Diamond PDF

Diamond–metal interfaces in
cutting tools
Report submitted by –
Madhu.T.K BT10MME006
Dharmendra BT10MME028
Mitali Sahare BT10MME057
Sneh Shikha BT10MME079
INDEX
Sr.No. TOPIC PAGE
NO.
1. Introduction: 1
i>Basic requirements for
matrix
ii>Effects of minor
additions
iii>Advantages of
diamond tools
2. Categories of diamond 2
tools:
i>Impregnated tools
ii>Brazed tools
iii>Electroplated tools
3. Conclusion 3
Introduction
Diamond-Metal Composite materials are wear-resistant having a super hard surface
coating of diamond bonded to a stiff, tough, high strength and ductile substrate of
metal with an excellent interfacial adhesion. Their use in cutting tools results in
highest reproducibility and reliability for each individual tool tip thereby significantly
enhancing the economical mass production.
Basic requirements for matrix:

• Erosion rate of matrix must be proportional to wear rate of diamond
• Alloy used should not result in Diamond → Graphite reaction that would
damage diamond & strongly reduce cutting performance, coating on diamond
grits can prevent oxidation and graphitization under sintering conditions.
• High density
Selection of metal matrix must be done by taking into consideration the abrasiveness
and hardness of the workpiece and the interfacial bonding strength between metal and
diamond
Reliable adhesion necessary for tools is achieved by appropriate interfacial

modification. Diamonds have low reactivity towards most metals; in order to increase
interfacial adhesion active elements such as Cr, V or Ti are added in small quantities
to promote formation of chemical bond.
Coating with carbide layers ensures stronger interfacial adhesion and protects
diamond grit from an excessive reaction with matrix. Reactivity of metals towards
carbon is related to number of electrons vacancies in their d-electrons. The greater the
amount of vacant d - orbital the stronger will be the reactivity.
Diamonds are widely employed:
• As an abrasive element in polishing suspensions
• In grinding and cutting tools (as circular tools or saws) for processing of hard
materials ( like concrete, cemented carbides or natural stone ) ensures longer
tool life
Effects of Minor Additions:
Phosphorus(P) is added to certain compositions in order to lower the
melting point and surface tension
Tin(Sn) inhibits the graphitization of diamond
Addition of rare earths reduces metal oxides which enhances
densification, better sintering quality and an improved hardness degree
Advantages of diamond tools:
• Self sharpening characteristics of the segment i.e. proportional matrix and
diamond wear rate, provides recovered cutting efficiency. If matrix wears too
rapidly, diamonds get pulled out during service & if matrix wears too slowly,
diamond grit losses its cutting efficiency before detaching.
• Low comprehensive cost: The processing cost of each workpiece is lower
• Long lifespan, long dressing period: diamond’s extremely high thermal
conductivity removes heat from the cutting edge helps to extend tool life. This
can also greatly increase the work efficiency.
The performance of diamond cutting tools is based on diamond matrix adhesion strength,
retention capacity of the matrix and the tool workpiece compatibility.
CATEGORIES OF DIAMOND TOOLS:
Impregnated tools –
Diamonds are embedded in metal powder and are usually sintered by hot press
technique in graphite moulds
this composite is attached to steel core by brazing or laser welding
Matrixes of impregnated tools:
1) Cobalt based matrix
Cobalt(Co) based matrixes are widely employed due to its high hardness and
toughness, relatively low sintering temperature, remarkable low retention and
good abrasion resistance
Diamonds embedded in cemented carbides results in good adhesion with
composite due to presence of Co
High temperature WC is dispersed in the Co matrix for improvement of
mechanical properties
Use of Co powders are limited as they are highly toxic and expensive
2) Cobalt free matrixes
i) Copper (Cu) based matrix: Cu doesn’t form stable carbides due to its orbital
configuration. Additions in Copper used in cutting tools are as follows:
a) Cu-Sn alloys: It provides higher hardness but poor grit retention and does not show
any self-sharpening effect
b) Cu-Ti alloys: it leads to formation of TiC layer at the diamond matrix interface leading
to stronger adhesion
c) Addition of P causes significant decrease of M.P.
o If P content is less than 3%, sintering temperature decreases from 960° to
880°C
o If P content is 5- 7% , it results in brittleness due to formation of Cu3P
ii) Iron (Fe) based matrix: Coated diamonds should be employed. Fe is alloyed with Ni
which provides high hardness, high density and transverse rupture strength. SiC is added
to increase the abrasion resistance and for this purpose Fe-Cu-SiC alloys are used.
iii) Titanium based matrix: It improves adhesion between diamond and matrix by forming
titanium carbide at diamond surface. Due to its softness, Ni is added to harden the matrix
by formation of Ti2Ni.It also lowers the sintering temperature but if added in excess
causes porosity due to difference in diffusion coefficients of Ni and Ti.
Brazed tools-
single diamond layer brazed to steel core using filler phase( such as Cu, Ni or
Ag- based alloys)
comparatively, they have higher protrusion height and cutting speed and longer
tool life than impregnated tools
a template can distribute grits regularly thereby avoiding wastage & segregation
of diamonds within the matrix
filler phase should have relatively low M.P. and must adequately wet the diamond
to minimize damage
Matrixes in Brazed tools:

i) Cr-Ni Matrixes:
o Widely used as they show high toughness and heat resistance
o show excellent adhesion and good wetting properties due to formation
of Cr3C2 at the diamond metal interface
o TiC coated diamonds are employed to protect from graphitization
ii) Cu-Sn-Ti matrixes: More widely used due to lower M.P. than Ni-Cr matrix.
Small amount of Zr is added to increase the interfacial adhesion.At the
interface a) continuous layer and stoichiometric composition B) columnar
particles containing small particles of C. The wear resistance properties are
improved by dispersion of hard particles like Si3N4, TiC, Mo,W,SiC or WC. It
is most effective in diamond retention.
Electroplated tools-
A Ni matrix is bonded to tool substrate by electroplating and diamonds are
mechanically entrapped in the Ni layer
weak bonds between tool substrate & diamond results in low cutting speeds
and shorter service life
Conclusion:
i) In the processing of cutting tools, workpiece, metal matrix and diamond
interactions are considered.
ii) By using diamond metal interfaces in cutting tools the work efficiency and tool
life is significantly increased
iii) Sintering temperature of metal matrix plays an important role in designing
cutting tools as it influences diamond→ graphite reaction.
iv) Choice of additions to metal matrix depends on sintering conditions and desired
results.
v) Researches are carried out for replacing of Co as it is toxic and causes
environmental hazards
vi) The characteristics of metal matrix can be tuned by addition of minor amount of
other elements
Trend of hardness and toughness of metal Machinability and wear resistance of
Matrix vs diamond size different cutting tools
Micrograph of diamonds embedded in a Co/50% WC
Micrograph of diamonds embedded in a bronze matrix.

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Diamond–metal interfaces in

Basic requirements for matrix:

Reliable adhesion necessary for tools is achieved by appropriate interfacial

CATEGORIES OF DIAMOND TOOLS:

Matrixes in Brazed tools:

Micrograph of diamonds embedded in a Co/50% WC

Micrograph of diamonds embedded in a bronze matrix.

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