palladium, chromium, manganese, tantalum or combinations thereof.
[0027] The superhard layer may be constructed from multimodal diamond.
[0028] In a preferred embodiment the pick body includes a front end located between the
tip and the shank, the front end having a wear resistant surface comprising high quality
steel, hardened steel and/or hard metal. The front end may be coated with or include
a hard-facing, or other abrasion resistant coated or treated portion.
[0029] Preferably the rounded top of the superhard layer has a radius greater than 0.5 mm.
The top of the superhard layer is preferably conical or ballistic shaped with the
half cone angle not exceeding 60 degrees.
[0030] Preferably the superhard layer is at least 1 mm thick in all working directions over
a central working surface comprising the inner ½ of the working surface diameter of
the substrate.
[0031] In a preferred embodiment of this aspect to the present invention, the layer over
the central working surface is PCD, is between 1 and 2.3 mm thick in all working directions
and tapers off towards the outer diameter of the tip.
[0032] The substrate is preferably a cemented carbide substrate such as cemented tungsten
carbide, cemented tantalum carbide, cemented titanium carbide, cemented molybdenum
carbide or a mixture thereof. The cemented carbide substrate may contain particles
of a grain inhibiting agent such as titanium carbide, tantalum carbide, vanadium carbide
or a mixture thereof. The binder metal for such cemented carbide may be any known
in the art such as nickel, cobalt, iron or an alloy containing one or more of these
metals. Typically the binder will be present in an amount of 6 to 20% by mass. Some
of the binder metal may infiltrate the abrasive compact during High Pressure High
Temperature (HPHT) treatment. A shim or layer of binder may be used for this purpose.
[0033] To improve the service life of the tip, it is preferable to reduce the residual stresses
induced in the tip, inter alia, as a result of the HPHT treatment. The residual stresses
due to the thermal expansion differences between the abrasive layer and the substrate
may be minimised providing a graduated change in thermal expansion from the substrate
to the outer or working region of the abrasive compact layer (tip).
[0034] More particularly this may be achieved by the introduction of a number of intermediate
regions or layers between the outer abrasive region or layer and the substrate, each
region or layer having a thermal expansion such that there is a graduated change in
thermal expansion from the outer region or layer to the substrate. The control of
thermal expansion may be achieved by admixing one or more types of refractory particles
of low thermal expansion with superhard abrasive particles, and adjusting the relative
proportions of superhard abrasive particles and refractory particles to achieve the
desired thermal expansion. A metal or alloy may be present in each or some of the
regions.
[0035] When such a metal or alloy is present, the amount relative to the amount of superhard
abrasive particle and refractory particle may be adjusted to achieve the desired graduated
thermal expansion. Examples of suitable refractory particles with low thermal expansion
are carbides, oxides and nitrides of silicon, hafnium, titanium, zirconium, vanadium
and niobium, an oxide and nitride of aluminium, cubic boron nitride, and carbides
of tungsten, tantalum and molybdenum. Tungsten carbide is a particularly suitable
refractory particle. Examples of suitable metals and alloys are nickel, cobalt, iron
or an alloy containing one or more of these metals.
[0036] Preferably, the metal or alloy is the same as the metal or alloy present in the cemented
carbide substrate.
[0037] The proportion of superhard abrasive particles is generally in the range 20 to 80
volume per cent of the region and the proportion of refractory particles is generally
in the range 80 to 70 volume per cent of the region. The metal binder, when used,
is generally present in the amount of about 8 to 12 volume per cent of the total volume
of the particles. In one embodiment of the present invention, the proportion of superhard
particles is about 25 volume per cent, the proportion of refractory particles is about
75 volume per cent, and the metal binder about 10 volume per cent. It will be appreciated,
however, that if there is only a single interlayer, a 50/50 mix of carbide and diamond
by volume may be selected. In the event there are three interlayers present, the first
interlayer, closest to the substrate, preferably contains 25 vol% diamond and the
two subsequent interlayers 50 and 75 vol.% respectively.
[0038] In the tip the superhard abrasive particles are generally in the particle size range
5 to 100 microns, and preferably in the size range 15 to 30 microns.
[0039] The superhard particles are characterised by containing at least three, and preferably
four, different particle sizes. The proportion of metal binder is about 2 per cent
of the volume of superhard abrasive particles. In the case of a mixture comprising
three particle sizes, an example of the composition by average particle size is :
Average particle size |
Per cent by mass |
greater than 10 microns |
at least 20 |
between 5 and 10 microns |
at least 15 |
less than 5 microns |
at least 15 |
[0040] The term "average particle size" as used above and hereinafter means that a major
amount of the particles by mass will be close to the specified size although there
will be some particles larger and some particles smaller than the specified size.
Thus, for example, if the average particle size is stated as 20 microns, there will
be some particles that are larger and some particles that are smaller than 20 microns,
but the major amount of the particles will be at approximately 20 microns in size
and a peak in the size distribution by mass of particles will be at 20 microns.
[0041] The term "percent by mass" as used above and hereinafter means that the percentages
are the percentages by mass of the entire abrasive particle mass.
[0042] A specific particle size composition containing three particle sizes which is useful
for the superhard layer is:
Average particle size |
Per cent by mass |
12 microns |
25 |
8 microns |
25 |
4 microns |
50 |
[0043] In the case of a mixture comprising four diamond particle sizes, an example of the
composition by average particle size is:
Average particle size |
Per cent by mass |
25 to 50 microns |
25 to 70 |
15 to 24 microns |
15 to 30 |
8 to 14 microns |
5 to 45 |
less than 8 microns |
minimum 5 |
[0044] A specific particle size composition containing four particle sizes which is useful
for the superhard layer is:
Average particle size |
Per cent by mass |
30 microns |
65 |
22 microns |
20 |
12 microns |
10 |
4 microns |
5 |
[0045] A specific composition containing five particle sizes which is useful for the superhard
layer is:
Average particle size |
Per cent by mass |
22 microns |
28 |
12 microns |
44 |
6 microns |
7 |
4 microns |
16 |
2 microns |
5 |
[0046] In all regions, the binder metal powder, when present, will generally have a particle
size of less than 10 microns, and preferably will be about 3 microns.
[0047] Preferably the substrate has a hardness of at least 1000 Hv, preferably at least
1100Hv, more preferably at least 1200Hv, most preferably at least 1300Hv. The hardness
is preferably less than 2500Hv, more preferably less than 2400Hv, more preferably
less than 2300Hv, most preferably less than 2200Hv.
[0048] In a preferred embodiment of the present invention the pick contains 8% Co, 2-3 um
average grain size, 1400-1500 Hv
[0049] In one embodiment of the invention the pick body includes at least one interlayer
between the superhard layer and the substrate which interlayer has a thermal expansion
coefficient and Young's modulus between those of the superhard layer and the substrate.
The effect of this is to reduce peak mismatch stress between the superhard layer and
the substrate.
[0050] A pick body may therefore include one or more composite interlayers of intermediate
thermo-mechanical properties as hereinbefore described. In this regard reference is
made to
WO03/064806, the contents of which are incorporated herein by reference.
[0051] As such the superhard layer may be PCD and the substrate of high compressive strength
and matched thermo-elastic properties to the PCD layer.
[0052] The term 'high compressive strength" is defined to include compressive strengths
of greater than 2000 N/mm
2, preferably greater than 2200 N/mm
2, more preferably greater than 2400 N/mm
2, more preferably greater than 2600 N/mm
2, more preferably greater than 2800 N/mm
2, most preferably greater than 3000 N/mm
2 and less than 6000 N/mm
2, preferably less than 58000 N/mm
2, more preferably less than 5600 N/mm
2, more preferably less than 5400 N/mm
2, more preferably less than 5200 N/mm
2, most preferably less than 5000 N/mm
2.
[0053] Examples of preferred compressive strength are between 4500 ± 200 N/mm
2 and 3600 ± 200 N/mm
2.
[0054] The substrate is preferably a carbide, most preferably a metal carbide substrate.
The substrate may comprise 6 - 10 % by weight cobalt. The carbide substrate may further
comprise tungsten, titanium, tantalum, molybdenum, niobum, cobalt and/or combinations
thereof, as hereinbefore described.
[0055] Preferably the superhard layer is bonded to the substrate via a non-planar interface.
[0056] The interlayer(s) may be bonded to the substrate via a planar or non-planar interface.
[0057] According to a second aspect to the present invention there is provided a high impact
resistant tool comprising a pick body as hereinbefore described, preferably non-rotatably
mounted in a tool holder or mounting block.
[0058] The high impact resistant tool may be mounted on a rotatable drum or barrel.
[0059] According to a third aspect to the present invention there is provided a method of
formation degradation including the step of engaging a pick body as hereinbefore described
with the formation to degrade the formation.
[0060] According to a fourth aspect to the present invention there is provided the use of
a pick body as hereinbefore described in a method of formation degradation.
[0061] It is expected that a 'thick' PCD layer would be essential to achieve a significant
increase over conventional shaped cutters (thin layers < 1 mm, less aggressive geometry)
in impact resistance as measured by perpendicular drop testing. The applicant has
confirmed this trend. However, a significant increase in impact resistance with a
non-optimal interface design at a thickness of 2.2 mm has been observed. For impact
resistance both PCD thickness and pointed geometry are important but the cutters taught
in the prior art are over designed. See in this regard
USSN 11/673,634, Hall et al.
[0062] The benefits of the present invention of 'thin' layers of superhard material are:-
- reduced costs;
- less processing;
- easier to sinter;
- reduced residual stresses; and
- better shape control.
[0063] In one embodiment of the pick tools of the present invention, a more abrasion resistant
grade of PCD is included as the superhard layer. As such, overall wear resistance
is the same but with reduced thickness. Preferably this is matched with a WC substrate
of slightly higher cobalt (Co) content achieving a new local optimum in minimising
residual stresses between substrate and more wear resistant, thinner PCD layer.
[0064] The prior art suggests a thicker tip is required (2.5 - 3.2mm) and that furthermore,
with a fixed pick one would expect more wear on the working surface as it does not
have the benefit of rotation. However, the applicants have surprisingly found that
a thinner tip than would be expected still provides sufficient pick performance and
lifetime. Fixed picks are needed in preference to rotational ones to help prevent
the pick body from wearing out before the tip, the wear on the body being exacerbated
by the rotational movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] The invention will now be described with reference to the following illustrations
in which:
Figure 1 shows a schematic cross section through a pick body according to the invention;
Figure 2 shows tips including interlayers according to the present invention;
Figures 3 A - F show a non-rotating pick with a PCD layered tip engaged in a tool
holder which is engaged in a mounting block;
Figures 4 A - E show a non-rotating pick with a PCD layered tip engaged in a mounting
block; and
Figures 5 A - D show a non-rotating pick with a PCD layered tip screw threadingly
engaged in a mounting block;
SPECIFIC DESCRIPTION OF THE INVENTION
[0066] In Figure 1 a tip 100 of a pick body includes a carbide substrate 101, an interlayer
102 and a layer of superhard material 103 in a ballistic shape including a rounded
top. A thickness (a) of the layer of superhard material 103 is from 0.05mm to 2.3mm
from an apex of the tip of the ballistic shape to the substrate 101.
[0067] The rounded top of the superhard layer 103 has a radius R greater than 0.5 mm.
[0068] The top of the superhard layer 103 has a half cone angle (β) not exceeding 60 degrees.
[0069] The superhard layer 103 over a central working surface comprising the inner ½ (y)
of the working surface diameter (y + 2x (where 2x = y)) of the tip, is at least 1
mm thick (b) in all working directions being 45 degrees off the central axis of the
ballistic.
[0070] The central working surface tapers off towards the outer diameter of the tip.
[0071] Figure 2 illustrates impact and abrasion resistant tips including at least one interlayer
according to the present invention.
[0072] The details of the tips shown are as follows
Tips 200A, 200B and 200C
[0073]
Name |
Value |
Unit |
Crest thickness (a) |
2.2 |
mm |
Crest radius (R) |
2 |
mm |
Rim thickness (z) |
1 |
mm |
Cone Angle (β) |
50 |
deg |
Tips 201A and 201 B
[0074]
Name |
Value |
Unit |
Crest thickness (a) |
2.2 |
mm |
Crest radius (R) |
2 |
mm |
Rim thickness (z) |
1 |
mm |
Cone Angle (β) |
42 |
deg |
[0075] In Figures 3 A - F a pick assembly 300 is shown including a pick body 301 according
to the present invention, a tool holder 302 and a mounting block 303. The pick body
301 includes a tip 304 including a layer of superhard material exposed to perform
a cutting action in a forward direction in use (not shown). The tool holder includes
a base 302A and a shank 302B extending from the base 302A, the shank 302B being eccentric
with respect to the base 302A in the forward direction.
[0076] In this arrangement, the pick body 301 and tool holder 302 are fixedly held in the
mounting block 303 such that rotation of the pick body 301 and/or tool holder 302
is not permitted in use.
[0077] The pick assembly 300 is adapted to be attached to a rotating drum or barrel (not
shown).
[0078] In Figures 4 A - E a pick assembly 400 is shown including a pick body 401 according
to the present invention and a mounting block 402. The pick body 401 includes a tip
403 including a layer of superhard material exposed to perform a cutting action in
a forward direction in use (not shown). The pick body includes a base 401A and a shank
401 B extending from the base 401A, the shank 401 B being eccentric with respect to
the base 401A in the forward direction. The pick body 401 is retained in the mounting
block 402 by means of a retaining means (not shown). In this arrangement, the pick
body 401 is fixedly held in the mounting block 402 such that rotation of the pick
body 401 is not permitted in use.
[0079] The pick assembly 400 is adapted to be attached to a rotating drum or barrel (not
shown).
[0080] In Figures 5 A - D a pick assembly 500 is shown including a pick body 501 according
to the present invention and a mounting block 502. The pick body 501 includes a tip
504 including a layer of superhard material exposed to perform a cutting action in
a forward direction in use (not shown). The pick body 501 includes a collar 501A and
a threaded shank 501 B extending from the collar 501A, the shank 501 B being concentric
with respect to the collar 501A. The pick body 501 is retained in the mounting block
502 by means of the threaded shank 501 B engaging with complementary threading in
the mounting block (not shown). A retaining means 505 is accommodated within a mounting
block bore. In this arrangement, the pick body 501 is fixedly held in the mounting
block 502 such that rotation of the pick body 501 is not permitted in use.
[0081] The pick assembly 500 is adapted to be attached to a rotating drum or barrel (not
shown).
1. A pick body comprising a shank, a substrate and an impact resistant tip bonded to
the substrate and exposed to perform a cutting action in a forward direction in use,
the impact resistant tip having an exposed layer of superhard material selected from
PCD, PCBN, single crystal diamond and cBN composite materials, wherein the impact
resistant tip is of conical, frustoconical, ballistic, hemispherical, chisel or wedge
shaped including a rounded top and wherein a thickness of the layer of superhard material
is from about 0.05mm to about 2.3mm from an apex of the tip of the conical, frustoconical,
ballistic, hemispherical, chisel or wedge shape to the substrate.
2. A pick body according to claim 1 wherein the shank of the pick body is adapted to
be received non-rotatably in use in a tool holder or mounting block.
3. A pick body according to claim 2 including a base with the shank extending from the
base wherein the shank is threaded to engage with corresponding threading in a mounting
block or tool holder bore.
4. A pick body according to claim 2 including a base with the shank extending from the
base, the shank being eccentric with respect to the base.
5. A pick body according to any previous claim wherein the superhard material is PCD.
6. A pick body according to claim 5 wherein the PCD comprises an impact resistant grade
of diamond with an average grain size range between 10 and 30 um.
7. A pick body according to any previous claims wherein the superhard layer includes
an average cobalt content between 15 and 20 wt.%.
8. A pick body according to any one of claims 5, 6 and 7 wherein the superhard layer
is constructed from multimodal diamond.
9. A pick body as claimed in any preceding claim wherein the pick body includes a front
end located between the tip and the shank, the front end having a wear resistant surface
comprising high quality steel, hardened steel and/or hard metal.
10. A pick body as claimed in claim 9 wherein the front end is coated with or includes
a hard-facing, or other abrasion resistant coated or treated portion.
11. A pick body according to any preceding claim wherein the rounded top of the superhard
layer has a radius greater than 0.5 mm.
12. A pick body according to any preceding claim wherein the top of the superhard layer
is conical or ballistic shaped with the half cone angle not exceeding 60 degrees.
13. A pick body according to any preceding claim wherein the superhard layer over a central
working surface comprising the inner ½ of the working surface diameter of the substrate,
is at least 1 mm thick in all working directions.
14. A pick body according to claim 13 wherein the layer over the central working surface
is PCD and is between 2.3 and 1 mm thick in all working directions and tapers off
towards the outer diameter of the tip.
15. A pick body according to any preceding claim wherein the substrate has a hardness
of at least 1000 Hv.
16. A pick body according to any preceding claim including at least one interlayer between
the superhard layer and the substrate, the interlayer having a thermal expansion coefficient
and Young's modulus between those of the superhard layer and the substrate to reduce
peak mismatch stress between the superhard layer and the substrate.
17. A pick body according to any preceding claim wherein the superhard layer is PCD and
the substrate is of high compressive strength and matched thermo-elastic properties
to the PCD layer.
18. A pick body according to any preceding claim wherein the substrate comprises 6 - 10
% by weight cobalt.
19. A pick body according to any preceding claim wherein the superhard layer is bonded
to the substrate via a non-planar interface.
20. A pick body according to any preceding claim wherein the pick includes one or more
composite interlayers of intermediate thermo-mechanical properties.
21. A pick body according to any preceding claim wherein the interlayer(s) are bonded
to the substrate via a planar or non-planar interface.
22. A high impact resistant tool comprising a pick body according to any one of claims
1 to 21 non-rotatably mounted in a tool holder or mounting block.
23. A high impact resistant tool according to claim 22 mounted on a rotatable drum or
barrel.
24. A method of formation degradation including the step of engaging a pick body according
to any one of claims 1 to 21 with the formation to degrade the formation.