Papers by Keyword: Diamond Brazing

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Authors: James C. Sung, Shao Chung Hu, Yen Shuo Chang
Abstract: The thick braze alloy coating can hold diamond much firmer than thin element coatings (Ti, Cr, Si) of commercial saw diamond grits. Moreover, the braze alloy can form metallurgical bonding readily with the metal matrix of saw segments. As a result, diamond saws that employ ABCD can cut much faster and last much longer than conventional designs. ABCD can be planted in metal matrix to form three dimensional pattern, the chemical bonding of diamond and its controlled spacing can virtually eliminate diamond loss due to pullouts and diamond breakage due to excessive impact force. The greatly increased number of working crystals can extend the segment life by one order of magnitude. With the thick coating, ABCD can join together to form needles or plates that could not be possible with thinly coated diamond. The ABCD needles or plates can be planted or arranged in a metal matrix to form a three-dimensional structure. Such unique designs can greatly expand the functions of diamond saws.
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Authors: James C. Sung, Shao Chung Hu, Yen Shuo Chang
Abstract: Diamond grits in tools are typically held in a sintered matrix of metal powder (e.g. Co). The bonding between diamond and the matrix is essentially mechanical. As a result, most diamond grits are easily knocked out from the tool during cutting. The diamond industry has designed various metal coatings (e.g. Ti, Cr, Si) to improve the adherence of diamond grits in the matrix, but the improvements have been modest (e.g. up to 50% increase of tool life). A revolutionary “Active Braze Coated Diamond” (ABCD) is now being developed. The coating of ABCD is much thicker (e.g. 20 microns) than conventional ones (about 1 micron). The molten braze is wetted and reacted with diamond to form strong chemical bond at the interface so that the diamond does not become knocked out of tools. ABCD is coated with a nickel alloy that can form metallurgical diffusion bonds readily with the metal matrix of the tool. In essence, ABCD turns diamond into a metal grain so that the diamond tools can be made by conventional powder metallurgical process without being concerned about the poor bonding between matrix metal powder and the diamond as before.
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