JP2004196595A - Heat-resistant diamond compound sintered compact and method for manufacturing the same - Google Patents

Heat-resistant diamond compound sintered compact and method for manufacturing the same Download PDF

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JP2004196595A
JP2004196595A JP2002367354A JP2002367354A JP2004196595A JP 2004196595 A JP2004196595 A JP 2004196595A JP 2002367354 A JP2002367354 A JP 2002367354A JP 2002367354 A JP2002367354 A JP 2002367354A JP 2004196595 A JP2004196595 A JP 2004196595A
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diamond
sintered body
heat
sintered compact
powder
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JP3877677B2 (en
JP2004196595A5 (en
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Minoru Akaishi
實 赤石
Keigo Kawamura
啓吾 川村
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Japan Science and Technology Agency
National Institute for Materials Science
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National Institute for Materials Science
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Priority to US10/539,507 priority patent/US20070009374A1/en
Priority to RU2005121920/03A priority patent/RU2312844C2/en
Priority to KR1020057010387A priority patent/KR100642841B1/en
Priority to PCT/JP2003/014763 priority patent/WO2004054943A1/en
Priority to CNB2003801062522A priority patent/CN1300053C/en
Publication of JP2004196595A publication Critical patent/JP2004196595A/en
Priority to ZA200505162A priority patent/ZA200505162B/en
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat-resistant diamond compound sintered compact required particularly for speeding up of cutting of an oil bit for oil drilling and automobile special parts, and to provide a method for manufacturing the same. <P>SOLUTION: The heat-resistant diamond compound sintered compact comprises a sintered compact of superfine particulate synthetic diamond powder having an average particle diameter of ≤200 nm sintered without a sintering aid. It is a compound sintered compact consisting of diamond crystals and a very small amount of generated non-diamond carbon, and has a Vickers hardness of ≥85 GPa. The heat-resistant diamond compound sintered compact is manufactured by sealing synthetic diamond powder having an average particle diameter of ≤200 nm in a tantalum or molybdenum capsule, and heating and pressurizing the capsule with an ultrahigh pressure synthesizer at a temperature of ≥2,100°C and a pressure of ≥7.7 GPa which are required conditions of thermodynamic stability of diamond. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、耐熱性ダイヤモンド複合焼結体とその製造法に関する。
【０００２】
【従来の技術】
従来、Ｃｏ等の金属を焼結助剤とするダイヤモンド焼結体や炭酸塩を焼結助剤とするダイヤモンド焼結体が通常の超高圧合成装置で製造されることが知られている（特許文献１，２）。また、金属焼結助剤を全く使用しないで、アルカリ土類金属の炭酸塩を焼結助剤に用いて、従来よりも高い圧力、温度条件下で焼結することにより、耐熱性に優れた高硬度ダイヤモンド焼結体を得る合成法が知られている（非特許文献１）。しかしながら、これらの焼結体は、溶融炭酸塩の粘性が高いために、その粒子径は小さくても約５μmと比較的大きな粒子径に限定されている。
【０００３】
本発明者らは、CO2-H2O流体相の源となるシュウ酸二水和物を炭酸塩に添加した混合粉末を作製し、この混合粉末上に粒径幅０〜１μｍの天然ダイヤモンド粉末を積層し、微粒ダイヤモンド焼結体を製造する方法を報告した（特許文献３，非特許文献２，３）が、その製造には２２００℃以上の高温を必要とする。
【０００４】
本発明者らは、同様な方法で、さらに微細なダイヤモンド粉末、例えば、粒径幅０〜０．１μmのダイヤモンド粉末を焼結した例を報告した（非特許文献４）。しかし、ダイヤモンドの異常粒成長が起こり、高硬度ダイヤモンド焼結体を製造することが出来なかった。
【０００５】
最近、黒鉛からダイヤモンドヘの直接変換反応により１２〜２５GPa、２０００〜２５００℃の条件で焼結助剤なしでダイヤモンド焼結体を合成する方法が発表され、透光性焼結体となると報告されている（非特許文献５）。
【０００６】
【特許文献１】
特公昭52-12126号公報
【特許文献２】
特公平4-50270号公報
【特許文献３】
特開2002-187775号公報
【０００７】
【非特許文献１】
Diamond and Related Mater.,5巻,34-37ページ,Elsevier Science S.A,1996年
【非特許文献２】
第４１回高圧討論会講演要旨集,108ページ,日本高圧力学会,2000年
【非特許文献３】
Proceedings of the 8th NIRIM International Symposium on Advanced Materials,33-34ページ,無機材質研究所,2001年
【非特許文献４】
第４２回高圧討論会講演要旨集,89ページ,日本高圧力学会,2001年
【非特許文献５】
T．Irifune et al.，「Characterization of polycrystalline diamonds synthesized by direct conversion of graphite using multi anvil apparatus」,6thHigh Pressure Mineral Physics Seminar,28 August,2002,Verbania, Italy
【０００８】
【発明が解決しようとする課題】
切削工具の分野での高性能工具としての使用は勿論、耐熱性が高く、従来は専ら単結晶が用いられていた超精密加工工具、さらには、宝飾品としても価値の高いダイヤモンド焼結体が求められている。特に、石油掘削用オイルビットや自動車用特殊部品の切削の高速化にともないダイヤモンド焼結体工具の耐熱性が求められている。
【０００９】
従来、金属及び非金属を問わず焼結助剤を用いて、高硬度ダイヤモンド焼結体が、５．５Gpa〜７．７GPaの超高圧条件下で高圧高温焼結により製造されている。このような焼結助剤を用いるダイヤモンド焼結体の製造法では、焼結助剤に用いた物質が高圧高温焼結後に焼結体中に固体として残留するため、ダイヤモンド粒子間の結合の割合が減少する。焼結助剤を全く含有しない理想的なダイヤモンド焼結体に比較して、それらの焼結体の硬さは低くなったり、焼結体中に残存する焼結助剤が、ダイヤモンドと化学反応したりして、焼結体の特性を低下させる原因となる。また、焼結助剤を全く含有しない焼結体の合成は大変高い圧力と温度が必要である。
【００１０】
炭酸塩-C-O-H流体相からなる焼結助剤を用いて、粒径幅０〜０．１μmの天然ダイヤモンド粉末を焼結するとダイヤモンド粒子間に均質に炭酸塩が分布した高硬度微粒ダイヤモンド焼結体を７．７GPa、１７００℃以上の条件で容易に合成することが可能である（特願2002-030863号）。
【００１１】
そこで、本発明者らは、炭酸塩を焼結助剤とする高硬度微粒ダイヤモンド焼結体の合成のコストの低減を目的に、平均粒径１００nmの水素終端処理した合成ダイヤモンド粉末を炭酸塩-C-O-H流体相からなる焼結助剤上に積層し、高圧高温条件下で処理して、ダイヤモンド焼結体の合成を試みた。回収試料は層状に割れて、途中まで炭酸塩は溶浸していたが、ダイヤモンド粉末中への炭酸塩-C-O-H流体相からなる焼結助剤の均質溶浸は実現できなかった。この理由を検討してみた結果、合成ダイヤモンド粉末が塑性変形し易いために、ダイヤモンド粉末粒子間の空隙が一部潰れてしまうため、溶融焼結助剤が均質溶浸しないとの結論に到達した。
【００１２】
また、本発明者らは、焼結助剤を全く使用しない系において、粒径幅０〜０．１μmの天然ダイヤモンド粉末を７．７Gpa、２３００℃の条件で１５分間焼結処理を行った。その結果、粒径幅０〜０．１μmの天然ダイヤモンド粉末からは高硬度ダイヤモンド焼結体を合成することは難しいことが明らかとなった。
【００１３】
【課題を解決するための手段】
本発明者らは、平均粒子径２００nm以下の合成ダイヤモンド粉末を出発物質に用い、炭酸塩等の焼結助剤を用いてダイヤモンド焼結体を製造している高圧高温条件と同等の製造条件で高圧高温焼結すると意外にも上記のような問題が発生しないことを見出し、焼結助剤を全く含有しない微細な粒子からなる耐熱性ダイヤモンド焼結体を合成することに成功した。
【００１４】
しかも、この製造法で得られた焼結体には微量の非ダイヤモンド炭素が生成物として含有され、ダイヤモンド結晶と非ダイヤモンド炭素との複合焼結体となり、焼結体に電気伝導性が付与される。この非ダイヤモンド炭素は、出発物質のダイヤモンド粉末が一部黒鉛化することにより生成したものと推定される。その結果、電気伝導性が付与されることにより、放電加工が可能となる。また、従来のダイヤモンド焼結体に全くない輝きと光沢有する。
【００１５】
すなわち、本発明は、（１）平均粒子径が２００nm以下である超微粒合成ダイヤモンド粉末の焼結体からなり、該焼結体は焼結助剤なしで焼結され、ダイヤモンド結晶と生成した微量の非ダイヤモンド炭素とからなる複合焼結体であり、ヴィカース硬さが８５GPa以上であることを特徴とする耐熱性ダイヤモンド複合焼結体、である。
【００１６】
また、本発明は、（２）平均粒子径が２００nm以下である合成ダイヤモンド粉末をＴａ又はＭｏ製カプセルに封入し、該カプセルを超高圧合成装置を用いてダイヤモンドの熱力学的安定条件の２１００℃以上の温度、７．７GPa以上の圧力下で加熱加圧することによりダイヤモンド粉末を焼結することを特徴とする上記（１）の耐熱性ダイヤモンド複合焼結体の製造法、である。
【００１７】
ダイヤモンド粉末の粒子径を略同じで比較した場合、合成ダイヤモンド粉末は、天然ダイヤモンド粉末に比較し、塑性変形し易い粉末である。出発ダイヤモンド粉末の粒子径の分布が少ない粉末は、分布の大きな粉末に比較し、粒子間の空隙の大きさの分布が少ないと考えられる。そこで、ダイヤモンド粉末の粒子径が略一定でかつ平均粒子径の可能な限り小さい合成ダイヤモンド粉末を出発物質に使用すれば、ダイヤモンド粒子は容易に塑性変形し、小さいダイヤモンド粒子が固有に持っている大きな表面エネルギーを駆動力にして、焼結助剤を全く使用しないでも耐熱性ダイヤモンド複合焼結体が合成されると考えられる。
【００１８】
平均粒子径が２００nmを超えて大きい合成ダイヤモンド粉末を用いるとダイヤモンド粒子の粒径が大きくなるにつれて、粒子の表面エネルギーが小さくなりダイヤモンド焼結体の合成が困難となる。
【００１９】
本発明のダイヤモンド焼結体は、優れた耐熱性と耐摩耗性を有し、高硬度であり、例えば、高Ｓｉ-Ａｌ合金等の難削材料の仕上げ切削、金属・合金の超精密加工、線引きダイス等に適用した場合、優れた切削性能や線引き性能を発揮する。さらには、石油掘削用オイルビットや自動車用特殊部品の高速切削に適する十分な耐熱性を有する。また、非ダイヤモンド炭素からなる生成物が複合されて焼結体に電気伝導性が付与されているので、焼結体の切断加工に放電加工が適用可能になり、加工コストの低減を図ることが可能となる。さらに、放電加工に加えて、レーザー加工、研削及び研磨加工によって様々な形状を付与することが可能な焼結体であるので、従来のダイヤモンド焼結体にない輝きと光沢有する宝飾用ブラックダイヤモンドとして利用が期待される。
【００２０】
【発明の実施の形態】
本発明のダイヤモンド焼結体の製造法には、合成超微粒ダイヤモンド粉末を出発物質として用いる。図１は、本発明の製造法において、ダイヤモンド粉末を焼結するための焼結体合成用カプセルにダイヤモンド粉末を充填した状態の一例を示す断面図である。
【００２１】
図１に示すように、円筒状のＴａ製カプセル３の底にカプセルの変形抑制用の黒鉛製円盤４Ａを置き、Ｔａ又はＭｏ箔１Ａを介してダイヤモンド粉末２Ａを加圧充填する。Ｔａ又はＭｏ箔は、所望の厚さの焼結体を合成するためのダイヤモンド粉末どうしの分離、黒鉛とダイヤモンド粉末の分離、圧力媒体の侵入防止、流体相のシール等のために用いている。このダイヤモンド粉末２Ａ上にＴａ又はＭｏ箔１Ｂを配置する。同様な方法により、さらに３層のダイヤモンド粉末２Ｂ、２Ｃ、２ＤをＴａ又はＭｏ箔１Ｃ、１Ｄを介在させて充填した後にＴａ又はＭｏ箔１Ｅを配置し、その上にカプセルの変形抑制用の黒鉛製円盤４Ｂを配置する。
【００２２】
このカプセルを圧力媒体中に収容し、ベルト型超高圧合成装置などの静的圧縮法による超高圧装置を用いて、室温条件下で７．７GPa以上まで加圧し、同圧力条件下で２１００℃以上の所定の温度まで加熱して、焼結を行う。圧力が７．７GPa未満では、２１００℃以上の温度でも所望の耐熱性焼結体が得られない。また、焼結温度が２１００℃未満では、７．７GPa以上の圧力でも所望の耐熱性焼結体が得られない。温度、圧力は必要以上に高くしてもエネルギー効率を悪くするだけであるから、装置の対応限度も考慮して必要最小限度とすることが望ましい。
【００２３】
平均粒子径が２００nm以下である合成ダイヤモンド粉末は、粒子径の大きな合成ダイヤモンド粉末を粉砕後分級によって得られた粉末であり、測定法はマイクロトラックUPA粒度測定器による測定値である。このような測定法は公知である（例えば、特開2002-35636号公報参照）。このような合成ダイヤモンド粉末は、市販品として入手できる（例えば、東名ダイヤモンド社製商品名MD200（平均粒子径200nm）、MD100（平均粒子径100nm））。
【００２４】
【実施例】
以下、本発明のダイヤモンド焼結体の製造法を実施例に基づいて具体的に説明する。
（実施例１）
市販の平均粒子径１００nmの合成ダイヤモンド粉末を出発物質として用意した。肉厚０．８mm、外径１１．６mmの円筒状Ｔａ製カプセルの底にカプセルの変形抑制用の２．６mm厚の黒鉛製円盤を置き、Ｔａ箔を介してダイヤモンド粉末２５０mgを層状に１００MPaの圧力で充填した。このダイヤモンド粉末上にＴａ箔を置き、Ｔａ箔の上には、カプセルの変形を抑制するために、２．６mm厚の黒鉛製円盤を配置した。カプセルを加圧成形後に上部の余分の黒鉛を削り落とした。
【００２５】
次に、カプセルををNaCl-１０%ZrO2の圧力媒体中に充填し、ベルト型超高圧合成装置を用いて、７．７GPa、２２００℃の条件で３０分間焼結した後、合成装置よりカプセルを取り出した。
焼結体の表面に形成されたＴａＣ等をフッ化水素酸−硝酸溶液で処理して除去し、焼結体の上下面を平面にするため、ダイヤモンドホィールで研削した。研削抵抗の高い焼結体であり、研削後の焼結体のヴィカース硬さの平均値は９０GPa以上であった。
【００２６】
この焼結体の耐熱性を評価するため、真空中、１２００℃で３０分間処理した。処理後のヴィカース硬さは処理前と全く変わらなかった。図２に、得られた焼結体のＸ線回折図形を示す。図２(a)は、熱処理前、図２(b)は、１２００℃、３０分間真空中熱処理後である。図２(a)に示す結果から明らかなように、非ダイヤモンド炭素の回折線の位置は、黒鉛の(002)の回折線より高角側のｄ＝３．２６〜３．１９の位置に幅広い回折線として観測され、ダイヤモンドと非常に僅かな非ダイヤモンド炭素（図中●で示した）が確認されるが、図２(b)の結果から明らかなように、この回折線の位置も強度も全く変化は認められず、非ダイヤモンド炭素の量は熱処理後も全く変化していない。図３に示すように、焼結体の破面の電子顕微鏡による組織観察の結果、平均粒子径８０nmと微細粒子からなる焼結体であることが明らかとなった。
【００２７】
（比較例１）
焼結温度を２０００℃とした他は、実施例１と同じ方法で焼結した。得られた焼結体は研削抵抗が低く、ヴィカース硬さの平均は、５０GPaであった。
【００２８】
（実施例２）
平均粒子径２００nmの合成ダイヤモンド粉末を出発物質とし、焼結温度を２３００℃とした他は、実施例１と同じ方法で焼結した。得られた焼結体は研削抵抗が極めて高く、ヴィカース硬さの平均は、８５GPa以上と非常に高硬度であった。
【００２９】
（比較例２）
平均粒子径３００nmの合成ダイヤモンド粉末を出発物質とした他は、実施例２と同じ方法で焼結した。得られた焼結体は層状割れが認められ、その研削抵抗は、実施例２の焼結体に比較し、著しく低いものであった。平均粒子径を大きくすると高硬度ダイヤモンド焼結体を合成することは難しい。
【００３０】
【発明の効果】
本発明の製造法により合成される耐熱性ダイヤモンド複合焼結体は、切削工具の分野での高性能工具、耐熱性の要求されるオイルビット等の工業用用途ばかりでなく、ダイヤモンド固有の高い屈折率を持っていることはもちろんであるが、焼結助剤なしのダイヤモンド焼結体独特の輝きを持っていることや、大型焼結体を製造することが容易であことから、宝飾用の用途としての新たな用途が期待される。
本発明の製造法は、炭酸塩を焼結助剤とするダイヤモンド焼結体と同等の圧力・温度条件での製造が可能であるため、大型焼結体の製造が容易である。
【図面の簡単な説明】
【図１】図１は、本発明の製造法において、ダイヤモンド粉末を焼結するための焼結体合成用カプセルにダイヤモンド粉末を充填した状態の一例を概念的に示す断面図である。
【図２】図２は、実施例１で得られた焼結体のＸ線回折図形（(a)は熱処理前、(b)は熱処理後）である。
【図３】図３は、実施例１で得られた焼結体の破面の図面代用電子顕微鏡組織写真である。
【符号の説明】
１Ａ，１Ｂ、１Ｃ，１Ｄ，１Ｅ Ｔａ又はＭｏ箔
２Ａ，２Ｂ，２Ｃ，２Ｄ ダイヤモンド粉末
３ Ｔａ又はＭｏ製カプセル
４Ａ，４Ｂ 黒鉛製円盤[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a heat-resistant diamond composite sintered body and a method for producing the same.
[0002]
[Prior art]
Conventionally, it has been known that a diamond sintered body using a metal such as Co as a sintering aid or a diamond sintered body using carbonate as a sintering aid are manufactured by a normal ultra-high pressure synthesizing apparatus. Literatures 1 and 2). Also, without using any metal sintering aid, by using alkaline earth metal carbonate as a sintering aid, and sintering under higher pressure and temperature conditions than before, excellent heat resistance A synthesis method for obtaining a high hardness diamond sintered body is known (Non-Patent Document 1). However, these sintered bodies are limited to relatively large particle diameters of about 5 μm even if their particle diameters are small due to the high viscosity of the molten carbonate.
[0003]
The present inventors have prepared a mixed powder in which oxalic acid dihydrate, which is a source of a CO 2 —H 2 O fluid phase, has been added to a carbonate, and a natural diamond having a particle size range of 0 to 1 μm is formed on the mixed powder. A method of manufacturing a fine-grained diamond sintered body by laminating powders has been reported (Patent Literature 3, Non-Patent Literatures 2 and 3), but the production requires a high temperature of 2200 ° C. or higher.
[0004]
The present inventors reported an example in which a finer diamond powder, for example, a diamond powder having a particle size range of 0 to 0.1 μm was sintered by the same method (Non-Patent Document 4). However, abnormal grain growth of diamond occurred, and a high-hardness diamond sintered body could not be manufactured.
[0005]
Recently, a method of synthesizing a diamond sintered body without a sintering aid at a temperature of 12 to 25 GPa and a temperature of 2000 to 2500 ° C. by a direct conversion reaction from graphite to diamond has been announced, and it is reported that a transparent sintered body will be obtained. (Non-Patent Document 5).
[0006]
[Patent Document 1]
Japanese Patent Publication No. 52-12126 [Patent Document 2]
Japanese Patent Publication No. 4-50270 [Patent Document 3]
JP 2002-187775 A
[Non-patent document 1]
Diamond and Related Mater., Vol. 5, pp. 34-37, Elsevier Science SA, 1996 [Non-Patent Document 2]
Abstracts for the 41st High Pressure Symposium, 108 pages, Japan High Pressure Society, 2000 [Non-Patent Document 3]
Proceedings of the 8th NIRIM International Symposium on Advanced Materials, pages 33-34, Research Institute for Inorganic Materials, 2001 [Non-Patent Document 4]
Abstracts of the 42nd High Pressure Symposium, 89 pages, The Japan High Pressure Society, 2001 [Non-Patent Document 5]
T. Irifune et al., `` Characterization of polycrystalline diamonds synthesized by direct conversion of graphite using multi anvil apparatus '', 6th High Pressure Mineral Physics Seminar, 28 August, 2002, Verbania, Italy
[0008]
[Problems to be solved by the invention]
Not only is it used as a high-performance tool in the field of cutting tools, but it also has high heat resistance.Ultra-precision processing tools, which used to be exclusively made of single crystals, and diamond sintered compacts that are also valuable as jewelry. It has been demanded. In particular, as the cutting speed of oil bits for oil drilling and special parts for automobiles is increased, the heat resistance of the sintered diamond tool is required.
[0009]
BACKGROUND ART Conventionally, a high-hardness diamond sintered body has been produced by high-pressure high-temperature sintering under an ultra-high pressure condition of 5.5 GPa to 7.7 GPa using a sintering aid regardless of a metal or a nonmetal. In the method of manufacturing a diamond sintered body using such a sintering aid, the ratio of bonding between diamond particles is high because the substance used as the sintering aid remains as a solid in the sintered body after high-pressure high-temperature sintering. Decrease. Compared to ideal diamond sintered bodies that do not contain any sintering aid, the hardness of those sintered bodies is lower, and the sintering aid remaining in the sintered body reacts chemically with diamond. For example, it may cause deterioration of the characteristics of the sintered body. Also, synthesis of a sintered body containing no sintering aid requires extremely high pressure and temperature.
[0010]
Sintering of natural diamond powder with a particle size range of 0 to 0.1 μm using a sintering aid consisting of carbonate-COH fluid phase, a high-hardness fine-grained diamond sintered body in which carbonate is uniformly distributed between diamond particles Can be easily synthesized under the conditions of 7.7 GPa and 1700 ° C. or higher (Japanese Patent Application No. 2002-030863).
[0011]
In view of this, the inventors of the present invention aimed to reduce the cost of synthesizing a high-hardness fine-grained diamond sintered body using carbonate as a sintering aid by using a hydrogen-terminated synthetic diamond powder having an average particle diameter of 100 nm as a carbonate- We tried to synthesize a diamond sintered body by laminating it on a sintering aid consisting of a COH fluid phase and treating it under high pressure and high temperature conditions. The recovered sample was broken into layers and the carbonate was infiltrated halfway, but homogeneous infiltration of the sintering aid consisting of the carbonate-COH fluid phase into the diamond powder could not be realized. After examining the reason, it was concluded that the synthetic sintering aid was not homogeneously infiltrated because the synthetic diamond powder was liable to plastically deform, which partially collapsed the voids between the diamond powder particles. .
[0012]
In addition, the present inventors performed sintering treatment of a natural diamond powder having a particle size range of 0 to 0.1 μm at 7.7 GPa and 2300 ° C. for 15 minutes in a system using no sintering aid. As a result, it became clear that it was difficult to synthesize a high hardness diamond sintered body from natural diamond powder having a particle size range of 0 to 0.1 μm.
[0013]
[Means for Solving the Problems]
The present inventors have used synthetic diamond powder having an average particle diameter of 200 nm or less as a starting material, and under the same manufacturing conditions as high pressure and high temperature conditions for manufacturing a diamond sintered body using a sintering aid such as carbonate. It was found that the above-mentioned problems did not occur when high-pressure and high-temperature sintering was unexpectedly performed, and the inventors succeeded in synthesizing a heat-resistant diamond sintered body composed of fine particles containing no sintering aid.
[0014]
In addition, the sintered body obtained by this manufacturing method contains a small amount of non-diamond carbon as a product, and becomes a composite sintered body of diamond crystal and non-diamond carbon, which imparts electrical conductivity to the sintered body. You. This non-diamond carbon is presumed to have been generated by partially graphitizing the starting diamond powder. As a result, electric discharge machining can be performed by imparting electric conductivity. In addition, it has a brightness and luster that are not found in conventional diamond sintered bodies.
[0015]
That is, the present invention provides (1) a sintered body of ultrafine synthetic diamond powder having an average particle diameter of 200 nm or less, and the sintered body is sintered without a sintering aid, and a minute amount of diamond crystal is formed. And a heat-resistant diamond composite sintered body having a Vickers hardness of 85 GPa or more.
[0016]
The present invention also provides (2) encapsulating a synthetic diamond powder having an average particle diameter of 200 nm or less in a capsule made of Ta or Mo, and using an ultra-high pressure synthesizer to stabilize the diamond at 2100 ° C. under thermodynamic stability conditions. (1) The method for producing a heat-resistant diamond composite sintered body according to the above (1), wherein the diamond powder is sintered by heating and pressurizing at the above temperature and a pressure of 7.7 GPa or more.
[0017]
When the particle diameters of the diamond powders are substantially the same, the synthetic diamond powder is a powder that is more easily plastically deformed than the natural diamond powder. It is considered that a powder having a small particle size distribution of the starting diamond powder has a smaller distribution of the size of the voids between the particles than a powder having a large distribution. Therefore, if synthetic diamond powder having a substantially constant average particle diameter and a small average particle diameter is used as the starting material, the diamond particles are easily plastically deformed, and the small diamond particles inherently have a large diameter. It is considered that a heat-resistant diamond composite sintered body can be synthesized using surface energy as a driving force without using any sintering aid.
[0018]
When a synthetic diamond powder having an average particle diameter exceeding 200 nm is used, as the particle diameter of the diamond particles increases, the surface energy of the particles decreases, and it becomes difficult to synthesize a diamond sintered body.
[0019]
The diamond sintered body of the present invention has excellent heat resistance and wear resistance, and has high hardness.For example, finish cutting of difficult-to-cut materials such as high Si-Al alloys, ultra-precision processing of metals and alloys, When applied to a drawing die, etc., it exhibits excellent cutting performance and drawing performance. Furthermore, it has sufficient heat resistance suitable for high-speed cutting of oil bits for oil drilling and special parts for automobiles. In addition, since the product made of non-diamond carbon is compounded to impart electrical conductivity to the sintered body, electric discharge machining can be applied to the cutting of the sintered body, and the machining cost can be reduced. It becomes possible. Furthermore, since it is a sintered body that can be given various shapes by laser machining, grinding and polishing in addition to electric discharge machining, it is a jewelry black diamond with shine and luster not found in conventional diamond sintered bodies Use is expected.
[0020]
BEST MODE FOR CARRYING OUT THE INVENTION
In the method for producing a diamond sintered body of the present invention, synthetic ultrafine diamond powder is used as a starting material. FIG. 1 is a cross-sectional view showing an example of a state in which a diamond powder is filled in a sintered body synthesis capsule for sintering the diamond powder in the production method of the present invention.
[0021]
As shown in FIG. 1, a graphite disc 4A for suppressing capsule deformation is placed on the bottom of a cylindrical Ta capsule 3, and diamond powder 2A is pressure-filled via Ta or Mo foil 1A. The Ta or Mo foil is used for separating diamond powder for synthesizing a sintered body having a desired thickness, separating graphite and diamond powder, preventing intrusion of a pressure medium, sealing a fluid phase, and the like. The Ta or Mo foil 1B is arranged on the diamond powder 2A. In a similar manner, three layers of diamond powder 2B, 2C, and 2D are further filled with Ta or Mo foils 1C and 1D interposed therebetween, and then Ta or Mo foil 1E is arranged thereon. The disc 4B is placed.
[0022]
This capsule is housed in a pressure medium, and is pressurized to 7.7 GPa or more at room temperature using an ultra-high pressure device by a static compression method such as a belt type ultra-high pressure synthesizer, and is heated to 2100 ° C. And sintering is performed. If the pressure is less than 7.7 GPa, a desired heat-resistant sintered body cannot be obtained even at a temperature of 2100 ° C. or more. If the sintering temperature is lower than 2100 ° C., a desired heat-resistant sintered body cannot be obtained even at a pressure of 7.7 GPa or more. Even if the temperature and the pressure are made higher than necessary, the energy efficiency will only be deteriorated.
[0023]
The synthetic diamond powder having an average particle diameter of 200 nm or less is a powder obtained by pulverizing a synthetic diamond powder having a large particle diameter and then classifying the powder. The measuring method is a value measured by a Microtrac UPA particle size analyzer. Such a measuring method is known (for example, refer to JP-A-2002-35636). Such a synthetic diamond powder is available as a commercial product (for example, trade names MD200 (average particle diameter 200 nm), MD100 (average particle diameter 100 nm) manufactured by Tomei Diamond Co., Ltd.).
[0024]
【Example】
Hereinafter, a method for producing a diamond sintered body of the present invention will be specifically described based on examples.
(Example 1)
A commercially available synthetic diamond powder having an average particle diameter of 100 nm was prepared as a starting material. At the bottom of a cylindrical Ta capsule having a thickness of 0.8 mm and an outer diameter of 11.6 mm, a 2.6 mm-thick graphite disk for suppressing deformation of the capsule was placed, and 250 mg of diamond powder was layered into 100 MPa through a Ta foil. Filled with pressure. A Ta foil was placed on the diamond powder, and a 2.6 mm thick graphite disk was placed on the Ta foil to suppress deformation of the capsule. After pressing the capsule, excess graphite on the top was scraped off.
[0025]
Next, the capsule was filled in a pressure medium of NaCl-10% ZrO 2 and sintered at 7.7 GPa and 2200 ° C. for 30 minutes using a belt type ultra-high pressure synthesizer. Was taken out.
TaC and the like formed on the surface of the sintered body were removed by treatment with a hydrofluoric acid-nitric acid solution, and the sintered body was ground with a diamond wheel to make the upper and lower surfaces flat. The sintered body had high grinding resistance, and the average value of Vickers hardness of the sintered body after grinding was 90 GPa or more.
[0026]
In order to evaluate the heat resistance of this sintered body, it was treated at 1200 ° C. for 30 minutes in a vacuum. The Vickers hardness after the treatment was not different from that before the treatment. FIG. 2 shows an X-ray diffraction pattern of the obtained sintered body. FIG. 2A shows the state before the heat treatment, and FIG. 2B shows the state after the heat treatment in vacuum at 1200 ° C. for 30 minutes. As is clear from the results shown in FIG. 2 (a), the diffraction line position of the non-diamond carbon is broadly diffracted at d = 3.26 to 3.19, which is higher than the diffraction line of (002) of graphite. As a result, diamond and a very small amount of non-diamond carbon (indicated by ● in the figure) are confirmed. However, as is clear from the results of FIG. No change was observed, and the amount of non-diamond carbon did not change at all after the heat treatment. As shown in FIG. 3, as a result of microscopic observation of the fracture surface of the sintered body by an electron microscope, it was revealed that the sintered body was a sintered body composed of fine particles having an average particle diameter of 80 nm.
[0027]
(Comparative Example 1)
Sintering was performed in the same manner as in Example 1 except that the sintering temperature was set to 2000 ° C. The obtained sintered body had a low grinding resistance, and the average Vickers hardness was 50 GPa.
[0028]
(Example 2)
Sintering was performed in the same manner as in Example 1 except that a synthetic diamond powder having an average particle diameter of 200 nm was used as a starting material and the sintering temperature was 2300 ° C. The obtained sintered body had extremely high grinding resistance, and the average Vickers hardness was very high, that is, 85 GPa or more.
[0029]
(Comparative Example 2)
Sintering was carried out in the same manner as in Example 2 except that synthetic diamond powder having an average particle diameter of 300 nm was used as a starting material. Layered cracks were observed in the obtained sintered body, and the grinding resistance was significantly lower than that of the sintered body of Example 2. If the average particle diameter is increased, it is difficult to synthesize a high-hardness diamond sintered body.
[0030]
【The invention's effect】
The heat-resistant diamond composite sintered body synthesized by the production method of the present invention is used not only for industrial applications such as high-performance tools in the field of cutting tools and oil bits requiring heat resistance, but also has a high refraction inherent to diamond. Of sintering, but because of the unique shine of diamond sintered bodies without sintering aids and the ease of manufacturing large sintered bodies, New applications are expected.
Since the production method of the present invention can be produced under the same pressure and temperature conditions as a diamond sintered body using carbonate as a sintering aid, it is easy to produce a large-sized sintered body.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view conceptually showing an example of a state in which a capsule for synthesizing a sintered body for sintering diamond powder is filled with diamond powder in the production method of the present invention.
FIG. 2 is an X-ray diffraction pattern ((a) before heat treatment, (b) after heat treatment) of the sintered body obtained in Example 1.
FIG. 3 is a scanning electron micrograph of a fracture surface of the sintered body obtained in Example 1.
[Explanation of symbols]
1A, 1B, 1C, 1D, 1E Ta or Mo foil 2A, 2B, 2C, 2D Diamond powder 3 Ta or Mo capsule 4A, 4B Graphite disk

Claims (2)

平均粒子径が２００nm以下である超微粒合成ダイヤモンド粉末の焼結体からなり、該焼結体は焼結助剤なしで焼結され、ダイヤモンド結晶と生成した微量の非ダイヤモンド炭素とからなる複合焼結体であり、ヴィカース硬さが８５GPa以上であることを特徴とする耐熱性ダイヤモンド複合焼結体。It consists of a sintered body of ultrafine synthetic diamond powder having an average particle diameter of 200 nm or less, and the sintered body is sintered without a sintering aid, and is a composite sintered body composed of diamond crystals and a small amount of non-diamond carbon generated. A heat-resistant diamond composite sintered body which is a consolidated body and has a Vickers hardness of 85 GPa or more. 平均粒子径が２００nm以下である合成ダイヤモンド粉末をＴａ又はＭｏ製カプセルに封入し、該カプセルを超高圧合成装置を用いてダイヤモンドの熱力学的安定条件の２１００℃以上の温度、７．７GPa以上の圧力下で加熱加圧することによりダイヤモンド粉末を焼結することを特徴とする請求項１記載の耐熱性ダイヤモンド複合焼結体の製造法。A synthetic diamond powder having an average particle size of 200 nm or less is encapsulated in a capsule made of Ta or Mo, and the capsule is heated at a temperature of 2100 ° C. or more, which is a condition of thermodynamic stability of diamond and 7.7 GPa or more, using an ultra-high pressure synthesizer. The method for producing a heat resistant diamond composite sintered body according to claim 1, wherein the diamond powder is sintered by heating and pressing under pressure.
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