What should we do if the diamond segment is not welded firmly?

Diamond segment and the saw balde blank are finally combined into one through the welding process to become the diamond saw blade. In this process, the firmness of the welding is very important. There are different ways of welding, usually we are divided into flame welding, high frequency welding and laser welding. Below we will introduce these three different welding methods respectively.
Flame welding; Flame welding is a welding method used by people in the early days. During this period, people used flame spray guns to continuously heat the teeth of the saw blade blank, solder and segments. Skilled operators gradually master the size of the flame of the spray gun, the distance between the flame and the sawtooth, and the heating time of the flame, and finally judge according to the familiar experience and the state of the segment for many years, and finally complete the welding according to manpower.

Undoubtedly, there will be some problems in this simple and rough heating process. The first thing to face is the problem that the welding of the segment is not firm. This welding method is often determined according to the experience and proficiency of the welding master. 80%-90% is qualified, while the success rate of new welding masters may be less than 50%. This welding method is almost impossible to weld firmly, mainly because manual welding requires long-term accumulation to achieve precision and refinement in the welding process. And novices cannot ensure these, which will lead to welding the quality varies. This method of flame welding can hardly change its firmness, because the fundamental problem (arbitrary and unstable welding) makes the firmness impossible to guarantee.

High-frequency welding; This is the focus of this article. High-frequency welding is currently the most popular and widely used welding method in the market. In order to improve the firmness of the segment, high-frequency welding is usually improved in the following ways

1. Using more than 35% silver solder for welding will be much better than using silver-copper solder or copper solder, especially for some marble saw blades, using silver solder can significantly improve sawing stability and prevent saw blades from tooth loss, to avoid many poor cutting problems (such as edge chipping, cutting a lot of debris).

2. At the same time as the soldering piece is selected, some solder pastes can be selected for use together. If some have a better function of deoxidizing during the welding process, this will avoid the oxidation of the segment or the saw balde blank and cause the final welding to be weak.  In addition, the solder paste can better enhance the connection strength between the solder piece and the substrate and the segment.

3. Choose a welding machine with higher power. Generally speaking, high-frequency welding machines can perform normal welding regardless of the temperature. However, in the actual product selection process, if the power of the high-frequency welding machine is too low, the welding time will be too long. If the heating time is long, the situation will become complicated, such as oxidation of the segment and bubbling of the weld seam. However, if the frequency of the welding machine is higher, the heating time will be shorter, the welding speed will be higher. The welding efficiency will be improved, and the welding strength and welding stability will be improved. If possible, try to choose a higher power welding machine, 45KW, 55KW welding machine power has better performance.

4: Choose a high-precision automatic welding machine. There are many kinds of high-frequency welding machines. Often the precision and degree of automation greatly improve the stability of the welding of the diamond segment. The high precision solves the problems of the welding angle and welding surface of the diamond segment. The degree of automation can maintain the welding stability of each segment. Both of these aspects determine the firmness of the welding of the segment.
Laser welding. Laser welding is actually a very advanced welding method. In addition to the high cost of this welding method, the welding strength is much higher than the above two types of welding methods, but there is still room for improvement in laser welding, For example, the area of laser welding points, the number of welding surfaces and the speed of rapid temperature increase all determine the firmness of laser welding，and the follow-up will specifically address the issue of laser welding.

Generally speaking, the weak diamond welding is mainly caused by the lack of experience of the operators, the welding materials are not good enough, and the welding machinery is not advanced enough. There are also many solutions. According to different needs, the quality of welding materials should be improved as much as possible during the welding process, the welding technology should be continuously improved, and the problem can be solved by choosing a more reasonable welding machine.