Common Quality Problems And Solutions Of Diamond Segments

The following situations are prone to quality problems for diamond segments:

There is a problem with the size specification of the segment
Although the diamond segment is a mixture of metal alloy and diamond sintered in a fixed mold, the final product is completed by cold pressing and hot pressing sintering, and the material is relatively fixe. But due to the insufficient sintering pressure and sintering temperature during the machining process of the segment, or in the sintering process, the temperature and pressure of heat preservation and pressure are insufficient or too high, which will cause uneven force on the segment.So there will be a reason for the difference in the size and specification of the segment. The most obvious one is reflected in the height of the segment,the height of diamond segment will be more higher if the pressure is insufficient;But the height of segment will be lower if the pressure is too high. Therefore, in the production process, it is very necessary to stabilize the same pressure and temperature. In addition, in the pre-loading process, the cold pressing material of the diamond segment should also be weighed; Also pay attention not to take the wrong mold, there is a situation where the diamond segment is scrapped, such as the size of the diamond segment does not meet the requirements, the density is not enough, the hardness does not meet the requirements, the transition layer has impurities, and the strength of the segment is not enough.

The density is not enough, the segment is soft
In the process of cutting stone with a dense and soft segment, the problem of segment breakage will occur. The breakage is divided into local breakage and overall breakage. No matter which kind of breakage, such a segment cannot be reused. Of course, the breaking of the segment is the limit. When the segment with insufficient density is cutting the stone, it will not cut due to its insufficient Mohs hardness, or the segment will be consumed too fast. In general, the density of the segment must be guaranteed.

This kind of situation is generally caused by the sintering temperature, holding time, insufficient pressure, wrong choice of binder material, Too much diamond powder content in the segment, etc. This kind of situation is very common, and it will also appear in old formulas. The general reason is the improper operation of the workers, and if it is a new formula, most of the reasons are caused by the designer's lack of experience of the formula.Designers need to make better adjustments to the segment formula, and combine the temperature and pressure to give a more reasonable sintering temperature and pressure.

The segment cannot cut the stone
The main reason why the diamond segment cannot cut the stone is because the strength is not enough, and the strength is not enough mainly for the following five reasons:

1: The diamond is not enough or the selected diamond is of poor quality;

2: Impurities such as graphite particles, dust, etc. are mixed in the segment during mixing and charging, especially during the mixing process, uneven mixing will also cause this situation;

3: The diamond is excessively carbonized and the temperature is too high, resulting in serious diamond carbonization. During the cutting process, the diamond particles easily fall off;

4: The formula design of the segment is unreasonable, or the sintering process is unreasonable, resulting in low strength of the working layer and the transition layer (or the working layer and the non-working layer are not tightly combined), which usually occurs in new formulas;

5: The segment bond is too soft or too hard, resulting in a disproportion between the consumption of diamond and the metal bond, which make the diamond matrix bond cannot hold the diamond powder.

The segment falls off
There are many reasons for the segment to fall off, such as too many impurities, too high or too low temperature, too short heat preservation and pressure holding time, inappropriate formula ratio, unreasonable welding layer, the difference in working layer and non-working formulations which leads to different coefficients of thermal expansion of the two. When the segment is cooled, shrinkage stress occurs at the connection between the working layer and the non-working layer, which eventually leads to a decrease in the strength of the segment, then eventually causes the segment to fall off and so on. These reasons are all the reasons for the diamond segment to fall off or the saw blade to lose teeth. To solve these problem, first ensure that the powder is fully stirred and free of impurities, match a reasonable pressure, temperature, heat preservation time, and then try to ensure that the thermal expansion coefficients of the working layer and the non-working layer are close to each other.

When the diamond segments are in the process of processing stone, Other problems may also arise, such as excessive consumption, jamming, such as eccentric grinding, etc. Many problems are not only the problem of the segment, but may be related to machinery, stone types, etc. factor related.