The performance of diamond tools also depends on the design of the binder. Ultrafine iron powder (particle size 1-20μm) becomes a key material by enhancing sintering activity and interface bonding strength. The addition amount of ultrafine iron powder is usually 5%-30% of the total mass of the binder, while cutting tools require 15%-25%, and precision grinding tools are reduced to 8%-12%. According to Sagwell's research, optimizing the particle size distribution of iron powder can reduce porosity and improve the stability of diamond tools when processing hard and brittle materials.
Under complex working conditions, ultrafine iron powder needs to work synergistically with metals such as copper, cobalt, nickel, tin, and zinc. When ultrafine iron powder accounts for 15%-18%, the thermal expansion coefficient of the matrix matches that of diamond, and the sintering stress is reduced by more than 30%.
Taking Sagwell's Fe-Cu-Co alloy powder as an example, 20%-30% of iron powder is combined with 30%-40% of copper powder, the bending strength reaches 1500MPa, and the diamond shedding rate is reduced by 25%.
The gradient particle size design (mixed with 1μm and 30μm) takes into account both density and toughness. Sagwell's ultrafine metal powder can extend the life of diamond tools by 10%-15%.
Diamond tool optimization requires a combination of materials and processes. When the ultrafine iron powder content exceeds 30%, the sintering pressure (≥50MPa) needs to be increased to suppress porosity; when processing superhard materials, 2%-3% chromium powder can be added. Sagwell verified through orthogonal experiments that the iron powder ratio and sintering temperature have a significant impact on performance. In the future, surface modification technologies (such as chemical nickel plating) may provide a more cost-effective solution for precision machining.
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