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Fabrication of Complex Shaped Diamond Tools Via Powder Injection Moulding

PM2010 WORLD CONGRESS

Florence, 10-14 October 2010

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Fabrication technologies

Hot pressing: advantages and drawbacks

Electroplating: advantages and drawbacks

Pressureless sintering: advantages and drawbacks

HIP: advantages and drawbacks

DIM technology

Advantages

Still to improve:

•Powders

•Equipments

•Modelling

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Traditional Technologies

ElectroplatingHot pressing

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Sintering furnaces set

Traditional Technologies

Hot isostatic pressing

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Powder Binder

Feedstock

DIM

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Injection Moulding

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Metal Powder

Temporary binder

Backbone binder

Debinding

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Pressureless sintering

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DIM MATERIALS

TypicalVolume loading

Typical Viscosity

(Pa*s)100°C 100 s-1

Sintering temperature Typical

final density

Cobalt 45-50% 150-160 850-950°C 98%

Cobalt/WC 44-47% 170-180 950-1000°C 93-97%

Cobalt/Bronze 44-60% <100 840-900°C >98%

Cobalt/Iron 45-50% 150-160 900-950°C 97%

Cobalt/IronBronze

45-50% 120-130 850-950°C 93-97%

NEXT 400 45-50% 230-250 900-950°C 97-98%

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Equipments: Granulation and Moulding

Still to improve

Powders: Variety and Grades

Research: Modelling

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

diamond pauber & MIMITALIA Info@mimitalia.c

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DIM is a trade mark

diamond pauber & MIMITALIA Info@mimitalia.c

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DIM is a trade mark

diamond pauber & MIMITALIA Info@mimitalia.c

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DIM is a trade mark

diamond pauber & MIMITALIA Info@mimitalia.c

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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DIM is a trade mark

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GradeDiamond

(40/60 mesh)

Co Cr SiO2 W WC WC/W2C WC-6%Co Total

Granite, harder (GH) 9.9% 83.5% 1.2% 0.0% 1.1% 1.3% 2.1% 0.9% 100.0%Granite, softer (GS) 9.6% 85.5% 1.2% 0.0% 1.1% 1.1% 0.8% 0.9% 100.0%Marble, soft (MS) 7.8% 87.2% 0.0% 4.1% 0.0% 0.8% 0.0% 0.0% 100.0%

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MATERIALS Class Block Length

Block Height

SLATEm2

FEED cm/h

Vs m/sec

Brown Chocolate

4 287 187 5,37 16 29

Kashmir Gold 1 344 198 6,81 35 31

New Bengal Black

3 312 190 5,93 20 29

Emerald Pearl

1 335 187 6,26 26 28

Absolute Black

3 337 140 4,72 20 29

Vizag Blue 2 277 204 5,65 35 30

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Traditional bead•Yield 7 m2/m•Feed 19 cm/h•Multiple re assembling

Monolithic bead•Yield 9 m2/m (present)•Feed 25 cm/h•No re assembling

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•A new process based on Diamond Injection Moulding has been developed and patented. The process allows to produce tools with intricate geometries not possible to make so far

•With the new process a innovative monolithic diamond bead has been produced and tested in a full scale plant

•Yield can be improved more than 50%, with a 25% higher feed

Conclusions