Diamond-coated hard material and a process for the production th

Details Diamond-coated hard material and a process for the production th Diamond-coated hard material and a process for the production th

1993-04-27

1994-12-06

Walsh, Donald P.

Stock material or miscellaneous articles

All metal or with adjacent metals

Having metal particles

428547, 428548, 428551, 428552, B22F 707, B22F 706, C23C 1622

Patent

active

053709446

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

This invention relates to a diamond-coated hard material having a very high wear resistance and excellent bonding strength to a substrate and a process for the production of the same, the hard material of the present invention being suitable for use as cutting tools, wear resistant tools, mine tools, electronics parts, mechanical parts, grinding wheels, etc.


BACKGROUND TECHNIQUE

Diamond has many excellent properties, for example, very high hardness, chemical stability, high heat conductivity, high sound wave propagation speed, etc. At the present time, in the market, there have widely and practically been used, as polycrystalline diamond, (1) a polycrystalline diamond sintered compact comprising at least 70 volume % of diamond grains bonded with each other, (2) a diamond-coated hard material comprising a hard material the surface of which is coated with diamond polycrystal and (3) a hard material brazed with diamond polycrystal, for example,
1 cutting tools such as throwaway inserts, drills, microdrills, endmills, routers, etc., which are used for cutting working light metals such as Al, Al--Si alloys, etc., plastics, rubbers, graphite and the like;
2 rock mining tools;
3 various wear resistant tools, wear resistant jigs and environment resistant tools such as bonding tools, printer heads, dies, guide rollers for hot working, rolls for making pipes and the like;
4 various machine parts such as radiating plates;
5 various vibration plates such as speakers;
6 various electronic parts; and
7 various grinding or polishing wheels such as electrodeposited grinding wheels and dressers.
The polycrystalline diamond compact obtained by sintering diamond fine powder under ultra-high pressure has been disclosed in, for example, Japanese Patent Publication No. 12126/1977. According to a production process described in this publication, diamond powder is arranged to be in contact with a formed or sintered body of cemented carbide and sintered at a temperature of higher than the liquidus temperature of the cemented carbide under an ultra-high pressure, during which a part of Co in the cemented carbide intrudes into the diamond powder and functions as a binder metal. The thus obtained diamond compact is worked in a desired shape, brazed to various alloys and widely used for, for example, cutting tools, wear resistant tools, digging tools, dressers, wire-drawing dies, etc.
The diamond-coated hard material comprising a hard material the surface of which is coated with polycrystalline diamond has widely been used in the similar manner to the above described diamond compact. As the prior art, there are a number of publications such as Japanese Patent Laid-Open Publication Nos. 57802/1987, 57804/1987, 166904/1987, 14869/1988 and 140084/1988, in which the surface of a hard material with a suitable shape is coated with polycrystalline diamond synthesized from gaseous phase to markedly improve the wear resistance of the substrate. The diamond-coated hard material obtained by this method has a high degree of freedom in shape and a large advanatge such that it can economically be produced in a large amount, and has widely been used as, for example, cutting tools, wear resistant tools, digging tools, dressers, wire-drawing dies, etc.
Furthermore, a diamond coated layer is formed on a surface of a substrate from gaseous phase and the substrate is removed by etching to prepare a plate of polycrystalline diamond, which is worked in a desired shape and brazed to various base metals. The resulting article has been applied to, in addition to the above described uses, various vibrating plates including those of speakers, filters, window materials, etc.
At the present time, there are methods of coating the surface of a substrate with polycrystalline diamond from gaseous phase, for example, microwave plasma CVD method, RF-plasma CVD method, EA-CVD method, induction field microwave plasma CVD method, RF hot plasma CVD method, DC plasma CVD method, DC plasma jet method, filament hot CVD method, combustion method and like. T

REFERENCES:
patent: 4966501 (1990-10-01), Nomura et al.
patent: 5068148 (1991-11-01), Nakahara et al.
patent: 5100703 (1992-03-01), Saijo et al.
patent: 5181953 (1993-01-01), Nakano et al.

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