Rotary tools with thermally stable diamond

Abstract

A tool for removing material includes a body, a superhard insert, and a substrate. The body has a front portion, an opposite rear portion, and a longitudinal axis therebetween. The superhard insert includes a superhard material, and the superhard insert is mounted to the body and contacts the front portion of the body. The substrate contacts the body and the superhard insert. The substrate is mechanically interlocked with the body, and at least a portion of the substrate is circumferentially positioned around at least a portion of the front portion of the body.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Application No. 62 / 739,725, filed October 1, 2018, the entire contents of which are incorporated herein by reference. Background Art

[0003] Road construction and repair may require the removal of existing or damaged roads or surfaces. The road surface may contain a variety of materials that must be removed before repair or replacement can be performed. Systems for the removal or breaking of asphalt, cement, concrete, rock or other hard and brittle materials can be subject to considerable damage during use. Conventional systems utilizing a series of picks on a rotating body can be used for applications such as road milling, road stabilization, longwall or continuous mining, trench or surface mining, paint strip removal and vibrating strip milling, and can impact and break asphalt, rock, composite or other materials into small pieces that can then be removed.

[0004] The picks can wear or break during use, limiting or eliminating the effectiveness of that portion of the system or the entire system. The uptime of the system depends at least in part on the durability of the picks, but also on the speed with which the picks can be replaced or repaired. Conventional systems include superhard cutters brazed to a rotating body to increase the useful life of the system. However, brazing the cutters to the body weakens the cutters, and brazing the cutters to the body makes replacement or repair of the cutters costly and time consuming, requiring the rotating body to remain stationary during repair or the rotating body to be replaced as a whole. Summary of the invention

[0005] In some embodiments, a tool for removing material includes a body, a superhard insert, and a substrate. The body has a front portion and an opposite rear portion. The superhard insert includes a superhard material, and the superhard insert is located near the front portion. The substrate contacts the body and the superhard insert. The substrate is mechanically interlocked with the body, and at least a portion of the substrate is circumferentially positioned around at least a portion of the front portion of the body.

[0006] In other embodiments, a system for removing material includes a rotating drum and a plurality of tools selectively connected to the rotating drum. The rotating drum is configured to rotate around an axis of rotation. At least one of the plurality of tools includes a body, a superhard insert, and a substrate. The body has a front portion and an opposite rear portion. The superhard insert includes a superhard material, and the superhard insert is located near the front portion. The substrate contacts the body and the superhard insert. The substrate is mechanically interlocked with the body, and at least a portion of the substrate is connected to the superhard insert.

[0007] In other embodiments, a method of manufacturing a tool for removing material includes forming a body. The body has a front portion that includes at least one mechanically interlocking feature in the body. The method also includes positioning a superhard insert at the front portion of the body and filling at least a first space in the at least one mechanically interlocking feature in the body and a second space outside the body with a matrix precursor. The method also includes curing the matrix precursor to form a matrix near the superhard insert and outside the body.

[0008] This summary is provided to introduce some concepts that will be further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used to help limit the scope of the claimed subject matter.

[0009] Additional features and advantages of the embodiments of the present disclosure will be set forth in the following description, and in part will be apparent from the description, or may be understood through the practice of these embodiments. The features and advantages of these embodiments may be realized and obtained by the tools and combinations specifically pointed out in the appended claims. These and other features will become more apparent from the following description and the appended claims, or may be understood through the practice of these embodiments set forth below. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to describe the manner in which the above and other features of the present disclosure can be obtained, a more specific description will be given with reference to the specific embodiments shown in the accompanying drawings. For better understanding, the same elements are represented by the same reference numerals in the various drawings. Although some of the drawings may be schematic or exaggerated representations of the concepts, at least some of the drawings may be drawn to scale. It should be understood that the drawings depict some exemplary embodiments, and the embodiments will be described and explained with additional specificity and detail through the use of the drawings, in which:

[0011] Figure 1 is a schematic diagram of a rotational system for removing material from a surface according to at least one embodiment of the present disclosure;

[0012] Figure 2-1 is a perspective view of a tool according to at least one embodiment of the present disclosure;

[0013] Figure 2-2 yes Figure 2-1 A perspective exploded view of an embodiment of a tool;

[0014] Figure 2-3 yes Figure 2-1 A longitudinal cross-sectional view of an embodiment of a tool;

[0015] Figure 2-4 yes Figure 2-1 A longitudinal cross-sectional view of an embodiment of a tool that rotates about a longitudinal axis;

[0016] Figure 2-5 yes Figure 2-1 A longitudinal cross-sectional view of an embodiment of a tool in a mold during tool manufacturing;

[0017] Figure 3 is a flow chart illustrating an embodiment of a method of manufacturing a tool according to at least one embodiment of the present disclosure;

[0018] Figure 4 is a longitudinal cross-sectional view of another tool according to at least one embodiment of the present disclosure;

[0019] Figure 5 is a longitudinal cross-sectional view of yet another tool according to at least one embodiment of the present disclosure;

[0020] Figure 6 is a perspective view of a superhard insert with a peak according to at least one embodiment of the present disclosure;

[0021] Figure 7 is a longitudinal cross-sectional view of another superhard insert with a peak according to at least one embodiment of the present disclosure;

[0022] Figure 8 is a perspective view of a planar superhard insert according to at least one embodiment of the present disclosure;

[0023] Fig. 9 is a longitudinal cross-sectional view of yet another superhard insert with a peak according to at least one embodiment of the present disclosure;

[0024] Figure 10-1 is a longitudinal view of another pointed superhard insert according to at least one embodiment of the present disclosure;

[0025] Figure 10-2 yes Figure 10-1 A perspective view of a superhard insert with a peak;

[0026] Figure 11-1 is a longitudinal view of another pointed superhard insert according to at least one embodiment of the present disclosure;

[0027] Figure 11-2 yes Figure 11-1 A perspective view of a superhard insert with a peak;

[0028] Figure 12-1 is a longitudinal view of another Vertex superhard insert according to at least one embodiment of the present disclosure;

[0029] Figure 12-2 yes Figure 12-1 A perspective view of a superhard insert with a peak;

[0030] Figure 13-1is a longitudinal view of another Vertex superhard insert according to at least one embodiment of the present disclosure;

[0031] Figure 13-2 yes Figure 13-1 A perspective view of a superhard insert with a peak;

[0032] Figure 14-1 is a longitudinal view of another pointed superhard insert according to at least one embodiment of the present disclosure;

[0033] Figure 14-2 yes Figure 14-1 A perspective view of a superhard insert with a peak;

[0034] Fig.15 is a perspective view of another tool according to at least one embodiment of the present disclosure;

[0035] Fig.16 is a perspective view of yet another tool according to at least one embodiment of the present disclosure;

[0036] Fig.17 is a perspective view of another tool according to at least one embodiment of the present disclosure;

[0037] Fig.18 is a partial side cross-sectional view of a tool connected to a drum according to at least one embodiment of the present disclosure; and

[0038] Fig.19 is a partial side cross-sectional view of another tool connected to a drum according to at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0039] The present disclosure generally relates to apparatus, systems and methods for removing material using a rotating device having one or more replaceable superhard inserts. More specifically, the present disclosure relates to embodiments of a tool having a superhard insert at the front end of the tool for fracturing, cracking, crushing or otherwise releasing material for removal. In a specific embodiment, the present disclosure relates to an apparatus and method of manufacturing an apparatus having a superhard insert secured by a ceramic matrix shoulder circumferentially surrounding the superhard insert.

[0040] Although rotary tools for removing asphalt are described herein, it should be understood that the present disclosure may be applicable to other material removal tools, such as drills, milling cutters, reamers, hole openers and other cutting tools, and for removing other materials, such as earth materials, cement, concrete, metals or combinations thereof.

[0041] Figure 1An embodiment of a rotating system 100 for breaking and removing material from a formation 102 is shown. In some embodiments, the formation 102 may be asphalt. In other embodiments, the formation 102 may be earthen material, cement, concrete, metal, or a combination thereof. The rotating system 100 includes a rotating drum 104 having an axis of rotation 106. The rotating drum 104 may rotate about the axis of rotation 106 and carry one or more tools 108 in a substantially circular path around the circumference of the rotating drum 104 as the rotating drum 104 rotates. Thus, the movement of the rotating drum 104 may cause the tool 108 to contact the formation 102. In some embodiments, the tool 108 may contact the formation 102 with an ultra-hard insert 110 that breaks, cracks, lifts, loosens, or otherwise removes one or more blocks 112 of the formation 102. For example, the formation 102 may be asphalt covering a road, and the tool 108 may break the asphalt into blocks 112, which may then be transported or recycled. In other examples, formation 102 may be rock or sediment that includes or covers ore or other commercially valuable materials. Reducing formation 102 into blocks 112 may facilitate mining, excavation, or construction in areas with hard ground.

[0042] In some embodiments, the superhard insert 110 may include a superhard material. As used herein, the term "superhard" is understood to refer to a material known in the art having a hardness of about 1,500 HV (Vickers hardness, kg / mm 2 ) or higher grain hardness. Such superhard materials may include those that can be formed from consolidated materials that can exhibit physical stability at temperatures above about 750°C and for certain applications above about 1000°C. Such superhard materials may include, but are not limited to, diamond or polycrystalline diamond (PCD), including leached metal catalyst PCD, non-metal catalyst PCD, binderless PCD, nano-polycrystalline diamond (NPD), or hexagonal diamond (Lonsdaleite); cubic boron nitride (cBN); polycrystalline cBN (PcBN); Q-carbon; binderless PcBN; diamond-like carbon; suboxide boron; aluminum manganese boride; metal borides; carbon boron nitride and other materials that exhibit hardness values ​​above 1500 HV in the boron-nitrogen-carbon-oxygen system, oxides, nitrides, carbides and boride ceramics and / or cermets, and combinations of the foregoing materials. In at least one embodiment, the superhard insert 110 may be a monolithic carbonate PCD. For example, the superhard insert 110 may consist of a PCD compact without an attached substrate or metal catalyst phase. In some embodiments, the superhard material may have a hardness value greater than 3,000 HV. In other embodiments, the superhard material may have a hardness value greater than 4,000 HV. In other embodiments, the superhard material may have a hardness value greater than 80 HRa (Rockwell A).

[0043] In some embodiments, at least one tool 108 may be oriented tangentially to the rotation of the rotating drum 104. For example, the tool 108 may be oriented substantially perpendicular to the radius 109 of the rotating drum 104. In other embodiments, at least one tool 108 may be oriented at an angle within a range relative to the radial direction (i.e., radius 109) of the rotating drum 104, the range having a lower value, an upper value, or both, including any of 25, 30, 40, 45, 50, 60, 70, 80, 90, 100, 110, 120, or any value therebetween. For example, at least one tool 108 may be oriented at an angle greater than 25° relative to the radial direction of the rotating drum 104. In other examples, at least one tool 108 may be oriented at an angle less than 120° relative to the radial direction of the rotating drum 104. In yet another example, at least one tool 108 may be oriented at an angle between 25° and 120° relative to the radial direction of the rotating drum 104. In a further example, at least one tool 108 may be oriented at an angle between 45° and 110° relative to the radial direction of the rotating drum 104. In yet another example, at least one tool 108 may be oriented at an angle between 70° and 100° relative to the radial direction of the rotating drum 104.

[0044] In some embodiments, the tool 108 is selectively coupled to the rotating drum 104. The tool 108 may have a connector thereon that connects the tool 108 to the rotating drum 104 during operation and allows the tool 108 to be removed for replacement and / or repair. In other embodiments, the tool 108 is secured to the rotating drum 104 by welding, brazing, adhesives, or other non-selective coupling mechanisms. In other embodiments, the tool 108 has a connector that allows the tool 108 to be moved relative to the rotating drum 104 about a central axis of the tool 108 (e.g., Figure 2-3 and Figure 2-4 The cutting surface is rotated about a longitudinal axis 242) so that when used to remove material, erosion, wear, heat, or a combination thereof generated during use can be distributed around the circumference of the cutting surface.

[0045] In some embodiments, tool 108 can be used for any degradation tool. For example, tool 108 can be used for rotating downhole drill bits, such as "claw drill bits". The claw drill bit includes a plurality of tools 108 attached to the bottom end of the drill bit, so that when the claw drill bit rotates, a wellbore is formed. In some embodiments, tool 108 can be attached to an annular cutter. The annular cutter can include a hollow metal cylinder, and tool 108 can be attached to the end of the cylinder. In this way, tool 108 can be used to drill a cylindrical hole with a diameter of a hollow metal cylinder to erode the formation or material. In some embodiments, tool 108 can be attached to the outer surface of a rotating chain or other flexible track, such as a chain used on a chain trencher. When the chain on the chain trencher rotates, tool 108 may degrade the material and may dig out a ditch or other excavation. In some embodiments, any degradation tool (degradation) can be used in combination with tool 108.

[0046] Figure 2-1 to Figure 2-5 An embodiment of a tool 208 according to the present disclosure is shown, which can be used with Figure 1 The tool 208 may be used in conjunction with the rotating drum 104 and / or any other degradation tool. The tool 208 may have a superhard insert 210 at the front end of the front portion of the tool 208. In some embodiments, the superhard insert 210 may be a pointed insert. For example, the superhard insert 210 may have a cutting surface with a vertex 214. In some embodiments, the vertex 214 may be located at the center of the cutting surface (e.g., a conical insert). In other embodiments, the vertex 214 may be offset from the center of the cutting surface. In other embodiments, the vertex 214 may have a lateral dimension, such as a ridged insert.

[0047] In some embodiments, the superhard insert 210 may have a cutting surface having a substantially conical profile. In other embodiments, the superhard insert 210 may have a cutting surface having a substantially parabolic profile. In other embodiments, the superhard insert 210 may have a profile that is a trapezoidal profile.

[0048] The tool 208 may have a substrate 216 located behind at least a portion of the superhard insert 210. In some embodiments, the substrate 216 may include a superhard material. In other embodiments, the substrate 216 may include a ceramic material. For example, the substrate 216 may include a carbide, a nitride, an oxide, a boride, or a combination thereof. In other embodiments, the substrate 216 may include superhard particles embedded in another material. For example, the substrate 216 may include superhard particles embedded in a ceramic material.

[0049] In some embodiments, at least a portion of the superhard insert 210 may contact the substrate 216. In other embodiments, the superhard insert 210 may be connected to the substrate 216. In at least one embodiment, the superhard insert 210 may be cast directly into the substrate 216.

[0050] In some embodiments including carbonate PCD, the superhard insert may be damaged by temperatures above a threshold temperature. For example, exposure to temperatures above 2200 degrees Fahrenheit (1204 degrees Celsius) may damage carbonate PCD. Thus, such embodiments may be damaged by brazing. Because the substrate 216 may be cast at a casting and / or sintering temperature that is lower than the brazing temperature, the carbonate PCD insert may be cast directly into the substrate 216.

[0051] In some embodiments, the base 216 can be connected to a body 218 of the tool 208. The body 218 can include a rear portion 220 located at the rear end of the tool 208. In some embodiments, the rear portion 220 can include a connector, such as a friction fit connector, a compression fit connector, a snap fit connector, or a combination thereof. In other embodiments, the rear portion 220 and / or the body 218 can include a connector having one or more mechanically interlocking features 222 to engage with a rotating drum (e.g., Figure 1 The mechanically interlocking feature 222 mechanically interlocks at least a portion of the rotating drum 104 or other device in the tool 208 to connect the tool 208 to the rotating drum or other device. In some embodiments, the mechanically interlocking feature 222 may include a twist lock; one or more threads; a spline; a recess; a mechanical connector such as a bolt, screw, clip, clamp or pin; or a combination thereof.

[0052] Figure 2-2 yes Figure 2-1 208. The substrate 216 may have an inner surface 224 that contacts the superhard insert 210 to limit and / or prevent movement of the superhard insert 210 relative to the substrate 216 and / or the body 218. The body 218 may include a front portion 225 forward of the rear portion 220 of the body 218.

[0053] In some embodiments, the front portion 225 may generally taper in a forward direction toward the front face 226. The front face 226 may contact the superhard insert 210. For example, when the substrate 216 is positioned on the front portion 225, the superhard insert 210 may be positioned adjacent to the front face 226 to limit and / or prevent movement of the superhard insert 210.

[0054] In some embodiments, the front face 226 may include an alignment feature 228. In some embodiments, the alignment feature 228 may align or assist in aligning the superhard insert with the front portion 225 of the body 218 during assembly. In other embodiments, the alignment feature 228 may apply a reactive lateral force during operation of the tool 208 to limit damage to the substrate 216, since the material of the substrate 216 may be more brittle than the body material. For example, the body material may be steel and the matrix material may be a ceramic material. In other embodiments, the alignment feature may apply a radial compressive force to the superhard insert 210 to limit and / or prevent movement of the superhard insert 210 relative to the body 218. For example, when the body 218 is at an elevated temperature, the superhard insert 210 may be positioned in contact with the front face 226 and radially within the alignment feature 228. As the temperature of the body 218 decreases, the body material may undergo thermal contraction, providing a residual compressive force on the superhard insert 210.

[0055] In some embodiments, the alignment features 228 may circumferentially surround at least a portion of the superhard insert 210 at the front face 226. In other embodiments, the alignment features 228 may be positioned at equal angular intervals around the superhard insert 210 on the front face 226. In other embodiments, at least one of the alignment features 228 may be positioned at unequal angular intervals around the superhard insert 210 on the front face 226.

[0056] In some embodiments, the alignment feature 228 may have one or more gaps 230. In other embodiments, the gaps 230 may be positioned at equal angular intervals around the superhard insert 210 on the front face 226. In other embodiments, at least one gap 230 may be positioned at unequal angular intervals around the superhard insert 210 on the front face 226. In some embodiments, the gaps 230 may allow for greater surface area contact between the substrate 216 and the superhard insert 210. In other embodiments, the gaps 230 may allow for greater thermal contraction of the alignment feature 228 toward the superhard insert 210.

[0057] In some embodiments, the front portion 225 of the body 218 can have one or more mechanically interlocking features located thereon. For example, the front portion 225 can have one or more features on its surface that allow the base 216 to mechanically interlock with the front portion 225 to limit and / or prevent movement of the base 216 relative to the body 218.

[0058] The mechanically interlocking feature may include at least one recess 232 in the surface of the front portion 225. In some embodiments, the at least one recess 232 may be continuous circumferentially around the front portion 225. In other embodiments, the at least one recess 232 may be continuous in the rotational direction around the front portion 225 by an amount less than the entire circumference of the front portion 225. For example, the recess 232 may extend around approximately 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or any value therebetween of the circumference of the front portion 225 of the body 218. In some embodiments, a series of recesses may be located on the longitudinally spaced front portion 225.

[0059] In other embodiments, the mechanically interlocking feature may include one or more channels 234 oriented from the outer surface of the front portion 225 into the body 218. In some embodiments, a portion of the base 216 may be positioned in the one or more channels 234 to mechanically interlock with the body 218. The mechanical interlock may limit and / or prevent movement of the base 216 relative to the body 218 in a longitudinal direction, a lateral direction, a rotational direction, or a combination thereof.

[0060] Figure 2-3 yes Figure 2-1 and 2-2 A longitudinal cross-sectional view of an embodiment of tool 208 is shown. Figure 2-3 The interaction of the substrate 216 with one or more recesses 232 in the body 218 is shown. As described herein, the substrate 216 can be cast in place around a portion of the body 218. Prior to casting, at least a portion of the substrate precursor (e.g., ceramic powder) can be located in the recess 232. When casting, the protrusions 236 of the substrate 216 can be located in the recess 232. The protrusions 236 can interlock the substrate 216 or a portion of the substrate 216 with the body 218. In the illustrated embodiment, the mechanical interlock between the protrusions 236 and the recesses 232 can limit and / or prevent movement of the substrate 216 relative to the body 218 in at least the longitudinal direction (i.e., a direction parallel to the longitudinal axis 242 of the tool 208).

[0061] Figure 2-3Also shown is contact between the alignment features 228 and the longitudinally oriented sidewall 238 of the superhard insert 210. In some embodiments, at least one alignment feature 228 may contact a portion of the sidewall 238 of the superhard insert 210 within a range having a lower limit, an upper limit, or both, including 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, or any value therebetween. For example, at least one alignment feature 228 may contact more than 10% of the sidewall 238 of the superhard insert 210. In other examples, at least one alignment feature 228 may contact less than 100% of the sidewall 238 of the superhard insert 210. In other examples, at least one of the alignment features 228 may contact between 10% and 100% of the sidewall 238 of the superhard insert 210. In a further example, the at least one alignment feature 228 may contact between 20% and 90% of the sidewall 238 of the superhard insert 210. In yet another example, the at least one alignment feature 228 may contact between 30% and 80% of the sidewall 238 of the superhard insert 210.

[0062] In some embodiments, the body 218 may include a central passage 240 in which a portion of the substrate 216 may be positioned. Positioning a portion of the substrate 216 in the central passage 240 may provide additional contact surfaces between the substrate 216 and the body 218 and / or between the substrate 216 and the superhard insert 210. In some embodiments, the portion of the substrate 216 in the central passage 240 may limit and / or prevent movement of the superhard insert 210 in a longitudinal direction (i.e., a direction parallel to the longitudinal axis 242) during operation by providing longitudinal support to the superhard insert 210.

[0063] Figure 2-4 yes Figure 2-3 208 is rotated 45° about the longitudinal axis 242. In the depicted embodiment, the channels 234 are positioned at equal 90° intervals about the longitudinal axis 242, such that the channels 234 are opposite to each other in the longitudinal cross-section. In other embodiments, the tool 208 may include channels 234 oriented at other angles about the longitudinal axis 242.

[0064] As about Figure 2-2 As stated, Figure 2-4An example of a mechanical interlock between the substrate 216 and the body 218 at the channels 234 is shown. Channel extensions 244 of the substrate 216 can extend into one or more of the channels 234 to lock the substrate 216 to the body 218. In some embodiments, thermal contraction of the body 218 can radially compress the channel extensions 244, further locking the substrate 216 relative to the body 218. In at least one embodiment, the channels 234 can allow a substrate precursor to be positioned around a portion of the body during filling of the mold.

[0065] In some embodiments, at least one channel 234 can be oriented at an angle 246 relative to the longitudinal axis 242. At least one channel 234 can be oriented to provide mechanical interlocking and provide a filling path for the mold during manufacturing. In some embodiments, the angle 246 of at least one channel 234 relative to the longitudinal axis 242 can be within a range having an upper limit, a lower limit, or an upper limit and a lower limit, and the upper limit, the lower limit, or the upper limit and the lower limit include any one of 10°, 20°, 30°, 40°, 50°, 60°, 70°, 80°, 90° or any value therebetween. For example, the angle 246 of at least one channel 234 relative to the longitudinal axis 242 can be greater than 10°. In other examples, the angle 246 of at least one channel 234 relative to the longitudinal axis 242 can be less than 90°. In yet another example, the angle 246 of at least one channel 234 relative to the longitudinal axis 242 can be between 10° and 90°. In a further example, the angle 246 of at least one channel 234 relative to the longitudinal axis 242 can be between 20° and 80°. In yet another example, the angle 246 of the at least one channel 234 relative to the longitudinal axis 242 may be between 30° and 70°.

[0066] When tool 208 is Figure 2-4 In relative to Figure 2-3When rotated 45 degrees, the longitudinal cross section passes through the gap 230 near the superhard insert 210. A portion of the substrate 216 may be located in the gap 230 and contact a portion of the sidewall 238 of the superhard insert 210. In some embodiments, at least one alignment feature 228 may contact a portion of the sidewall 238 of the superhard insert 210 within a range having a lower limit value, an upper limit value, or a lower limit value and an upper limit value, wherein the lower limit value, the upper limit value, or the lower limit value and the upper limit value include 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 100%, or any value therebetween. For example, at least one alignment feature 228 may contact more than 10% of the sidewall 238 of the superhard insert 210. In other examples, at least one alignment feature 228 may contact less than 100% of the sidewall 238 of the superhard insert 210. In other examples, at least one of the alignment features 228 may contact between 10% and 100% of the sidewall 238 of the superhard insert 210. In a further example, at least one alignment feature 228 may contact between 20% and 90% of the sidewall 238 of the superhard insert 210. In yet another example, at least one alignment feature 228 may contact between 30% and 80% of the sidewall 238 of the superhard insert 210.

[0067] In some embodiments, tool 208 may include a central hole 248 in communication with a passage of body 218. Central hole 248 may extend through body 218 along a portion of longitudinal axis 242 and open at a rear end of body 218. During manufacturing, a substrate precursor may be positioned in and / or around body 218 via central hole 248, for example, Figure 2-5 In the embodiment shown.

[0068] Figure 2-5 2 is a longitudinal cross-sectional view of an embodiment of a tool 208 in a mold 250 during assembly. The matrix 216 of the tool 208 can be cast around the superhard insert 210 in the mold 250. The matrix precursor 252 that is cast and / or sintered to form the matrix 216 can be a powder, a metal alloy, an epoxy resin, a gel, other fluids, or a combination thereof. Once positioned in the mold 250, the matrix precursor 252 can be formed complementarily with mechanically interlocking features (e.g., a recess 232 or a channel 234). After the matrix precursor 252 is cured, the matrix 216 can be mechanically interlocked with at least one other portion of the tool 208. In some embodiments, the curing of the matrix precursor 252 to the solid matrix 216 can occur at an elevated temperature (e.g., between 1,112°F (600°C) and 2,192°F (1,200°C)), and the matrix material can have a greater coefficient of thermal expansion than the superhard insert 210. During cooling from the solidification process, the thermal compression of the matrix 216 may apply a compressive force to the superhard insert 210 , thereby compressing the superhard insert 210 .

[0069] Figure 3 is a flow chart showing a method 300 of manufacturing a tool according to the present disclosure. The method 300 may include forming a tool body at 302. In some embodiments, forming the body may include forming one or more mechanically interlocking features in a surface of the body and / or within the body. For example, forming the body may include forming one or more surface features, such as recesses, and / or forming one or more channels therein. In other embodiments, forming the body may include forming a front face and / or alignment features to receive a superhard insert, align a superhard insert, support a superhard insert, or a combination thereof.

[0070] The method 300 may further include positioning the superhard insert at the front end of the body at 304. In some embodiments, positioning the superhard insert may include positioning the superhard insert against the front face of the body. In other embodiments, positioning the superhard insert may include positioning the superhard insert in contact with one or more alignment features of the body. In at least one embodiment, positioning the superhard insert may include press-fitting the superhard insert into the front end of the body, for example, in one or more alignment features.

[0071] In some embodiments, forming the body can also include shaping the body. For example, the body can be cut or machined into a final shape, or one or more mechanically interlocking features can be formed in the body. The body can be shaped by removing material by grinding, laser ablation, mechanical cutting, water jet cutting, electrical discharge machining, other material removal techniques, or combinations thereof.

[0072] In some embodiments, method 300 may include forming a superhard insert before positioning the insert in the body at 304. Forming the insert may include sintering the insert in a high temperature and high pressure press. In some embodiments, the superhard insert may be sintered with a carbonate catalyst and / or a carbonate binder. In embodiments with a carbonate catalyst, the insert may be sintered in a pressure range of 6 GPa to 10 GPa and a temperature range of 2,732 ℉ (1,500 ℃) to 4,532 ℉ (2,500 ℃). For example, the insert may include a PCD with a magnesium carbonate catalyst and / or a binder. In some embodiments, the binder may be at least partially leached from the insert. In other embodiments, the binder may be decomposed at least at an elevated temperature. For example, a PCD with a magnesium carbonate catalyst may decompose at least some of the magnesium carbonate into carbon monoxide and / or carbon dioxide by heating the insert to a temperature greater than 932 ℉ (500 ℃).

[0073] In some embodiments, at least 50% of the binder material may be removed from the ultrahard material after forming the insert. In other embodiments, at least 80% of the binder material may be removed from the ultrahard material after forming the insert. In other embodiments, substantially all of the binder material may be removed from the ultrahard material after forming the insert. In yet another embodiment, less than 5% of the binder material may be removed from the ultrahard material after forming the insert.

[0074] In some embodiments, forming the superhard insert may further include shaping the superhard insert. For example, the superhard insert may be cut or machined into a final shape, or one or more mechanically interlocking features may be formed in the insert. The superhard insert may be formed by removing material by grinding, laser ablation, mechanical cutting, water jet cutting, electrical discharge machining, other material removal techniques, or a combination thereof.

[0075] After positioning the superhard insert at the front end of the body at 304, the method 300 may further include filling a space in the body and adjacent to the superhard insert with a matrix precursor at 306. For example, the superhard insert may be positioned in a mold with the body, and a matrix precursor (e.g., a powder, a metal alloy, an epoxy, a gel, other fluids, or a combination thereof) may be positioned in the mold to fill a space in the mold that contacts and / or surrounds at least a portion of the superhard insert and at least a portion of the body. At 308, when the matrix precursor is cured in the matrix, the matrix precursor may become a matrix of the tool and / or blade.

[0076] In some embodiments, curing the matrix adjacent to the superhard insert and outside the body can also include curing the matrix within the body. For example, during curing, at least a portion of the matrix precursor can be located within one or more channels within the body. In such embodiments, the matrix precursor can be cured into a matrix that mechanically interlocks with the body. In at least one embodiment, at least a portion of the matrix is ​​cured outside the body and at least another portion of the matrix is ​​cured within the body (e.g., Figure 2-4 Channel extension 244 shown).

[0077] In some embodiments, the matrix precursor may include ceramic powder or be made of ceramic powder. In other embodiments, the matrix precursor may include tungsten carbide powder or be made of tungsten carbide powder. In other embodiments, the precursor material may include another carbide powder or be made of another carbide powder. In other embodiments, the matrix precursor may include metal or be made of metal. In further embodiments, the matrix precursor may include a suspended material or a material mixed with a fluid matrix, or be made of a suspended material or a material mixed with a fluid matrix. In yet another embodiment, the matrix precursor may include superhard particles to impregnate the matrix with superhard particles, thereby improving the wear resistance of the matrix. In at least one embodiment, the matrix precursor may include a binder alloy with a low melting point (i.e., below 2200℉ (1204℃) to cast a matrix with superhard inserts.

[0078] The method 300 may further include curing the matrix at a temperature not greater than 2200°F (1204°C). Curing the matrix precursor to secure the superhard insert may include heating the matrix precursor to an elevated temperature. Curing temperatures below 2,200°F (1,204°C) may limit damage to the carbonate PCD, thereby extending the useful life of the carbonate PCD and, in turn, the useful life of the tool. In some embodiments, the curing temperature may be less than 1900°F (1037°C). In other embodiments, the curing temperature may be less than 1700°F (927°C). In other embodiments, the curing temperature may be less than 1500°F (816°C).

[0079] During the solidification process, the substrate may develop one or more cracks, voids, fissures or other defects. The defects can be repaired by brazing or filler materials (e.g., metal) applied to the substrate. For example, a crack in the substrate can be filled and repaired using a brazing process or filler material. Broken parts can be replaced and repaired using a brazing process or filler material. In some embodiments, brazing or filling the substrate provides localized heat that does not damage the superhard insert.

[0080] Figure 4 4 is a side cross-sectional view of another embodiment of a tool 408 according to the present disclosure. The tool 408 includes a superhard insert 410 in contact with and supported by a substrate 416 bolster. Although the superhard insert 410 is illustrated as a pointed insert, in other embodiments, the superhard insert 410 may have any geometry suitable for the material being removed. For example, the superhard insert 410 may have a planar cutting surface, a plurality of planar cutting surfaces, a conical cutting surface, a curved cutting surface, or a combination thereof.

[0081] The superhard insert 410 may be mechanically locked to the substrate 416 by thermal compression of the substrate 416 during cooling of the solidification process. In other embodiments, the superhard insert 410 may be mechanically locked to the substrate 416 by one or more mechanically interlocking features, such as in combination with Figure 2-3 and Figure 2-4 The superhard insert 410 may include one or more recesses and / or projections, and the substrate 416 may include one or more complementary projections and / or recesses to interlock with the superhard insert. For example, the recesses and / or projections may include tapers, recesses, columns, indentations, extensions, or any other surface features that allow for longitudinal and / or rotational mechanical interlocking between the superhard insert 410 and the substrate 416. In other examples, the superhard insert 410 is connected to the substrate 416 by a press fit, a shrink fit, or other friction or compression connection technique.

[0082] In other embodiments, the superhard insert 410 is brazed to the substrate 416 to bond the substrate 416 and the superhard insert 410. In other examples, the tungsten carbide substrate 416 can be brazed to the superhard insert 410 to increase the strength of the mechanical connection between the substrate 416 and the superhard insert 410 in addition to mechanical interlocking. In other embodiments, the superhard insert 410 is brazed to the body 418 of the tool 408 to directly couple the superhard insert 410 to the body 418. For example, the superhard insert 410 can be secured to the body 418 independently of the substrate 416, bolster, or other similar component.

[0083] The substrate 416 is coupled to the body 418 of the tool 408. In some embodiments, the substrate 416 and the body 418 are connected by Figure 2-3 and Figure 2-4 The substrate 416 and the body 418 may be joined by any mechanical interlock described. In other embodiments, the substrate 416 and the body 418 are connected by brazing. For example, the tungsten carbide substrate 416 can be brazed to the steel body 418 to join the substrate 416 and the body 418. In other examples, in addition to the mechanical interlock, the tungsten carbide substrate 416 can be brazed to the steel body 418 to increase the strength of the mechanical bond between the substrate 416 and the body 418. In at least one example, the substrate 416 and the body 418 can have a mechanical interlock that limits and / or prevents longitudinal movement of the substrate 416 relative to the body 418 (e.g., with respect to Figure 2-3 The substrate 416 and the body 418 may have a mechanical interlock that limits and / or prevents rotational movement of the substrate 416 relative to the body 418 (e.g., a longitudinal groove), while the brazing limits and / or prevents rotational movement of the substrate 416 relative to the body 418. In at least another example, the substrate 416 and the body 418 may have a mechanical interlock that limits and / or prevents rotational movement of the substrate 416 relative to the body 418 (e.g., a longitudinal groove), while the brazing limits and / or prevents longitudinal movement of the substrate 416 relative to the body 418.

[0084] Figure 5 5 is a side cross-sectional view of another embodiment of a tool 508 according to the present disclosure. In some embodiments, the superhard insert 510 is brazed to a substrate 516 pillow at one end of the superhard insert 510, while the substrate 516 does not contact or support the sides of the superhard insert 510. For example, the superhard insert 510 can be located above the substrate 516, which is in turn connected to the body 518. The substrate 516 and the body 518 can be connected by Figure 2-3 and Figure 2-4 or Figure 4 Any combination of the described methods may be combined.

[0085] Although Figure 4 and Figure 5 The superhard inserts shown in are illustrated as conical, pointed inserts, but in other embodiments, the superhard inserts of the tools described herein may have other cross-sectional shapes. For example, Figure 6 6 is a perspective view of a ridged or chisel-shaped superhard insert 610. The ridged superhard insert 610 has a plurality of planar cutting surfaces 654-1, 654-2 with a vertex 614 located between them. The vertex 614 is positioned along the width of the superhard insert 610 so that the cutting surfaces 654-1, 654-2 form a chisel or shaft shape across the width of the superhard insert 610. In some embodiments, the vertex 614 is positioned to bisect the superhard insert through the central axis of the superhard insert 610 and follow the diameter of the superhard insert 610. For example, the cutting surfaces 654-1, 654-2 can be symmetrical about the vertex 614. In other embodiments, the vertex 614 is offset from the center of the superhard insert 610, making the superhard insert 610 asymmetrical.

[0086] In some embodiments, the ridged superhard insert 610 may include inclined surfaces, rather than planar cut surfaces 654-1, 654-2, that are oriented downwardly away from the apex 614. In this manner, the ridged superhard insert may be a dual-angle ridged superhard insert 610.

[0087] Figure 7 710 (e.g., a bullet chisel shaped insert). For example, the vertex 714 is positioned farther from the first cutting surface 754-1 and closer to the second cutting surface 754-2. The first cutting surface 754-1 is oriented at a lower angle than the second cutting surface 754-2, resulting in the superhard insert 710 being asymmetric about the vertex 714.

[0088] Figure 88 is a perspective view of another embodiment of a superhard insert 810 that can be used in a tool according to the present disclosure. For example, the superhard insert 810 includes a flat cutting surface 854 that is substantially perpendicular to the sidewall 838 of the superhard insert 810. The superhard insert 810 can be a shear cutting element without a vertex and uses the edge of the flat cutting surface 854 to remove material.

[0089] Fig. 9 9 is a side cross-sectional view of yet another embodiment of a superhard insert 910 having a vertex 914. In some embodiments, for example Fig. 9 The bullet-shaped cutting element shown, the superhard insert 910 includes a curved cutting surface 954 having an apex 914. In some examples, the apex 914 is located at the center of the curved cutting surface 954, and the curved cutting surface 954 is curved in both the longitudinal direction and the rotational direction, similar to the head of a bullet. In other examples, the apex 914 is elongated across the width of the superhard insert 910, and the curved cutting surface 954 is curved in one direction to form a curved ridge. Depending on the application, different cutting surface geometries may exhibit different cutting behaviors. It should be understood that the tools described herein can be used with superhard inserts having any cutting surface geometry.

[0090] Figure 10-1 and Figure 10-2 1 is a side view and a perspective view of another embodiment of a superhard insert 1010 according to the present disclosure. The superhard insert 1010 has a generally dome shape including a plurality of curved cutting surfaces 1054-1, 1054-2 that are curved in the rotational direction and are flat in the longitudinal direction. For example, in a longitudinal cross section, the first cutting surface 1054-1 and the second cutting surface 1054-2 are both planar and oriented at different angles. However, as shown in FIG. Figure 10-2 As shown, some or each cutting surface of the superhard insert may be curved and continuous in the rotational / circumferential direction. Although the apex 1014 of the superhard insert 1010 is shown as Figure 10-1 and 10-2 The apex 1014 of the superhard insert 1010 is pointed in the illustrated embodiment, but according to embodiments of the present disclosure, the apex 1014 of the superhard insert 1010 may have other geometries or shapes. For example, the apex 1014 may be pointed, planar (e.g., frustoconical), such as Figure 11-1 As shown in the embodiment of FIG; it can be round / curved, such as Figure 12-1 As shown in the embodiments, or having any other suitable shape.

[0091] In other embodiments, the superhard insert may optionally have one or more facets on the curved cutting surface. Figure 11-1 and Figure 11-2Another embodiment of a superhard insert 1110 is shown. Figure 11-1 is a side view of a superhard insert 1110 having a first cutting surface 1154-1 that is curved in both the longitudinal and rotational directions. The second cutting surface 1154-2 is one of a plurality of facets located in the first cutting surface 1154-1. Figure 11-2 1 is a perspective view showing a plurality of second cut surfaces 1154-2 distributed at equal angular intervals around a first cut surface 1154-1. In other embodiments, the planar facets of the second cut surface 1154-2 are positioned at unequal angular intervals around the first cut surface 1154-1. The proportions of the planar facets are illustrative of some example embodiments, but in other embodiments, the planar facets may have larger or smaller longitudinal and / or rotational dimensions.

[0092] In other embodiments, the facets are concave or convex areas within the curved domed cutting surface. For example, Figure 12-1 1 is a side view of an embodiment of a superhard insert 1210 having a domed or bullet-shaped first cutting surface 1254-1 and a plurality of recessed areas 1254-2 defining a second cutting surface 1254-2. The recessed areas 1254-2 are positioned at equal angular intervals around the first cutting surface 1254-1, but may be unequally spaced or at different ratios in other embodiments. Figure 12-2 yes Figure 12-1 A perspective view of a superhard insert 1210 is shown.

[0093] In a further embodiment, for example Figure 13-1 and 13-2 The illustrated superhard insert 1310 includes a cutting surface 1354 that is a plurality of planar facets that abut one another in segments positioned at angles around the superhard insert 1310. For example, Figure 13-2 As shown in the perspective view, Figure 13-1 The cutting surface 1354 of the embodiment of the superhard insert 1310 has seven planar facets intersecting at the vertex 1314. In yet another embodiment, Figure 14-1 and 14-2 As shown, the superhard insert 1410 includes a cutting surface 1454 having a plurality of recessed areas that abut one another in areas positioned at angles around the superhard insert 1410. For example, Figure 14-2 As shown in the perspective view, Figure 14-1 The cutting surface 1454 of the embodiment of the superhard insert 1410 has seven concave regions that meet at the apex 1414 .

[0094] For at least some materials, the embodiments of the superhard inserts described herein can have stronger removal performance than superhard inserts of other shapes. The manufacturing methods and systems described herein can provide improved insert retention and / or protection to remove materials more aggressively than some pick tools. In some embodiments, the tool can have additional changes in geometry, which further increases the durability and / or operating life of the tool.

[0095] Fig.15 15 is a perspective view of another embodiment of a tool 1508 according to the present disclosure. In some embodiments, the tool 1508 has a superhard insert 1510, a substrate 1516, a body 1518, or a combination thereof, which have a planar surface 1556. For example, Fig.15 A tool 1508 is shown having a body 1518 with a planar surface 1556 adjacent to a nearly conical substrate 1516 and a conical superhard insert 1510. In other examples, the substrate 1516 may have a planar surface 1556 while the body 1518 lacks a planar surface.

[0096] In other embodiments, for example Fig.16 The tool 1608 is shown in a perspective view of FIG. 1 , and one or more portions of the tool 1608 have a planar surface 1656. For example, Fig.16 The embodiment of tool 1608 in has a base 1616 and a body 1618, both of which have a planar surface 1656 to a rear portion 1620 of the body 1618. In some embodiments, the base 1616 and the body 1618 form a coherent and / or continuous planar surface 1656. In other embodiments, the base 1616 and the body 1618 each have a planar surface 1656 that is positioned and / or oriented at an angle to each other.

[0097] Reference now Fig.17In yet another embodiment, tool 1708 has superhard insert 1710, substrate 1716, body 1718, or a combination thereof, which are oriented at an angle to each other. For example, body 1718 has body axis 1758, and superhard insert 1710 has insert axis 1760. Although other embodiments described herein have coaxial body axis 1758 and insert axis 1760, some embodiments have body axis 1758 and insert axis 1760 positioned at angle 1762 to each other. In some embodiments, angle 1762 is within a range having a lower limit value, an upper limit value, or a lower limit value and an upper limit value, and the lower limit value, the upper limit value, or the lower limit value and the upper limit value include any value of 1°, 5°, 10°, 15°, 20°, 30°, 40°, 45°, 50°, 60°, 65°, or any value therebetween. For example, angle 1762 can be greater than 1°. In other examples, angle 1762 can be less than 65°. In yet another example, angle 1762 can be between 1° and 65°. In a further example, angle 1762 can be between 5° and 60°. In at least one example, angle 1762 can be between 35° and 50°, or approximately 45°.

[0098] As described herein, some embodiments of the tool include one or more connection features on the rear portion to allow for selective connection between the tool and the rotating drum. Fig.18 1804 with one embodiment of a tool 1808 connected to the drum 1804. The tool 1808 has a body 1818 with a threaded rear portion 1820. The body 1818 may also have faceted sides to allow the tool 1808 to be twisted to fit the threaded rear portion 1820 onto the drum 1804. Referring now to Fig.19 In other embodiments, the tool 1908 has a tapered rear portion 1920 such that a compressive force applied to the tool 1908 presses the tapered rear portion 1920 against a complementary tapered connection in the drum 1904. This arrangement can facilitate installation of the tool 1908 and / or distribute the compressive force to the drum 1904 so that the force is not primarily or solely borne by the threads of the rear portion 1920.

[0099] Embodiments of the tools have been described primarily with reference to asphalt removal operations or mining; however, the tools described herein may be used in applications. In other embodiments, tools according to the present disclosure may be used in a wellbore or other downhole environment for natural resource exploration or production, or in a borehole for placement of utility pipelines. Therefore, the terms "road," "asphalt," "wellbore," "borehole," and the like should not be construed to limit the tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0100] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the technology of the present disclosure. In addition, in order to provide a concise description of these embodiments, all features of the actual embodiments may not be described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, many embodiment-specific decisions will be made to achieve the developer's specific goals, such as meeting system-related and business-related constraints, which may vary from embodiment to embodiment. In addition, it should be understood that such development efforts may be complex and time-consuming, but for ordinary technicians who benefit from the present disclosure, it is still a routine task of design, production and manufacturing.

[0101] The articles "a", "an" and "the" are intended to indicate that there are one or more elements in the preceding description. The terms "including", "comprising" and "having" are intended to be inclusive, and mean that in addition to the listed elements, there may be additional elements. In addition, it should be understood that reference to "one embodiment" or "an embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional embodiments that also contain the features. For example, any element described in the embodiments herein may be combined with any element of any other embodiment described herein. The numbers, percentages, ratios or other values ​​described herein are intended to include the value, as well as other values ​​of "approximately" or "approximately" the value, as understood by those of ordinary skill in the art included in the embodiments of the present disclosure. Therefore, the value should be interpreted broadly enough to include values ​​at least close enough to the value to perform the desired function or achieve the desired result. The value includes at least the expected changes in a suitable manufacturing or production process, and may include values ​​within 5%, within 1%, within 0.1% or within 0.01% of the value.

[0102] In view of the present disclosure, those skilled in the art should recognize that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and modifications may be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions including functional "means plus function" clauses are intended to cover structures described herein that perform the listed functions, including structural equivalents that operate in the same manner and equivalent structures that provide the same functions. It is the express intention of the applicant not to invoke means plus function or other functional claims in any claim, except those that appear as "means for..." together with the associated functions. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims will be covered by the claims.

[0103] As used herein, the terms "approximately," "about," and "substantially" refer to an amount that is close to a stated amount and still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," and "substantially" may refer to an amount that is within less than 5%, within less than 1%, within less than 0.1%, and less than 0.01% of the stated amount. In addition, it should be understood that any directions or reference frames in the foregoing description are only relative directions or motions. For example, any reference to "up" and "down" or "above" or "below" only describes the relative position or motion of the associated elements.

[0104] Without departing from the spirit or features of the present invention, the present disclosure may be implemented in other specific forms. The described embodiments should be considered illustrative rather than restrictive. Therefore, the scope of the present disclosure is indicated by the appended claims rather than the preceding description. Changes within the equivalent meaning and scope of the claims should be included within their scope.

Claims

1. A tool for removing material, the tool comprising: a body having a front portion and an opposing rear portion; a superhard insert comprising a superhard material, the superhard insert being located adjacent the front portion; and a substrate contacting the body and the superhard insert, the substrate being mechanically interlocked with the body, and at least a portion of the substrate being positioned circumferentially around at least a portion of a front portion of the body, wherein the body has at least one channel oriented radially inwardly from the outer surface of the front portion toward the longitudinal axis of the tool, at least a portion of the base body being located in the at least one channel, The body is capable of radially compressing the at least a portion of the substrate located in the at least one channel during heat shrinkage to further lock the substrate relative to the body.

2. The tool according to claim 1, wherein the superhard insert is a superhard insert with a peak. The tool of claim 1 , wherein the substrate comprises a ceramic material.

4. The tool of claim 1, said superhard insert comprising a thermally stable superhard material.

5. The tool of claim 1, the matrix comprising superhard particles distributed therein.

6. The tool of claim 1, at least one channel being oriented at an angle in the range of 10° to 90° relative to the longitudinal axis.

7. The tool of claim 1, the body having at least one recess in an outer surface of the front portion, the recess being circumferential around the front portion, and at least a portion of the base being located in the at least one recess.

8. The tool of claim 1, said body comprising steel.

9. The tool of claim 1, the body comprising a mechanical connector at the rear portion.

10. A system for removing material, the system comprising: a degradation tool configured to degrade the material; and A plurality of tools selectively connectable to the degradation tool, at least one tool of the plurality of tools comprising: a body having a front portion and an opposing rear portion; a superhard insert comprising a superhard material, the superhard insert being located adjacent the front portion; and a substrate contacting the body and the superhard insert, the substrate being mechanically interlocked with the body and at least a portion of the substrate being connected to the superhard insert, wherein the body has at least one channel oriented radially inwardly from the outer surface of the front portion toward the longitudinal axis of the tool, and at least a portion of the substrate is located in the at least one channel, The body is capable of radially compressing the at least a portion of the substrate located in the at least one channel during heat shrinkage to further lock the substrate relative to the body.

11. The system of claim 10, the degradation tool being a rotating drum configured to rotate about a rotation axis, and at least a portion of at least one tool being located radially outward of the rotating drum relative to the rotation axis.

12. The system of claim 11, the at least one tool being oriented along a longitudinal axis extending through the front portion and the rear portion at an angle between 25° and 120° relative to a radial direction of the rotating drum.

13. The system of claim 11, the at least one tool being selectively connectable to the rotating drum via a mechanical connector located at a rear portion of the body.

14. The system of claim 10, the front portion of the body having one or more mechanically interlocking features, a portion of the base being positioned within the one or more mechanically interlocking features.

15. A method of manufacturing a tool, the method comprising: forming a body having a front portion, the front portion including at least one mechanically interlocking feature in the body; Positioning a superhard insert near the front of the body; filling at least a first space in at least one mechanically interlocking feature in the body and a second space external to the body with a matrix precursor; and curing the matrix precursor to form a matrix adjacent to the superhard insert and outside the body, wherein the matrix contacts the body and the superhard insert and is mechanically interlocked with the body, wherein the body has at least one channel oriented radially inwardly from the outer surface of the front portion toward the longitudinal axis of the tool, and at least a portion of the substrate is located in the at least one channel, The body is capable of radially compressing the at least a portion of the substrate located in the at least one channel during heat shrinkage to further lock the substrate relative to the body.

16. The method according to claim 15, further comprising: The body and the superhard insert are inserted into the mold before filling at least the second space.

17. The method of claim 15, curing the matrix precursor comprises curing at a curing temperature below 1204°C.

18. The method according to claim 15, further comprising: At least a portion of the carbonate binder of the superhard insert is decomposed.

19. The method of claim 15, wherein the matrix precursor comprises a ceramic powder.

20. The method of claim 19, wherein the matrix precursor comprises superhard particles.

21. The method according to any one of claims 15 to 20, wherein: The tool comprises the tool according to any one of claims 1-14.

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