Influence of diamond parameters on microstructure and properties of copper-based diamond composites manufactured by Fused Deposition Modeling and Sintering (FDMS)

Abstract

As an additive manufacturing technology, Fused Deposition Modeling and Sintering (FDMS) technology can give diamond tools some creative structures to be applied in more fields. To explore the influence of diamond parameters on diamond tools manufactured by FDMS, copper-tin-diamond composite samples with different diamond concentrations and particle size were prepared by FDMS technology in this paper. During the study, the morphological characteristics of diamond particles inside the samples during the debinding and sintering process are summarized and the influence of diamond parameters on the mechanical properties and structure of the samples was further explored. These influence laws were also verified by cutting experiments. The results show that most diamond particles are in an incomplete coating state because of the volatilization of the binder. Meanwhile, a higher concentration of diamond will lead to more pores and cavities in the samples; and the cavities can be connected to form a large area of cavity zone by the print layer, thereby resulting in a serious loss in the performance of the samples. On the other hand, a small diamond particle size can lead to agglomeration of particles. Subsequently, this will result in void generation and regional weakening of the holding ability. However, agglomeration and some pores or cavities will increase the wear of the matrix, expose more diamond particles, and finally improve the cutting efficiency of the dicing blades when cutting sapphire crystal. Excessive wear may reduce the life of the diamond tool, but improved of sharpness can be better applied in the field of precision machining.