Mechanical Alloying of Copper- or Iron-Based Metallic Binders for Diamond Tools

Abstract

Powder mixtures based on copper or iron are used as metal binder materials in the manufacturing of abrasive and cutting tools. This article discusses some aspects and possibilities of using a high-energy ball milling process to modify the structure and properties of Cu-Sn, Cu-Sn-Ti and Fe-Ti powders, their sintered materials and composites with diamond. The structures of powders and sintered materials, as well as the binder-to-diamond interfaces in metal matrix composites with diamond fillers, were studied by XRD analysis, scanning electron microscopy and X-ray spectroscopy. Tribological properties and thermal stability of materials in the temperature range of 250–800 °C were investigated. Various mechanisms of dispersion strengthening during the heating of sintered materials are described. It is shown that due to the grain boundary distribution of titanium, it is possible to obtain single-phase powders in the form of a supersaturated solid solution of CuSn20Ti5 and FeTi20, which ensure the formation of thermally hardened alloys with a microhardness of 357–408 HV and 561–622 HV, respectively, in the temperature range of 350–800 °C. The wear resistance of sintered powder alloys increases more than twice. Furthermore, the simultaneous enhancement in both the strength and ductility of metal–diamond titanium-containing composites is achieved through the nanostructural state and the formation of a thin layer (up to 2 μm) of titanium carbide at the interface between the metal matrix and diamond. The developed alloy shows great potential as a binder in diamond tools which are designed for machining abrasive materials.