CN1096532A - 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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CN1096532A
CN1096532A CN94108790A CN94108790A CN1096532A CN 1096532 A CN1096532 A CN 1096532A CN 94108790 A CN94108790 A CN 94108790A CN 94108790 A CN94108790 A CN 94108790A CN 1096532 A CN1096532 A CN 1096532A
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abrasive grain
exceptional hardness
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hardness abrasive
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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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
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    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
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    • B24D3/08—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for close-grained structure, e.g. using metal with low melting point
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    • B01J3/00—Processes of utilising sub-atmospheric or super-atmospheric pressure to effect chemical or physical change of matter; Apparatus therefor
    • B01J3/06—Processes using ultra-high pressure, e.g. for the formation of diamonds; Apparatus therefor, e.g. moulds or dies
    • B01J3/062—Processes using ultra-high pressure, e.g. for the formation of diamonds; Apparatus therefor, e.g. moulds or dies characterised by the composition of the materials to be processed
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    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
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    • B01J2203/06—High pressure synthesis
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    • B01J2203/062—Diamond
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2203/0685—Crystal sintering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
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    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B10/00—Drill bits
    • E21B10/46—Drill bits characterised by wear resisting parts, e.g. diamond inserts
    • E21B10/56—Button-type inserts
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Abstract

提供一种制备磨料制品，特别是金刚石磨料制品 的方法。该方法使用通常的制品制备条件并且其特 征在于，所使用的大部分磨料颗粒具有小于20微米 的平均颗粒大小，并由具有至少三种平均颗粒尺寸不 同的颗粒所组成。

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。磨料制品一般在升高温度和压力的条件下来制备，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3745623，3767371及3743489中。
复合磨料制品一般是通过将颗粒形式的、形成磨料制品所必须的一些组分置于烧结的碳化物基质物上而制备的。将该尚未结合的组合放在反应器中，然后，将此反应器放在通常的高温/高压设备的反应区中。反应器中的组份经受适当的较高压力和温度的处理。
美国专利4861350公开了一种工具元件，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，而另一区域则连结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料颗粒的混合物。
美国专利4311490公开了某种磨料制品，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4064106公开了某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5011514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。该专利还公开了混合的金属涂敷的金刚石颗粒与未涂敷的较小尺寸的金属涂敷的金刚石颗粒，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，其特征在于大部分超硬度磨料颗粒具有的平均颗粒大小小于20，优选小于15微米，并且由具有至少三种平均颗粒大小不同的颗粒所组成。
本发明进一步包括利用该方法而制备的磨料制品，并使用这种制品作为工具而嵌入用于钻削，车削或切削的基质物中。
图1和图2说明利用本发明的制品和现有技术的制品所进行的比较试验的图。
超硬度磨料颗粒可以是金刚石或立方体形的一氮化硼，但优选的是金刚石颗粒。
超硬度磨料颗粒混合物也可以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，及所使用的温度在1300℃至1600℃的范围。
用本发明的方法所制备的磨料制品一般并优选含有某种粘结剂组分。对于所使用的超硬度磨料颗料来说，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磨料颗粒相混合。一般该粘结剂将以占该制备的磨料制品的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，应将大部分的磨料颗粒放置于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的任意的已知的组分，例如，烧结的碳化钨、烧结的碳化钽烧结的碳化钛、烧结的碳化钼或者它们的混合物。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、铁或含有一种或者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，一般会渗入到磨料制品中。
本发明的方法，其特征在于是使用磨料颗粒原料。该原料含有至少三种类型的、其平均颗粒大小互相不同的磨料颗粒。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，大多数颗粒都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10微米，则某些颗粒将大于10微米，而某些颗粒将小于10微米。但多数颗粒大小将接近于10微米，其颗粒分布的峰值是10微米。为了接近峰值并减少当含有粘结剂时粘结剂的集中使用至少三种类型的磨料颗粒（它们彼此的平均颗粒大小不相同）具有增宽颗粒大小分布的效率。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原料中，磨料颗粒具有的平均颗粒大小小于20微米，并且由至少三类平均颗粒大小不同的磨料颗粒所组成。这类磨料颗粒原料的实例如下：
10至20微米  20至30%质量
5至9微米  20至30%质量
小于5微米  40至60%质量
及
10至20微米  20至30%质量
5至9微米  40至60%质量
小于5微米  20至30%质量
由于使用平均颗粒大小小于20微米的磨料颗粒，因此本发明的制品是细颗粒产品，它们可以用来作为用于车削或切削某种基质物的工具嵌入物，但特别用于钻削的操作，如油井钻井，及其它的土壤钻削操作。
现在，将说明本发明的实施例。
实施例1
将金刚石原料置于在通常的高温/高压设备中的反应器中的烧结碳化物基质物的表面上（占原料13%的钴粘结剂）。将反应器放在设备的反应区中，并施加1400℃温度和50至60千巴压力，并保持这种升高的温度和压力条件10分钟的时间。由反应器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。
制备该制品所使用的金刚石原料，由占50%质量的4微米的金刚石，25%质量的8微米的金刚石，及25%质量的12微米的金刚石所组成，每种微米尺寸是一种平均颗粒大小。
在生成制品时，钴由烧结的碳化物基质渗入到金刚石原料中。并发现钴是均一的，并且均匀地贯穿于该制品，而该制品经观测没有明显的钴的汇集作用。制品中钴的量为大约15%质量，由于作为起始金刚石原料，是使用平均颗粒大小小于20微米的颗粒，因此制品是一种细粒状产品。
实施例2
将金刚石原料与粉状钴混合，并置于烧结的碳化物基质物表面上。金刚石原料由80%质量的混合物所组成，而余量为钴。将未粘结的组分放置于在通常的高压/高温设备中的反应器中。将反应器置于反应区中，并施加1400℃的温度和50至60千巴的压力，保持此升高的温度和压力条件10分钟时间。由反应器中收集到的是一种由金刚石制品与烧结的碳化物基质物相结合而组成的复合金刚石制品。所用的该金刚石原料由五类金刚石所组成，各自具有不同的平均颗粒大小。
平均颗粒大小微米  质量百分数
19  27.8
9  44.4
5  6.7
4  16.7
2  4.4
如同实施例1的制品一样，发现钴均匀地分布于该制品中，该制品没有观测到钴的汇集作用。钴的量大约为15%质量。
如此制备的金刚石制品与根据现有技术所制备的二种相似的金刚石制品进行强度和耐磨特性上的比较。这些现有技术的金刚石制品是使用与该实施例制备金刚石制品相同的温度和压力条件下制备的。并使用相同的烧结的碳化物基质物组成。金刚石原料是由平均颗粒大小为25微米的颗粒所组成的普通金刚石原料。在一种制品的情况下（用A表示），钴由在金刚石颗粒和烧结的碳化物基质物之间的钴垫片而渗入金刚石原料中，在另一种制品情况下，（用B来表示），是用钴粉与金刚石颗粒相混合。
使用三种制品进行车削试验。将制品装在标准车削工具的末端，以使制品的边缘朝向工件。然后旋转工件，并通过将制品的切削边缘与车削工件接触而有效地切削或车削。进给速度在每种情况下是0.4mm，切割深度为0.5mm，该工件是Paarl花岗岩。使用湿式车削条件。
在一种情况下，使用力传感器测量离开的力量。当制品的切削边缘上的磨削平面增加时，摩擦增大，为了保持工具与工件的接触需要的力量也越大。因此，离去的力量越大，磨削的平面越大，切削的边缘越少。在旋转工件速度为每分钟50，60，70，80和90米时，测定三种样品的平均离去力，以牛顿表示。所得到的结果列于图1的图中。在该图中，A与B表示现有技术的制品，而本发明则表示该实施例的样品。由图1可以看出，除了每分钟50米之外，对于所有的速度来说，本发明的制品显示了较低的平均离去力，从而与现有技术的二种制品相比较，本发明的制品有较好的磨料强度和性能。在较高的速率下，本发明的切削边缘与现有技术的制品相比较，具有较长的有效操作寿命。
在相似的试验中，三种制品的磨削深度比速度是使用相同范围的速度来测量的。所得到的结果列于图2的图示中，它表明，在每种速度下，本发明的制品具有较低的磨削深度，说明本发明的磨削特性比二种现有技术的制品好。

Claims (12)

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，大部分超硬度磨料颗粒具有的平均颗粒大小小于20微米，并由含至少三种不同平均颗粒大小的颗粒所组成。
2、一种根据权利要求1所说的方法，其中，大部分超硬度磨料颗粒具有的平均颗粒大小小于15微米。
3、一种根据权利要求1或2所说的方法，其中，大部分磨料颗粒具有下列组成：
平均磨料颗粒大小（微米）  质量百分数
10-20  20-30
5-9  20-30
小于5  40-60
4、一种根据权利要求1或2所说的方法，其中，大部分超硬度磨料颗粒具有下列组成：
平均颗粒大小（微米）  质量百分数
10-20  20-30
5-9  40-60
小于5  20-30
5、一种根据前述任一权利要求所述的方法，其中，超硬度磨料颗粒选自金刚石和立方体形一氮化硼颗粒。
6、一种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下处理时，可使粘结剂渗入到超硬度磨料颗粒原料中去。
7、一种上述任一权利要求所说的方法，其中，粘结剂与大部分超硬度磨料颗粒相混合。
8、一种根据权利要求6或7所说的方法，其中，粘结剂对于超硬度磨料颗粒来说是一种溶剂/催化剂。
9、一种根据权利要求8所说的方法，其中，超硬度磨料颗粒是金刚石，而粘结剂选自钴、镍、铁及含有一种或多种这些金属的合金。
10、一种根据前述任一权利要求所说的方法，其中，将大部分超硬度磨料颗粒在进行升高温度和压力处理之前放在烧结的碳化物体的表面上。
11、一种根据前述任一权利要求所说的方法，其中，升高温度和压力的处理是在40至70千巴的压力范围，温度在1300至1600℃范围。
12、一种根据前述任一权利要求所说的方法，其中，超硬度磨料颗粒是未涂敷的。
CN94108790A 1993-05-27 1994-05-27 制备磨料制品的方法 Pending CN1096532A (zh)

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US5505748A (en) 1996-04-09
DE69400418T2 (de) 1997-01-16
EP0626237A1 (en) 1994-11-30
CA2124393C (en) 2004-07-13
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