CN1096531A - 制备磨料制品的方法 - Google Patents

制备磨料制品的方法 Download PDF

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CN1096531A
CN1096531A CN94108789A CN94108789A CN1096531A CN 1096531 A CN1096531 A CN 1096531A CN 94108789 A CN94108789 A CN 94108789A CN 94108789 A CN94108789 A CN 94108789A CN 1096531 A CN1096531 A CN 1096531A
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abrasive grain
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K·坦克
A·R·扎维斯
A·施图尔特
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De Beers Industrial Diamond Division Pty Ltd
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Abstract

本发明提供了一种使用通常的制品合成条件而 制备一种磨料制品的方法，该方法的特征在于，使用 超硬度磨料颗粒原料，它含有至少25％质量的，具有 平均粒度大小在10至100微米范围的超硬度磨料 颗粒，并且由具有至少三种平均颗粒大小不同的颗粒 组成，及，至少4％质量的磨料颗粒具有的平均颗粒 大小小于10微米。磨料制品优选一种金刚石制 品。

Description

本发明涉及一种制备磨料制品的方法。
磨料制品广泛地用于切削、研磨、磨削，钻削及其他研磨操作。磨料制品由大量的金刚石或立方体形的一氮化硼颗粒结合成粘附的多晶凝聚体而组成。组成磨料制品的磨料颗粒含量高，而且，一般，大量的是颗粒与颗粒的直接的结合。磨料制品一般在较高温度和压力条件下来制备，其中，作为磨料颗粒的是金刚石或立方体形的一氮化硼，它们在结晶学上是稳定的。
磨料制品有变脆的趋向，因此在使用时经常通过将其结合到烧结的碳化物基质物或者载体上而被支承，这种经过支承的磨料制品，在本技术领域中作为复合磨料制品是众所周知的了。复合磨料制品可以用作例如某种磨削工具的工作表面。
复合磨料制品的实例已被公开于美国专利说明书3，745，623，3，767，371及3，743，489中。
复合磨料制品一般是通过将颗粒形式的，形成磨料制品所必需的一些组分置于烧结的碳化物基质物上而制备的。将该尚未结合的组分放在反应皿中，然后，将此反应皿放在通常的高温/高压设备的反应区中。反应皿中的组份经受适当的较高压力和温度的处理。
美国专利4，861，350分开了一种工具元件，它包括一种结合于烧结的碳化物载体上的磨料制品，其中，该磨料制品具有二个区域， 该二区域通常通过联结的共同边界而连接。一个区域提供作为工具元件的切削边缘或凿头，而另一区域则连接在烧结的碳化物载体上。在工具元件的一种实施方案中，提供切削边缘或凿头的区域含有超硬度的磨料颗粒，该颗粒比在另一区域中的超硬度的磨料颗粒细。该专利没有公开使用不同颗粒尺寸的超硬度磨粒颗粒的混合物。
美国专利4，311，490公开了一种磨料制品，其中，该结合的磨料颗粒包括了一种粗的层和一种细的层。该专利也没有公开使用不同颗粒大小的磨料颗粒的混合物。
美国专利4，064，106公开了一种复合金刚石磨料制品，它包括至少一层金刚石结晶和预先烧结的碳化物部分，它们在加热与压力下被加压而生成一种复合多晶材料，其中，多晶金刚石和预先烧结的碳化物部分相互之间进行分散。在一种实施方案中，使用混合的金刚石颗粒，颗粒大小为4至8微米的占颗粒的65%，而在0.5至1微米的占颗粒的35%。
美国专利5，011，514公开了一种热稳定性的金刚石制品，它包括了许多独立的金属涂敷的金刚石颗粒，其中，在相邻颗粒之间的金属涂层相互连结而生成一种烧结的基体。金属涂层的实例是例如钨、钽、钼的碳化物形式。该独立的金属涂敷的金刚石颗粒在金刚石的合成温度和压力条件下而连结。该专利还公开了将金属涂敷的金刚石颗粒与未涂敷的较小尺寸的金刚石颗粒的混合，后者位于涂敷颗粒之间的空隙中。据称，该较小的颗粒会降低孔隙率并提高制品的金刚石含量。该专利还公开了双模式（即：二种不同颗粒大小）制品的实例，和三模式（即三种不同颗粒大小）制品的实例。
根据本发明，提供了一种制备磨料制品的方法，该方法包括将大量超硬度的磨料颗粒置于适于产生磨料制品的升高温度和压力的条件下的步骤，其特征在于，该制品包括至少25%质量的、含有平均颗粒大小在10至100微米的超硬度磨料颗粒，并且由含至少三种不同平均颗粒大小的颗粒所组成，而且，至少有4%质量的超硬度磨料颗粒具有平均颗粒大小为小于10微米。
本发明进一步包括利用该方法制备的磨料制品，并使用这种制品作为工具而嵌于用于钻削、车削或切削的基质物中。
图1和图2说明了利用本发明的制品和现有技术的制品所进行的比较实验的图。
超硬度磨料颗粒可以是金刚石或立方体形的一氮化硼，所优选的是金刚石颗粒。
该超硬度磨料颗粒混合物也可在已知的所必需的温度和压力条件下制备以生产磨料制品。这些条件一般是磨料颗粒自身所需要的合成条件。通常，所使用的压力在40至70千巴范围，所使用的温度在1300℃至1600℃的范围。
用本发明的方法所制备的磨料制品一般的并优选的含有粘结剂组分。对于所使用的超硬度磨料颗粒来说，该粘结剂优选的是一种催化剂/溶剂，对于金刚石和立方体形一氮化硼来说，该催化剂/溶剂是本技术领域中已知的了。在金刚石的情况下，粘结剂优选的是钴、镍、铁或含有一种或者多种这些金属的合金。
当使用粘结剂时，特别是在金刚石制品的情况下，当制备制品时，该粘结剂会渗入到大部分磨料颗粒中。为了这一目的，可以使用粘结剂的垫片或粘结剂层。另外，优选的是，该粘结剂是以颗粒 的形式并与大部分的磨料颗粒相混合。一般，该粘结剂将以占所制备的磨料制品的10至25%质量的含量来存在。
该磨料制品，特别是对于金刚石制品来说，一般是被结合到一种烧结的碳化物载体或基质物上来生成复合磨料制品。为了制备这种复合磨料制品，在为了制备制品而需要使其置于升高温度和压力的条件之前，应将大部分磨料颗粒放置在烧结的碳化物体的表面上。该烧结的，碳化物载体或基质物，可以是本技术领域中任意已知的组分，例如，烧结的碳化钨，烧结的碳化钽、烧结的碳化钛，烧结的碳化钼或其混合物。作为这类碳化物的粘结剂金属来说，可以是本技术领域中任意已知的，例如镍、钴、铁、或含有一种或多种这些金属的合金。一般，该粘结剂以10至20%质量的含量来存在，但是也可以低至6%质量，某些粘结剂金属在形成制品时，一般将渗入到磨料制品中。
本发明的方法，其特征在于是使用磨料颗粒混合物，该混合物至少含有4类平均颗粒大小互不相同的磨料颗粒。虽然有限数量的颗粒大小在指定的颗粒大小之上或之下，但是大多数颗粒却接近于指定的颗粒大小。颗粒分布的峰值将具有特定的大小。因此，例如，如果平均颗粒大小是50微米，则在混合物中的某些颗粒将大于50微米，而在混合物中的某些颗粒将小于50微米，而大多数颗粒大小将接近于50微米，其颗粒分布的峰值是50微米。为了接近峰值，使用了具有粗颗粒和细颗粒的颗粒范围，而且，当含有粘结剂时，则能够减少生成粘结剂集中的作用。优选的是，所有的颗粒是未经涂敷的。
在本发明的特性磨料颗粒混合物中，至少25%的磨料颗粒具有的平均颗粒大小在10至100微米范围，并且由至少三类平均颗粒大 小不同的磨料颗粒来组成。这种磨料颗粒混合物的实例如下（百分比含量是占全部磨料颗粒质量的百分比）
25至50微米  30至70%
15至24微米  15至25%
8至14微米  5至15%
在该特性混合物中，最小的磨料颗粒将具有小于10微米的平均颗粒大小，优选其平均颗粒大小在2至5微米范围，它在混合物中的含量为至少4%质量。一般，最小颗粒应以不超过12%质量的含量来存在。
现在，将说明本发明的实施例。将与钴粉（占混合物的20%质量）相混合的金刚石原料，置于在通常的高压/高温设备中的反应皿中的20%的钴烧结的碳化物基质物上。该反应皿被放于该设备的反应区中，并经受1400℃的温度和50至60千巴的压力，并在这种升高的温度和压力条件下保持10分钟时间。由反应皿中所收集的是由金刚石组分与烧结的碳化物基质物相结合而组成的复合金刚石制品，并发现钴是均一的，并且它通过所结合的金刚石原料进行均匀的分布，没有发现钴的汇集作用。
制备该制品所使用的金刚石原料，由占65%质量的30微米的金刚石，20%质量的22微米的金刚石，10%质量的12微米石金刚石和5%质量的4微米石金刚石所组成，每种微米尺寸都是平均颗粒尺寸。
除了所使用的金刚石颗粒仅由单一级别尺寸的金刚石颗粒（也就是25微米）组成之外，制备相似的复合金刚石磨料制品。在这种制品的情况下（指定为A）钴通过钴垫片渗入到金刚石原料中，而该钴垫片被放置在金刚石原料和烧结的碳化物基质物之间，在另一种产品的情况下（指定为B）钴粉与金刚石原料相混合。
将本发明的复合磨料制品与现有技术的二种复合磨料制品分别进行试验，并加以评价：
1.车削（Turning）试验-借助使用四种表面速度，在进行性能实验中对每类的4种制品进行评价，而且测量磨削至0.5mm时的时间（分）。时间越长，制品越好。所得的结果列于图1的图中。值得注意的是本发明的磨料制品（定名为四模式），超过二种现有技术制品所进行的实验。
2.成形机（Shaper）试验-在Norite花岗岩石上进行七种成形机试验。值得注意的是，与二种现有技术的制品相比较，本发明所制备的制品的散裂试验相当均匀而且散裂程度纸。
3.在标准的V一缺口韧性试验中，发现本发明的磨料制品比现有技术的二种制品好。
4.利用标准热膨胀试验，将本发明的制品与现有技术的B制品相比较，在该试验中，将制品层由烧结的碳化物基质物中除去，并将所有的残余碳化物经磨光而除去。由每种制品层切下试样，并在氩气氛下将试样放在膨胀仪上。在一种试验中，将温度升高到750℃，而在另一试验中，将温度升高到800℃，在观察到永久膨胀之前，以小时为单位测量时间。永久膨胀表示石墨化作用的开始。所得到的结果列于图2的图示中，在该图中，永久膨胀用快速增大的膨胀系数来表示。
应该注意到，在800℃下，本发明的制品达到永久膨胀的阶段比B制品晚。在750℃下，45个小时之后，没有观测到永久膨胀，B制品在大约41个小时则显示出永久膨胀。
该实验说明，本发明的制品与现有技术的B制品相比，具有较好的颗粒填密性，和较少的钴汇集作用。

Claims (11)

1、一种制备磨料制品的方法，它包括将大量超硬度磨料颗粒在适于制备磨料制品的升高温度和压力下处理的步骤，其特征在于，原料包括至少25%质量的其平均颗粒大小在10至100微米范围内的超硬度磨料颗粒，并由至少三种平均颗粒大小不同的颗粒所组成，而至少有4%质量的超硬度磨料颗粒具有的平均颗粒大小于10微米。
2、一种根据权利要求1所说的方法，其中，具有平均颗粒大小在10至100微米的超硬度磨料颗粒原料具有下列组成：
磨料颗粒大小（微米）  占磨料颗粒原料的质量百分比%
25-50  30-70
15-24  15-25
8-14  5-15
3、一种根据权利要求1或权利要求2所说的方法，其中，在磨料颗粒原料中最小的磨料颗粒具有的平均颗粒大小在2至5微米的范围。
4、一种根据前述任一权要求所说的方法，其中，在磨料颗粒原料中最小的磨料颗粒含量为4至12%质量。
5、一种根据前述任一权利要求所说的方法，其中，当将原料置于升高温度和压力的条件下时，可使粘结剂渗入到超硬度磨料颗粒原料中去。
6、一种根据前述任一权利要求所说的方法，其中，将粘结剂与大部分超硬度磨料颗粒相混合。
7、一种权利要求5或权利要求6所述的方法，其中，粘结剂对于超硬度磨料颗粒来说是一种溶剂/催化剂。
8、一种根据权利要求7所说的方法，其中，磨料颗粒是金刚石，而粘结剂选自钴、镍、铁及含有一种或多种这些金属的合金。
9、一种根据前述任一权利要求所说的方法，其中，在进行升高温度和压力的条件之前，将大部分超硬度磨料颗粒置于烧结碳化物体的表面上。
10、一种根据前述任一权利要求所说的方法，其中，升高温度和压力条件是压力在40至70千巴及温度是在1300至1600℃的范围。
11、一种根据前述任一权利要求所说的方法，其中，超硬磨料颗粒是未涂敷的。
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