Research Progress of Filler Metals for Brazing Diamond Tools
LONG Weimin1,2,†, HAO Qingle1,†, FU Yucan3, HUANG Guoqin4, WU Mingfang5, WANG Yuchang6
1 State Key Laboratory of Advanced Brazing Filler Metals and Technology, Zhengzhou Research Institute of Mechanical Engineering Co. Ltd., Zhengzhou 450001, China 2 China Innovation Academy of Intelligent Equipment Co., Ltd., Ningbo 315700, China 3 College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 211106, China 4 Institution of Manufacture Engineering, Huaqiao University, Xiamen 361021, China 5 School of Materials Science and Engineering, Jiangsu University of Science and Technology, Zhenjiang 212003, China 6 Henan Huanghe Whirlwind Co., Ltd., Xuchang 461500, China
Abstract: Because of its highest hardness among all known materials, diamond is especially suitable for cutting and grinding hard materials such as glass, stone, ceramics and so on. Diamond tools have been utilized in area of automobile manufacturing, mechanical engineering, oil drilling and military industries since the first synthetic diamond was successfully made in 1954. Diamond grits, which are very small with irregular shape, have to be bonded with the metal substrate. There are mainly three methods for diamond tools preparation. They are electroplating, sintering and brazing. Compared with electroplating and sintering, brazing can join diamond grits and metal substrate at higher temperature. The brazing filler metal is the medium between the two things, which is helpful for the diamond retention. As a result, brazed diamond tools have advantages of high exposure height and outstanding sharpness. Diamond grits feature low reactivity at ambient temperature. In order to design excellent brazing materials, researchers conducted research on the interaction between diamond and metal. They found that the number of vacancies in the 3d electron orbits of transition metal determines the interaction behavior with diamond. With respect to their behavior towards carbon, transition metals can be roughly divided into three groups: non interacting metals, graphitization catalyzer, and carbide former. Titanium (Ti), chromium (Cr), vanadium (V), zirconium (Zr) can actively react with carbon of diamond to form carbides, which can realize the firm holding of diamond particles. However, these active elements have high mel-ting temperature. High temperature leads to graphitization of diamond. In order to decrease the melting temperature of the brazing filler metal, the three types of transition metals mentioned above are often used in combination. At present, filler metal for brazed diamond tool mainly includes Ag-Cu-Ti, Cu-Sn-Ti and Ni-Cr. Ag-Cu-Ti provides the lowest melting temperature as well as tensile strength and wear resistance. Ni-Cr provides the highest. In recent years, researchers have conducted many studies on the function of these brazing filler metals in the diamond brazing process. Results showed that the active elements make diamond and metal substrate metallurgically bonded through reactive wetting. This is a complex process with cross diffusion of elements. The type, morphology, quantity and distribution of reactants strongly depend on the process conditions. The molten filler metal causes damage of diamond grits through heat transfer and catalyzer attack. In order to reduce the damage of diamond, researchers optimized the composition of brazing filler metal, adjusted the content of active elements. The melting temperature of filler metals was successfully decreased by addition of indium, phosphorus, rare earth element into present filler metal. The other new way to decrease the melting temperature of one certain filler metal is fabrication its amorphous counterpart. Ni-Cr brazing filler metal was paid great attention in the past several year with the application of high-efficiency brazing methods such as laser brazing. Laser welding is characterized by fast heating and cooling. The interface between diamond and brazing filler metal is prone to cracking under rapid thermal cycling conditions. The cracking behavior was believed to be related to the mismatch of the thermal expansion coefficient of diamond and brazing filler metal. The strengthening and toughening mechanism remains to be explored in the future. In this work, the brazing characteristics of diamond grits are introduced and the principles of designing the filler metals for diamond tools are explained. Then we discusses jointing mechanism between diamond grits and metals. The current research on Ag-Cu-Ti, Cu-Sn-Ti, Ni-Cr brazing filler metals are paid the most attention. Besides, some novel filler metals emerged in recent years are evaluated, and suggestions on the future fundamental research are made.
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2020, Vol. 34 
