Processing of Diamond Composites for Cutting Tools by Powder Metallurgy and Rotary Forging

This paper shows the manufacture route of the bronze 4% weight diamond composite rope for direct application as diamond wires, and linear saws in the slabbing and cutting of dimension stones. This route consists of powder mix compaction, sintering and rotary forging techniques. Tensile tests were performed, reaching an ultimate tensile strength of 230MPa for the diameter of ∅=1.84mm. Scanning electron microscopy showed the diamond crystals distribution along the composite rope during its manufacture, as well as the diamond adhesion to the bronze matrix. Cutting tests were carried out with the external cutting rope, showing a probable performance 4 times higher than the diamond sawing discs, however its probable performance was about 5 to 8 times less than the conventional diamond wires (pearl system) due to the low abrasion resistance of the bronze matrix, low adhesion between the pair bronze-diamond due to the use of not metallized diamond single crystals.