What is the Technology of Vacuum Brazed Diamond Tools ?
Diamond tools can be obtained by sintering, electroplating, laser welding, etc.
Brazing diamond tool has the following characteristics: The quality of diamond is high, cutting and grinding efficiency is very high. Diamond was brazing solder tightly on the substrate, not a mechanical package but a chemical combination, so the diamond is not easy to fall off during working. But because most diamond brazed products are single layer (there are multiple layers, it is understood that is not too mature), although it is very sharp and cutting efficiency is high, but iservice life is shorter than sintering.
In addition brazing diamond must be carried out at high temperatures, there is a certain damage to the diamond, it is important that the substrate will be deformed at high temperatures, especially for thin saw blades (it is understood that the brazing thin blade can be 0.3 OD 100) , so it can not completely replace the diamond plating products.
Besides, brazing diamond tool production equipment investment and production cost are very high, so brazing diamond tools will only occupy part of the diamond tool market, but it can be said that brazing diamond tools will have a very good market in the future, especially in some special-shaped diamond tools, such tools generally have very large profits.
Diamond vacuum brazing: first, the vacuum melting point of the solder under the vacuum environment is 50℃ to 80℃ lower than atmospheric pressure,it can reduce the heat damage of diamond, infiltration to solder and wettability to diamond and matrix are better than other environment. The vacuum degree generally about 2X10-2Pa has been basically meet the requirements of high-grade brazing diamond tools.
For some solder in low vacuum (about 2Pa) can also make good brazing diamond tools, butit need to use more than 16KG diamonds. Vacuum furnace must have a observation hole on the furnace door, so that to see the furnace inside situation, such as solder melting, climbing and so on.
In general terms, brazing is a method of joining materials by using a filling metal to create this joint. For stonemasonry tools, this refers to connecting the part of the tool that performs the operation, the synthetic diamonds, with the steel carrier. This could be, for example, the steel round shape of the body of a blade. Vacuum brazing specifically refers to the use of a furnace and heat to attach a diamond coating to the outside edge of a tool.The below information serves a rough guide to explain this process.
Vacuum Brazed Diamond Manufacturing Process
Manufacturing Step 1
The first requirement is to locate a tool carrier, and the specification will be application led. It is usually a steel body which needs to be cleaned and prepared. For a blade, this will be circular body around 3mm in thickness
Manufacturing Step 2
A dispensing system injects glue drops onto the tool surface. Diamond grits are then applied to the surface. Their specification will be selected based on the intended purpose of the tool. A braze alloy mix is then applied over the grits which contains a reactive metal. This mix usually contains a nickel component. The level of this braze alloy gives the desired grit embedment after brazing.
Manufacturing Step 3
The tool is then heated in a special air-tight brazing furnace at around 1,000C. The joint area between the metal body, braze alloy and diamond grit have direct heat applied to them. The temperature of the furnace is set above the melting point of the braze alloy but below the melting point of the steel body. The molten braze alloy flows into gaps between the other two materials and fuses the diamond crystals to the body of the tool. This forms a strong connection as it cools. This means that the diamond particles are joined at the points on the steel body of the tool that comes into contact with the material being worked. The grits now leave a 'sugar-coated' effect and leave a single layer of diamond on the outside of the tool carrier.
Glue is injected onto the tool body
For Brazing Different Diamond Tools Have Different Brazing Process, Such As;
* Thin steel plate tools, from room temperature to 400℃ using slow heating, the purpose is to let the flux completely volatile. From 400℃ to 680℃ using fast warming to improve work efficiency, about 680℃ will be the melting point of solder, then adopts medium temperature heating to buffer the temperature difference in the furnace. From solder melting point to solder melting point +50℃ using slow heating to give all the brazed workpiece to provide a uniform temperature field, and thermal insulation 5-15 minutes to stop heating and start cooling, according to the situation can also be directly cooling.
* For thick matrix tools, the final holding time should be about 20-35 minutes. Using slow heating, the maximum temperature is the solder melting point +30℃, holding time for about 5 minutes, after discharge if the amount of deformation is too big then put them into the furnace again, still string together clamping. Using medium temperature heating to about 600℃, holding time of about 10 minutes. Some saw blade can also be flat on press machine.
* For brazing too thin saw blade, it need to use low melting point solder, and do some special tooling, a pressure vacuum brazing furnace is a very good choice. High temperature brazing for metal workpiece is also annealing treatment in vacuum, for the carbon steel matrix damage is serious, but with the furnace slow cooling can be reduced the residual stress caused by diamond, metal matrix and solder thermal expansion coefficient difference after welding. Single chamber vacuum brazing furnace production efficiency is low, especially unfavorable for the high vacuum brazing, so three chamber vacuum brazing furnace is the ideal choice. Three chamber vacuum brazing furnace has a preheating chamber can be heated to about 500℃, flux and other harmful material are basically volatile and exhausted. And then into the brazing room, after the completion of brazing into the cooling room to quickly cool, which is good for the matrix, high production efficiency, good product quality, low production cost. It just the equipment investment is too large for one time.
MORE SUPERHARD vacuum brazed tools are used for foundry, metal working, composites, automotive sector, ship building , stone , ceramic, plastic processing ,etc
-All diamond tools can be ordered and fabricated!
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Henry Wang | Quote Manager
-WhatsApp:+86-13459035657
-Email: ceo@zdiamondtools.com
-Web www.zdiamondtools.com
Company Profile
Z-LION have been engaged in developing and manufacturing vacuum brazed diamond tools since its establishment 2002. Products include super thin brazed diamond wire saw,Vacuum Brazed Profile Wheel ，ZL-QH20 Vacuum brazed Diamond Core Drill Bits ，ZL-QH18 Vacuum Brazed Triangle Polishing Pad，ZL-QH17 Vacuum Brazed Polishing Pad, for all kinds of stone / Ceramic cutting，polishing，grinding, drilling etc.
If you would like to get a quotation about diamond tools, please contact us.
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