CN107866740A - 硅聚晶烧结物及其制造方法 - Google Patents
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Abstract
本发明涉及一种制作硅聚晶烧结物的方法,其包括将单晶钻石、及含有硅粉及金刚石粉末的混合物的硅聚晶钻石复合材料微粉分别置于模具的相连的第一凹室及第二凹室中,在高温高压下将该单晶钻石及该硅聚晶钻石复合材料微粉烧结,以形成硅聚晶烧结物。
Description
技术领域
本发明涉及一种可应用于作为修刀的修锐砂轮用的硅聚晶烧结物的制造方法。
背景技术
目前用于修整砂轮的钻石修整器等刀具的常见结构,主要是将钻石(金钢石)结合于于金属基材,钻石及金属基材间经由焊接,以金属黏着剂(焊剂)相互黏结。金属与钻石皆是耐热性佳的材质。刀具在操作过程中通常会产生高热。然而,由于金属黏着剂在高温时易融化,这种刀具在高温操作时容易在金属与钻石的接触面附近断裂。
使用焊接也有润湿性能及粘结性能的缺点。传统上都是使用钎焊。然而,钎焊时,钎料必须润湿被焊材料才能保证焊接部位无缺陷。由于钻石的表面能很高,润湿性差,因此找到对于钻石和金属基体表面均具有良好润湿性的钎料是钎焊成功的关键。
金刚石与金属的热膨胀系数相差近十倍,在焊接后的冷却过程中会形成很大的残余应力,从而影响焊接强度甚至损坏金刚石。
使用焊接另有金刚石的腐蚀的问题。金刚石在高温下会氧化或石墨化,某些金属对金刚石还具有侵蚀作用,因此必须选择合适的工作环境与钎料,将金刚石的腐蚀现象减小到最低程度。
因此,有必要提供一种刀具,不但可以提供较传统刀具更佳的耐热性,也能解决前述的润湿性能、粘结性能、残余应力及金刚石的腐蚀的问题。
发明内容
根据本发明,刀具是以单晶钻石作为切削端,而以硅聚晶钻石复合材料为基材。两者是经由烧结使硅聚晶钻石复合材料的硅原子包覆钻石分子而相互固定,并不需要黏着剂,所制成刀具可以可耐极高的温度。
聚晶钻石(Polycrystalline Diamond;PCD)是一种导热性佳、硬度高、耐磨性佳等优点的材料,可在切削中获得很高的加工精度和加工效率。硅聚晶钻石(SiliconPolycrystalline Diamond;SiPCD)复合材料的做法是将硅粉及金刚石微粉混合,置于模具中,以高温高压压制而成。
单晶钻石,例如含硼单晶钻石,不仅非常耐磨,更具有极佳的耐热性。另一方面,单晶钻石的热传导率倍优于聚晶钻石。
因此,本发明使用单晶钻石(例如含硼单晶钻石)作为切削端,结合于硅聚晶钻石复合材料。两者间利用烧结而产生化学键结,因而相互固定,即使在高温操作下,化学键结也不会破坏,并不需要传统刀具所使用的金属黏着剂,切削端与基材之间却有更高的结合力。另一方面,作为切削端的单晶钻石有高热传导性,能将切削加工时产生的热迅速传导至同样具有耐高温特性的硅聚晶钻石复合材料。
本发明的工艺,不需做钻石表面改性处理,且仅会产生较小的应力,更不用提金属对钻石结合时会造成的其他问题。最大的优点则是因为硅(Si)耐高温的特性,可以把工作时产生的热经由钻石的高热传导率传到硅上来保护钻石。本发明制成的硅聚晶烧结物,不但可以提供较传统刀具更佳的耐热性,也能解决前述的润湿性能、粘结性能、残余应力及金刚石的腐蚀的问题。
本发明的前述及其他优点,将可经由以下实施方式说明而进一步了解。
附图说明
图1A及1B是本发明的硅聚晶烧结物的示意图。
图2A至2C是本发明的硅聚晶钻石复合材料微粉中的硅粉与单晶钻石中的碳离子产生共价键结的示意图。
图3A及3B是本发明的用于制造本工艺的模具的外观的实施例。
图3C及3D是本发明的图3A及3B的模具内的结构的实施例。
具体实施方式
图1揭露本发明的硅聚晶烧结物100的一实施例,其包括:单晶钻石110,优选为含硼单晶钻石;经烧结的硅聚晶钻石复合材料基材120,其于接合部130接合该单晶钻石的110一部分,并将该单晶钻石固定;其中该单晶钻石110与该经烧结的硅聚晶钻石复合材料基材(120)之间的接合及固定,是经由将单晶钻石110与硅聚晶钻石复合材料微粉,经高温高压下进行的烧结反应,于两者之间的接合部所形成的化学键结来达成。
前述烧结反应工艺,简而言之,是于常温常压下将硅聚晶钻石复合材料微粉与单晶钻石110放在一起,两者间以一接合部保持接触,之后同时予以高温高压烧结。硅聚晶钻石复合材料微粉为包括硅粉及金刚石粉末的混合物。如图2A、2B、2C所示,在高温高压下,硅聚晶钻石复合材料微粉中与单晶钻石110接触的硅粉,于高温下融化(约为1,414℃),其硅(Si)离子经烧结反应与单晶钻石110中的碳(C)离子产生共价键结(SiC),该共价键结沿着接合部表面包围于单晶钻石110钻石分子外,因而使单晶钻石(110)与经烧结的硅聚晶钻石复合材料基材120相互固定。其余硅聚晶钻石复合材料微粉烧结成硅聚晶钻石复合材料基材120。化学键结可耐高温,即使在高温操作下,化学键结也不会破坏,因而,单晶钻石110与该经烧结的硅聚晶钻石复合材料基材(120)之间的固定非常稳固,所制成的硅聚晶烧结物,不易因高温操作而崩解断裂。
根据本发明,制成的硅聚晶烧结物尺寸,从底部到单晶钻石(110)的总长度可达10mm。
图3A、3B是用于制造本工艺的模具的外观的实施例,而图3C及3D是模具内的结构实施例。如图3A、3B、3C及3D所示,模具内有相连的第一凹室140及第二凹室150。第一凹室140优选具有符合单晶钻石110尺寸的轮廓。第二凹室150的实施例为细长形且具有一预定形状的剖面,如图3A所示的矩形或图3B所示的三角形。第一凹室140可用来置放/固定一或多颗单晶钻石110,而第二凹室150用来置放硅聚晶钻石复合材料微粉。装填单晶钻石110及硅聚晶钻石复合材料微粉时,是先放置单晶钻石110于第一凹室140的位置中,之后将硅聚晶钻石复合材料微粉填满于第二凹室150。又如图3D所示,在另一实施例中,可将多颗单晶钻石110以成串的整排单晶钻石结构置入第一凹室140及第二凹室150,其中,该整排单晶钻石仅有其末端的一颗单晶钻石110位于第一凹室140,而其他单晶钻石111位于第二凹室150。如此,若制成的硅聚晶烧结物于使用一段时间后,当该最末端露出的单晶钻石110磨耗完毕时,可再经由修磨最末端,使第二颗单晶钻石111露出使用。
根据前述说明,本发明揭露的制作硅聚晶烧结物的方法,包括:(1)提供单晶钻石;(2)提供硅聚晶钻石复合材料微粉,该硅聚晶钻石复合材料微粉为包括硅粉及金刚石粉末的混合物;(3)提供模具,该模具具有对应该聚晶烧结物的形状的模洞,该模洞包括用来固定该单晶钻石的第一凹室140、及供容置该该硅聚晶钻石复合材料微粉的第二凹室150,其中该第一凹室与该第二凹室相连;(4)将单晶钻石置于该第一凹室140中;(5)将该硅聚晶钻石复合材料微粉置于该第二凹室150中;(6)在高温高压下将该单晶钻石及该硅聚晶钻石复合材料微粉烧结,以形成硅聚晶烧结物。
前述步骤4中,如果是使用排列成串的整排单晶钻石,则将其末端的一颗单晶钻石110置于第一凹室(140),而其他单晶钻石111置于第二凹室150。
本发明前述优选实施例说明,仅是例示性,其目的并非在限制本发明的特征。任何具有权利要求所列特征的工艺或产品,均应认属落入于本发明所界定的保护范围。
Claims (6)
1.一种制作硅聚晶烧结物的方法,包括:
1)提供单晶钻石;
2)提供硅聚晶钻石复合材料微粉,所述硅聚晶钻石复合材料微粉为包括硅粉及金刚石粉末的混合物;
3)提供一模具,所述模具具有对应所述聚晶烧结物的形状的模洞,所述模洞包括相连的第一凹室及第二凹室;
4)将所述单晶钻石置于所述第一凹室中;
5)将所述硅聚晶钻石复合材料微粉置于所述第二凹室中;
6)在高温高压下将所述单晶钻石及所述硅聚晶钻石复合材料微粉一起烧结,以形成硅聚晶烧结物。
2.如权利要求1的方法,其中所述单晶钻石为含硼单晶钻石。
3.一种制作硅聚晶烧结物的方法,包括:
1)提供排列成串的多颗单晶钻石;
2)提供硅聚晶钻石复合材料微粉,所述硅聚晶钻石复合材料微粉为包括硅粉及金刚石粉末的混合物;
3)提供模具,所述模具具有对应所述聚晶烧结物的形状的模洞,所述模洞包括相连的第一凹室及第二凹室;
4)将所述排列成串的多颗单晶钻石置于所述模洞中,其中所述排列成串的多颗单晶钻石的一末端的单晶钻石位于所述第一凹室中,所述排列成串的多颗单晶钻石的其余单晶钻石位于所述第二凹室中;
5)将所述硅聚晶钻石复合材料微粉置于所述第二凹室中;
6)在高温高压下将所述排列成串的多颗单晶钻石及所述硅聚晶钻石复合材料微粉一起烧结,以形成硅聚晶烧结物。
4.如权利要求3的方法,其中所述多颗单晶钻石为含硼单晶钻石。
5.一种硅聚晶烧结物,包括:
单晶钻石;
经烧结的硅聚晶钻石复合材料基材,其接合所述单晶钻石的一部分并将所述单晶钻石固定;
其中所述单晶钻石与所述经烧结的硅聚晶钻石复合材料基材之间的接合,是经由将单晶钻石与硅聚晶钻石复合材料微粉于高温高压下进行的烧结反应所形成。
6.如权利要求5的硅聚晶烧结物,其中所述单晶钻石为含硼单晶钻石。
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JP2013245126A (ja) * | 2012-05-24 | 2013-12-09 | Sumitomo Electric Ind Ltd | 多結晶ダイヤモンド砥粒およびその製造方法、スラリー、並びに固定砥粒式ワイヤ |
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