1. Polycrystalline Diamond (PCD)
We can provide a wide range of polycrystalline diamond (PCD) products to meet the demands of the precision cutting, oil & gas and hardrock mining industries.
PCD consists of micron-sized synthetic diamond powders bonded together by sintering at high pressures and temperatures. PCD is produced on a cemented carbide substrate, so as to provide a source of ‘solvent metal catalyst’ to aide sintering, typically cobalt. Under extreme pressures and temperatures, the cobalt from the cemented carbide substrate infiltrates through the layer of micron synthetic diamond powder, causing neighbouring grains to
Every tool material must combine sufficient toughness with wear resistance. However, features with increased toughness will invariably have lower wear resistance. As a result, materials must be engineered to meet the demands of specific applications. In the case of PCD, the properties of the composite are engineered partly by modifying the size of the constituent synthetic diamond grains. As the grain size increases, so too does the wear resistance, albeit at the expense of strength. By reducing the grain size to one micron or less, the wear resistance and strength may both be increased beyond what is possible with slightly coarser materials and this. Finer grain size materials are easier to mechanically grind and electric-discharge machine, and also provide a better workpiece surface finish in precision machining applications. Now we can make fine grain size PCD (2 micron, 1 micron, and sub-micron), which exhibits the highest wear resistance but due to a proprietary coarse-to-fine multi-modal grain size distribution, does not present the drawbacks of conventional coarse grain materials.
2. Polycrystalline Diamond Compact (PDC)
Polycrystalline diamond cutters (PDC) comprise a polycrystalline diamond (PCD) top layer integrally sintered onto a tungsten carbide substrate using a high-pressure, high-temperature process. This layer combination allows consistently high drilling performance to be maintained. The polycrystalline diamond layer offers controlled wear and the retention of a sharp cutting edge. The tungsten carbide substrate provides a strong and tough support for the polycrystalline diamond layer while facilitating attachment to the drill bit body.
3. Polycrystalline cubic boron nitride (PCBN)
Polycrystalline cubic boron nitride (PCBN) composites are produced by sintering micron CBN (cubic boron nitride) powders with various ceramics, so as to produce extremely hard and thermally stable tooling materials. Most PCBN materials are integrally bonded to a cemented carbide substrate. CBN is the second hardest material known after synthetic diamond, but has high thermal and chemical resistance properties. PCBN composites provide extreme resistance to deformation and wear at high temperatures – typically an order of magnitude better than the nearest ceramic materials.
About two thirds of all PCBN tools are used for the machining of hardened steels, offering a viable, more cost effective alternative to conventional grinding processes. Other applications are in the machining of hard, grey and high-strength cast iron, and cold and hot-work tool steels. The machining of nickel and cobalt-based superalloys is a significant and rapidly growing application area for PCBN.
We can provide PCBN products range from material with low to high CBN content. The chemical composition and microstructure greatly depending on the application. Lower CBN content materials tend to be more resistant to chemical wear mechanisms prevalent when continuously turning hardened steels. Where there are interrupts in the workpiece – oil-holes in a shaft, for example – a medium content grade is preferred, as it offers the best combination of wear resistance and toughness.
For applications where abrasion resistance is dominant, as in the machining of grey and hard cast irons, the high CBN grade (90) is the preferred choice. The high CBN grade also exhibits excellent thermal properties, and being available as solid (unbacked) materials, provides additional economic benefits. The high CBN grade is the workhorse grade for the roughing and finishing of brake discs and cast iron engine blocks, and typically outlasts ceramic tools by more than an order of magnitude, whilst operating at cutting speeds in excess of 2500 m/min.
4. Electrodeposited Diamond Wire Saw
Now, we can make the Ring Electrodeposited Diamond Wire Saw.
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