Abstract
Since the initial research leading to the production of diamond composite materials, there have been several important developments leading to significant improvements in the properties of these superhard composite materials. Apart from the fact that diamonds, whether originating from natural resources or synthesised commercially, are the hardest and most wear-resistant materials commonly available, there are other mechanical properties that limit their industrial application. These include the low fracture toughness and low impact strength of diamond. By incorporating a range of binder phases into the sintering production process of these composites, these critically important properties have been radically improved. These new composites can withstand much higher operating temperatures without markedly reducing their strength and wear resistance. Further innovative steps are now being made to improve the properties of diamond composites by reducing grain and particle sizes into the nano range. This review will cover recent developments in diamond composite materials with special emphasis on microstructural characterisation. The results of such studies should assist in the design of new, innovative diamond tools as well as leading to radical improvements in the productivity of cutting, drilling and sawing operations in the exploration, mining, civil construction and manufacturing industries.
Highlights
Diamond is one of the allotropic forms of carbon [1,2] and is renowned for its outstanding physical, chemical, electrical and mechanical properties
It is important to note that this study has been undertaken on commercially available diamond composite products using optical and scanning electron microscopy (SEM equipped with energy dispersive system - EDS), electron probe microanalytical analysis (EPMA equipped for cathodoluminescence (CL), wavelength (WDS) and energy dispersive systems) with additional observations being made using micro-focus X-ray shadow imaging, X-ray diffraction (XRD) and Raman spectroscopy (RS)
The matrix is supposed to be SiC produced during the reactive bonding process at HPHT conditions in the diamond stability field—see Figure 1. While variations to this compositional mix will become obvious in the results presented in this review, the responsibility for these variations rests with the suppliers and such variations can be interpreted as issues of quality assurance which is outside the control of researchers
Summary
Diamond is one of the allotropic forms of carbon [1,2] and is renowned for its outstanding physical, chemical, electrical and mechanical properties. These subsystems include: (a) the diamond grains themselves, (b) the binder phase or phases used in the sintering operation to form the composite and (c) the method of bonding the composite element into the body of the tool As cutting elements, these composites are subjected to severe abrasive/erosive wear regimes leading to the generation of high temperatures. Is the wear resistance of the composite critical to its operational performance but important is its thermal stability, thermal conductivity, impact resistance, thermal fatigue limit and fracture toughness These properties determine the suitability of diamond composite materials for cutting, drilling and sawing operations in the mining and civil construction industries. Using the newly developed solid TSDC and diamond composite coated WC cutting elements, the micromechanics of the cutting of brittle materials such as stone and rocks has necessitated the development of a more general phenomenological model of the macro chipping processes
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