JP2014520757A - ロウ付けされたコーティング済みダイヤモンド含有材料 - Google Patents
ロウ付けされたコーティング済みダイヤモンド含有材料 Download PDFInfo
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Abstract
【選択図】なし
Description
本出願は、既に出願済みである米国特許仮出願第61/509,711号、2011年7月20出願、に基づくものであり、その優先権の利益を主張するものである。
ダイヤモンド含有材料のサンプルを、以下の方法を用いて炭化タングステン基材にロウ付けした。ダイヤモンド含有材料は、VERSIMAX(登録商標)(DIAMOND INNOVATIONS(登録商標),オハイオ州,米国)として知られる市販のダイヤモンドコンポジットとした。このダイヤモンドコンポジットは、およそ80体積%のダイヤモンド及び20体積%の炭化ケイ素を、少量のケイ素(<2.0体積%)と共に含んでなる。VERSIMAX(登録商標)のサンプルは、ワイヤEDM(放電機械加工)によって、0.260インチ径及び0.125インチ厚さの円柱体に切り出すことで作製した。炭化タングステン(Co含有量8%)のサンプルは、0.125インチの厚さに研削し、次に、ワイヤEDMによって0.260インチ径に切り出した。VERSIMAX(登録商標)及び炭化タングステンのサンプルは、ガラスビーズを用いて円形平面をグリットブラストし、続いてこれらのパーツをアセトンでリンスすることで洗浄した。WのCVDコーティングをVERSIMAX(登録商標)サンプルに適用した。CVDコーティングの厚さは8ミクロンであった。LUCAS‐MILHAUPT(登録商標)Braze 495ロウ付けホイルをSta‐Silv(登録商標)Black Flux(Harris Products Group,オハイオ州,米国)と共に用いた空気中での誘導加熱ロウ付けにより、VERSIMAX(登録商標)サンプルを、炭化タングステン基材にロウ付けした。
ダイヤモンド含有材料のサンプルを、以下の方法を用いて炭化タングステン基材にロウ付けした。ダイヤモンド含有材料は、COMPAX(商標)(DIAMOND INNOVATIONS(登録商標),オハイオ州,米国)として知られる市販の熱安定性PCDダイヤモンドコンポジットとし、これは、完全に浸出処理を行った実質的に触媒金属を含有しないダイヤモンドコンポジットであった。熱安定性COMPAX(商標)のサンプルのサンプルは、ワイヤEDM(放電機械加工)によって、0.260インチ径及び0.125インチ厚さの円柱体に切り出すことで作製し、次に、化学浸出プロセスによって金属バインダーを除去した。炭化タングステン(Co含有量8%)のサンプルは、0.125インチの厚さに研削し、次に、ワイヤEDMによって0.260インチ径に切り出した。COMPAX(商標)及び炭化タングステンのサンプルは、ガラスビーズを用いて円形平面をグリットブラストし、続いてこれらのパーツをアセトンでリンスすることで洗浄した。WのCVDコーティングをCOMPAX(商標)サンプルに適用した。CVDコーティングの厚さは約5ミクロンであった。LUCAS‐MILHAUPT(登録商標)Braze 495ロウ付けホイルをSta‐Silv(登録商標)White Flux(Harris Products Group,オハイオ州,米国)と共に用いた空気中での誘導加熱ロウ付けにより、COMPAX(商標)サンプルを、炭化タングステン基材にロウ付けした。
ダイヤモンド含有材料のサンプルを、以下の方法を用いて炭化タングステン基材にロウ付けした。VERSIMAX(登録商標)(DIAMOND INNOVATIONS(登録商標),オハイオ州,米国)として知られるダイヤモンドコンポジットは、およそ80体積%のダイヤモンド及び20体積%の炭化ケイ素を、少量のケイ素(<2.0体積%)と共に含んでなる。VERSIMAX(登録商標)のサンプルは、ワイヤ放電機械加工(EDM)によって、0.260インチ径及び0.125インチ厚さの円柱体に切り出すことで作製した。炭化タングステン(Co含有量8%)のサンプルは、0.125インチの厚さに研削し、次に、ワイヤEDMによって0.260インチ径に切り出した。VERSIMAX(登録商標)サンプルは、ガラスビーズを用いて円形平面をグリットブラストし、続いてこれらのパーツをアセトンでリンスすることで洗浄した。炭化タングステンサンプルは、ガラスビーズを用いて円形平面をグリットブラストすることで洗浄した。
Claims (34)
- 第一のダイヤモンド含有材料;
耐熱性金属又は耐熱性金属合金を含んでなる耐熱性金属層であって、ここで、前記耐熱性金属層は、前記第一のダイヤモンド含有材料と操作可能に接続される、耐熱性金属層;
ロウ付け金属を含んでなるロウ付け金属層であって、ここで、前記ロウ付け金属層は、前記耐熱性金属層の少なくとも一部分と直接接触している、ロウ付け金属層;並びに、
基材であって、ここで、前記基材の面の少なくとも一部分は、前記ロウ付け金属層と直接接触している、基材、
を含んでなるロウ付けされたコーティング済みダイヤモンド含有材料。 - 炭化物層をさらに含んでなり、ここで、前記炭化物層は、前記第一のダイヤモンド含有材料と前記耐熱性金属層との間に挟まれている、請求項1に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記炭化物層が、耐熱性金属炭化物を含んでなる、請求項2に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記基材が、第二のダイヤモンド含有材料、超硬質合金、多結晶立方晶窒化ホウ素(PcBN)超砥粒、セラミック、金属、金属合金、及び/又はこれらの組み合わせのうちの少なくとも1つを含んでなる、請求項1に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記第一のダイヤモンド含有材料が、単結晶ダイヤモンド、化学蒸着ダイヤモンド、炭化ケイ素結合ダイヤモンドコンポジット、コバルト‐多結晶ダイヤモンドコンポジット、熱安定性ダイヤモンドコンポジット、及び/又はこれらの組み合わせのうちの少なくとも1つを含んでなる、請求項1に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記第二のダイヤモンド含有材料が、単結晶ダイヤモンド、化学蒸着ダイヤモンド、炭化ケイ素結合ダイヤモンドコンポジット、コバルト‐多結晶ダイヤモンドコンポジット、熱安定性ダイヤモンドコンポジット、及び/又はこれらの組み合わせのうちの少なくとも1つを含んでなる、請求項4に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記耐熱性金属が、タングステン、チタン、ニオブ、ジルコニウム、タンタル、バナジウム、クロム、又はモリブデンを含んでなり;並びに、
前記耐熱性金属合金が、少なくとも1つの耐熱性金属を含んでなる、
請求項1に記載のロウ付けされたコーティング済みダイヤモンド含有材料。 - 前記耐熱性金属合金が、非耐熱性金属をさらに含んでなる、請求項1に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記耐熱性金属層が、約0.1μmから約100μmの厚さを有する、請求項3に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記耐熱性金属又は前記耐熱性金属合金が、コーティング法によって前記ダイヤモンド含有材料上に成膜されて、前記耐熱性金属層、及び所望に応じて存在してよい前記炭化物層を形成する、請求項3に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記コーティング法が、物理蒸着、化学蒸着、スパッタリング、蒸発(evaporation)、無電解メッキ、電気メッキ、熱拡散、又はこれらの組み合わせ若しくは連続を含んでなる、請求項10に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 前記ロウ付け金属が、銀、銅、マンガン、ニッケル、亜鉛、パラジウム、クロム、ホウ素、チタン、スズ、ケイ素、カドミウム、金、アルミニウム、インジウム、又はこれらの合金若しくはコンポジットのうちの少なくとも1つを含んでなる、請求項1に記載のロウ付けされたコーティング済みダイヤモンド含有材料。
- 第一のダイヤモンド含有材料に耐熱性金属層を適用すること;
熱源を適用して、ロウ付け金属、前記耐熱性金属層、及び基材を、前記ロウ付け金属を溶融させる所定の温度にて加熱すること;並びに、
前記溶融ロウ付け金属を、前記耐熱性金属層及び基材と接触させること、
を含んでなる方法。 - 前記基材と前記耐熱性金属層との間に、ロウ付け金属層を形成することをさらに含んでなる、請求項12に記載の方法。
- 前記ロウ付け金属が、銀、銅、マンガン、ニッケル、亜鉛、パラジウム、クロム、ホウ素、チタン、スズ、ケイ素、カドミウム、金、アルミニウム、インジウム、又はこれらの合金若しくはコンポジットのうちの少なくとも1つを含んでなる、請求項13に記載の方法。
- 前記熱源が、トーチ、炉、マイクロ波装置、アーク溶接機、レーザー、又は誘導コイルのうちの少なくとも1つである、請求項13に記載の方法。
- 前記熱源が、誘導コイルである、請求項13に記載の方法。
- 前記所定の温度が、少なくとも約5秒間にわたって約700℃から約1000℃に維持される、請求項13に記載の方法。
- 熱源を適用して、ロウ付け金属、耐熱性金属層、及び基材を、前記ロウ付け金属を溶融させる所定の温度にて加熱すること;並びに、
前記耐熱性金属層と前記基材との間にロウ付け金属層を形成すること、
を含んでなる、コーティング済みダイヤモンド含有材料を基材にロウ付けするロウ付け方法。 - 前記ダイヤモンド含有材料が:
第一のダイヤモンド含有材料;及び、
耐熱性金属又は耐熱性金属合金を含んでなる耐熱性金属層であって、ここで、前記耐熱性金属層は、前記第一のダイヤモンド含有材料と操作可能に接続される、耐熱性金属層、
を含んでなる、請求項19に記載の方法。 - 前記ダイヤモンド含有材料が、炭化物層をさらに含んでなり、ここで、前記炭化物層は、前記第一のダイヤモンド含有材料と前記耐熱性金属層との間に挟まれている、請求項19に記載の方法。
- 前記溶融ロウ付け金属を、前記耐熱性金属層及び前記基材に接触させることをさらに含んでなる、請求項19に記載の方法。
- 前記ロウ付け金属層が、銀、銅、マンガン、ニッケル、亜鉛、パラジウム、クロム、ホウ素、チタン、スズ、ケイ素、カドミウム、金、アルミニウム、インジウム、又はこれらの合金若しくはコンポジットのうちの少なくとも1つを含んでなる、請求項19に記載の方法。
- 前記基材が、第二のダイヤモンド含有材料、超硬質合金、多結晶立方晶窒化ホウ素(cBN)超砥粒、セラミック、金属、金属合金、及び/又はこれらの組み合わせを含んでなる、請求項19に記載の方法。
- 前記第一のダイヤモンド含有材料が、単結晶ダイヤモンド、化学蒸着ダイヤモンド、炭化ケイ素結合ダイヤモンドコンポジット、コバルト‐多結晶ダイヤモンドコンポジット、熱安定性ダイヤモンドコンポジット、及び/又はこれらの組み合わせのうちの少なくとも1つを含んでなる、請求項20に記載の方法。
- 前記第一のダイヤモンド含有材料が、単結晶ダイヤモンド、化学蒸着ダイヤモンド、炭化ケイ素結合ダイヤモンドコンポジット、コバルト‐多結晶ダイヤモンドコンポジット、熱安定性ダイヤモンドコンポジット、及び/又はこれらの組み合わせのうちの少なくとも1つを含んでなる、請求項24に記載の方法。
- 前記耐熱性金属が、タングステン、チタン、ニオブ、ジルコニウム、タンタル、バナジウム、クロム、又はモリブデンを含んでなり;並びに、
前記耐熱性金属合金が、少なくとも1つの耐熱性金属、及び所望に応じて含んでよい少なくとも1つの非耐熱性金属を含んでなる、
請求項20に記載の方法。 - 前記炭化物層が、前記耐熱性金属又は前記耐熱性金属合金の少なくとも1つの金属を含んでなる、請求項21に記載の方法。
- 前記炭化物層が、約0.005μmから約5μmの厚さを有する、請求項21に記載の方法。
- 前記所定の温度が、少なくとも約5秒間にわたる約700℃から約1000℃の範囲である、請求項6に記載の方法。
- 前記熱源が、トーチ、炉、マイクロ波装置、アーク溶接機、レーザー、又は誘導コイルのうちの少なくとも1つである、請求項19に記載の方法。
- 前記熱源が、誘導コイルである、請求項19に記載の方法。
- 前記ロウ付け方法が、雰囲気圧力下、空気中にて行われる、請求項19に記載の方法。
- 前記ロウ付け方法が、不活性ガス下にて行われる、請求項19に記載の方法。
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US20130022836A1 (en) | 2013-01-24 |
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