JP6871173B2 - 砕けやすいセラミック結合ダイヤモンドコンポジット粒子及びその製造方法 - Google Patents
砕けやすいセラミック結合ダイヤモンドコンポジット粒子及びその製造方法 Download PDFInfo
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- JP6871173B2 JP6871173B2 JP2017558629A JP2017558629A JP6871173B2 JP 6871173 B2 JP6871173 B2 JP 6871173B2 JP 2017558629 A JP2017558629 A JP 2017558629A JP 2017558629 A JP2017558629 A JP 2017558629A JP 6871173 B2 JP6871173 B2 JP 6871173B2
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Description
ここで、P=最大荷重であり、Iは試験取り付け具スパンであり、hは、試験バーの高さであり、またbは、試験バーの幅である。本明細書に開示された様々なプロセスに対するTRS値が、表1に報告されている。
Claims (20)
- セラミック結合ダイヤモンドコンポジット粒子を製造するための方法であって、
複数のダイヤモンド結晶粒、ケイ素粒子、及び、酸化物、炭化物、窒化物、アルミン酸塩、ケイ酸塩、硝酸塩、炭酸塩、シリカ砂、及び立方晶窒化ホウ素(cBN)からなる群から選択される不活性材料を含むダイヤモンド供給原料を生成すること;
前記ダイヤモンド供給原料を、少なくとも1つの圧密化前プロセスに付して、顆粒を生成すること;
前記顆粒を用いた圧密化プロセスにおいて緻密化成形体を生成することであって、前記緻密化成形体は、セラミック結合ダイヤモンドコンポジット材料を含み;並びに
前記緻密化成形体を、複数のセラミック結合ダイヤモンドコンポジット粒子が形成される圧密化後プロセスにおいて、機械的に破壊すること
を含み、
前記セラミック結合ダイヤモンドコンポジット粒子が、複数のダイヤモンド結晶粒、及び前記ダイヤモンド結晶粒に反応により結合した炭化ケイ素を含み、
前記セラミック結合ダイヤモンドコンポジット粒子の組成が、60〜90wt%のダイヤモンド、10〜40wt%の炭化ケイ素、≦2wt%のケイ素を含む、
方法。 - 前記セラミック結合ダイヤモンドコンポジット粒子が、40/50から400/500の間のメッシュサイズ、及び40から100の間の靭性指数を有し、前記靭性指数は、標準的な砕けやすさ試験によって室温で測定され、当該試験は、ある量の製品を制御された条件下でボールミリングを行うこと、及び残留物を篩にかけて、製品の粒子サイズの低下を評価することを含み、プロセス100のスコアが、結晶の最高の靭性である、請求項1に記載の方法。
- セラミック結合ダイヤモンドコンポジット粒子を製造するための方法であって、
複数のダイヤモンド結晶粒、ケイ素粒子、を含むダイヤモンド供給原料を生成すること;
前記ダイヤモンド供給原料を、バインダー及び液体溶媒と混合して、スラリーを生成すること;
前記スラリーを処理して固化顆粒を生成すること;
固化顆粒を、少なくとも1つの圧密化前プロセスを用いて処理すること;
圧密化プロセスにおいて、セラミック結合ダイヤモンドコンポジット材料を含む緻密化成形体を生成すること;及び
前記緻密化成形体を、複数のセラミック結合ダイヤモンドコンポジット粒子が形成される圧密化後プロセスにおいて、機械的に破壊すること、
を含み、
少なくとも1つの圧密化前プロセスが、
前記固化顆粒を、酸化物、炭化物、窒化物、アルミン酸塩、ケイ酸塩、硝酸塩、炭酸塩、シリカ砂、及び立方晶窒化ホウ素(cBN)からなる群から選択される不活性材料、又は炭化物生成金属によりコーティングすること、
前記コーティング後の固化顆粒を含むグリーン体を生成すること、及び
前記グリーン体を脱バインダー処理すること
を含み、
前記セラミック結合ダイヤモンドコンポジット粒子が、複数のダイヤモンド結晶粒、及び前記ダイヤモンド結晶粒に反応により結合した炭化ケイ素を含み、
前記セラミック結合ダイヤモンドコンポジット粒子の組成が、60〜90wt%のダイヤモンド、10〜40wt%の炭化ケイ素、≦2wt%のケイ素を含む、
方法。 - 前記スラリーを処理して固化顆粒を生成することが、前記スラリーを液体窒素の中に噴霧して、複数の凍結顆粒を生成すること、それに続いて、前記凍結顆粒を凍結乾燥して、前記固化顆粒から溶媒を除去することを含む、請求項3に記載の方法。
- 前記スラリーを処理して固化顆粒を生成することが、加熱環境において前記スラリーを噴霧乾燥して、固体の、溶媒を含まない顆粒を生成することを含む、請求項3に記載の方法。
- 前記固化顆粒が、前記グリーン体を生成する前に、前記不活性材料によりコーティングされる、請求項3に記載の方法。
- 2次的加熱プロセスを含み、前記脱バインダー処理されたグリーン体が1000℃から1600℃に加熱されて、前記脱バインダー処理されたグリーン体の強度が改善される、請求項3又は6に記載の方法。
- 前記圧密化プロセスがHPHTプロセスである、請求項1又は3に記載の方法。
- 前記不活性材料が、酸化物、炭化物、窒化物、アルミン酸塩、ケイ酸塩、硝酸塩、及び炭酸塩からなる群から選択される、請求項1又は6に記載の方法。
- 前記不活性材料が、1から100ミクロンの範囲の粒子サイズ(D50に基づく)を有し、1から10重量パーセント(wt%)の量で存在する、請求項1に記載の方法。
- 前記不活性材料が、立方晶窒化ホウ素(cBN)である、請求項1又は3に記載の方法。
- 前記不活性材料が、Al2O3、SiO2及びSiCからなる群から選択され、前記不活性材料が、1から50ミクロンの範囲の粒子サイズ(D50に基づく)を有し、1から10重量パーセント(wt%)の量で存在する、請求項1又は3に記載の方法。
- セラミック結合ダイヤモンドコンポジット粒子を製造するための方法であって、
複数のダイヤモンド粒子及びケイ素粒子を含むダイヤモンド供給原料を生成すること;
前記ダイヤモンド供給原料を、バインダー及び溶媒と混合してスラリーを生成すること;
前記スラリーを液体窒素の中に噴霧して複数の凍結顆粒を生成し、それに続いて、前記凍結顆粒を凍結乾燥して、前記凍結顆粒から溶媒を除去すること、又は、前記スラリーを加熱チャンバ内に噴霧して、揮発成分を除去して固化顆粒を生成すること;
前記凍結顆粒又は前記固化顆粒を、酸化物、炭化物、窒化物、アルミン酸塩、ケイ酸塩、硝酸塩、炭酸塩、シリカ砂、及び立方晶窒化ホウ素(cBN)からなる群から選択される不活性材料でコーティングすること;
不活性又は還元性雰囲気内で前記凍結顆粒又は前記固化顆粒を加熱して、前記凍結顆粒又は前記固化顆粒から前記バインダーを除去すること;
多孔質顆粒を不活性又は還元性雰囲気内で焼結して、セラミック結合ダイヤモンドコンポジット材料のグリットを生成すること;並びに
前記グリットを機械的に破壊して、複数のセラミック結合ダイヤモンドコンポジット粒子を生成すること
を含み、
前記セラミック結合ダイヤモンドコンポジット粒子が複数のダイヤモンド粒子、及びダイヤモンド粒子に反応により結合した炭化ケイ素を含み、
前記セラミック結合ダイヤモンドコンポジット粒子の組成が、60〜90wt%のダイヤモンド、10〜40wt%の炭化ケイ素、≦2wt%のケイ素を含む、
方法。 - 前記セラミック結合ダイヤモンドコンポジット粒子が、40/50から400/500のメッシュサイズ、及び40から100の靭性指数を有し、前記靭性指数は、標準的な砕けやすさ試験によって室温で測定され、当該試験は、ある量の製品を制御された条件下でボールミリングを行うこと、及び残留物を篩にかけて、製品の粒子サイズの低下を評価することを含み、プロセス100のスコアが、結晶の最高の靭性である、請求項13に記載の方法。
- 前記バインダーを除去することが、前記コーティング後の凍結顆粒又は固化顆粒を含むグリーン体を生成し、前記グリーン体を脱バインダー処理することを含む、請求項13に記載の方法。
- 2次的加熱プロセスをさらに含み、脱バインダー処理されたグリーン体が1000℃から1600℃に加熱されて、前記脱バインダー処理されたグリーン体の強度が改善される、請求項15に記載の方法。
- セラミック結合ダイヤモンドコンポジット粒子を製造するための方法であって、
複数のダイヤモンド結晶粒及びケイ素粒子及び、酸化物、炭化物、窒化物、アルミン酸塩、ケイ酸塩、硝酸塩、炭酸塩、シリカ砂、及び立方晶窒化ホウ素(cBN)からなる群から選択される不活性材料の粒子を含むダイヤモンド供給原料を生成すること;
前記ダイヤモンド供給原料からセラミック結合ダイヤモンドコンポジット材料を含む緻密化成形体を生成する圧密化プロセスに、前記ダイヤモンド供給原料を付すこと;
前記緻密化成形体を機械的に破壊して複数のセラミック結合ダイヤモンドコンポジット粒子を生成する圧密化後プロセスに、前記緻密化成形体を付すこと;並びに
前記複数のセラミック結合ダイヤモンドコンポジット粒子から不活性材料の粒子を分離すること
を含み、
前記セラミック結合ダイヤモンドコンポジット粒子が複数のダイヤモンド結晶粒、及び前記ダイヤモンド結晶粒に反応により結合した炭化ケイ素を含み、
前記セラミック結合ダイヤモンドコンポジット粒子の組成が、60〜90wt%のダイヤモンド、10〜40wt%の炭化ケイ素、≦2wt%のケイ素を含み、
前記セラミック結合ダイヤモンドコンポジット粒子が、40/50から400/500のメッシュサイズ、及び40から100の靭性指数を有し、前記靭性指数は、標準的な砕けやすさ試験によって室温で測定され、当該試験は、ある量の製品を制御された条件下でボールミリングを行うこと、及び残留物を篩にかけて、製品の粒子サイズの低下を評価することを含み、プロセス100のスコアが、結晶の最高の靭性である、方法。 - 前記ダイヤモンド供給原料を生成する前に、前記複数のダイヤモンド結晶粒の表面モルホロジーを改質すること、又は、前記複数のセラミック結合ダイヤモンドコンポジット粒子をリーチングすることをさらに含み、リーチングが、前記セラミック結合ダイヤモンドコンポジット粒子を、硝酸及び硫酸のような酸、又は水酸化ナトリウム若しくは水酸化カリウムのような苛性化学物質に接触させることを含む、請求項1、3、及び17の何れか一項に記載の方法。
- 前記表面モルホロジーを改質することが、酸化又は黒鉛化による改質を含む、請求項18に記載の方法。
- 前記複数のセラミック結合ダイヤモンドコンポジット粒子を、金属の合金又は化合物でコーティングすることをさらに含む、請求項1、3、13、及び17の何れか一項に記載の方法。
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WO2019235478A1 (ja) * | 2018-06-04 | 2019-12-12 | 積水化学工業株式会社 | ダイヤモンド粒子、ダイヤモンド含有組成物、及びダイヤモンド粒子の製造方法 |
CN108621024B (zh) * | 2018-07-11 | 2023-11-28 | 北京中研环科科技有限公司 | 金刚石研磨设备 |
CN109534750B (zh) * | 2018-12-25 | 2021-03-30 | 河南联合精密材料股份有限公司 | 一种金刚石团粒及其制备方法和应用 |
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TW202323547A (zh) | 2021-12-13 | 2023-06-16 | 美商合銳材料科技公司 | 具有高熵合金黏合劑之燒結碳化物及金屬陶瓷組成物 |
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