Abstract
Due to their excellent physical and mechanical properties, third-generation super-hard semiconductor materials (such as SiC, GaN) are used widely in the field of microelectronics. However, due to its ultra-high hardness, the machining is very difficult, which has become the bottleneck of its development. Slicing is the first machining procedure that directly affects the subsequent process. Fixed abrasive diamond wire saw (DWS) has been widely used in cutting hard and brittle materials. However, the diamond abrasives are attached to a core wire by resin or electroplated, that slicing super hard crystals is very difficult and inefficient. In order to improve the slicing efficiency, it is necessary to improve the holding strength and wear resistance of the DWS. The electro-spark deposition (ESD) process can deposit electrode materials on the substrate under the condition of low heat input to achieve metallurgical bonding between metal materials. And it can improve the wear resistance, corrosion resistance, and repair the size of the workpiece. It has been widely used in the field of surface modification engineering. It can effectively improve the bonding strength of the abrasive grains, and the sawing ability of the wire saw to make the consolidated DWS by the ESD process. Due to its thin matrix and poor thermal properties, the saw wire is easy to burning or even breaking in the manufacturing process. At present, the selection of pulse interval time in the ESD process is generally determined by the duty factor. However, the pulse interval time selected according to duty factor is difficult to meet the heat dissipation requirements of electro-spark deposition DWS (ESDDWS). In this paper, two kinds of motion modes of ESDDWS manufacturing are put forward, according to the manufacturing characteristics of ESDDWS. The boundary conditions of the continuous pulse discharge of ESDDWS are established. The thermal simulations of continuous pulse discharge of ESDDWS under two motion modes are analyzed. According to the simulation results, the basis of the value of pulse interval in the ESDDWS process is put forward. The effect of pulse interval time on the mechanical performance of the wire saw is analyzed experimentally. The results show that selected the discharge interval time base on the simulation results can ensure the continuous production of the ESDDWS.
Highlights
The third-generation semiconductor materials have the characteristics of a high breakdown field, great charge carrier saturation, and elevated dissociation temperatures
The selection of pulse interval time in the electro-spark deposition (ESD) process is generally determined by the duty factor
The pulse interval time selected according to duty factor is difficult to meet the heat dissipation requirements of electro-spark deposition diamond wire saw (ESDDWS)
Summary
The third-generation semiconductor materials (such as SiC and GaN) have the characteristics of a high breakdown field, great charge carrier saturation, and elevated dissociation temperatures. ESD is a deposition process in which the electrode material is deposited on the metal substrate by applying a short duration and high current pulse between cathode and anode [13, 14] It has become the new surface treatment technology that improves the wear resistance and corrosion resistance of workpieces. It is necessary to research the temperature field in the continuous pulse discharge of the ESDDWS process. There are little researches on the selection of pulse interval time in the ESD process It is determined mainly by the duty factor. According to the simulation results, the basis of determining the pulse interval time in the ESDDWS process was put forward. It is ignoring the change of electrode material consumption and wire surface material accumulation
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