The Almighty Diamond Blade

Posted on May 6, 2021

Diamond Blade

There are diamond blades available in different shapes. The most commonly used diamond blades are diamond blades with circular saws. A long steel plate with diamond segments welded to it is a diamond blade. Typically, to cut raw stone blocks, tens or hundreds of diamond saws are used together.

If you take a diamond blade and make a microscopic view of it, you can see the wear of metal on the blade below the diamonds. If you need to cut extremely hard materials, or cutting rough or abrasive materials, a diamond blade is a saw blade with diamonds added to the tip. In the construction and building industry, there are many kinds of diamond blades that have many uses, including cutting steel, concrete, cement, bricks, carbon beads, glass, and ceramics; cutting semiconductor materials in the IT industry; and cutting precious stones in the gemstone industry, including diamonds. Besides diamond blades, diamonds are used in the construction of other types of diamond tools such as diamond drill bits.
 

General Features of Diamond Blades

There are diamond blades available in different shapes. The most commonly used diamond blades are diamond blades with circular saws. A long steel plate with diamond segments welded to it is a diamond blade. Typically, to cut raw stone blocks, tens or hundreds of diamond saws are used together.

A lightweight, closed steel band with diamonds secured (often by electroplating) to one edge of the band is a diamond band saw. Marble, blades, and diamond blades designed for particular applications include marble, gravel, brick, masonry, and precious stones. Diamond blades are also available as general-purpose knives.
 

:: Read More: What's a Blade for Cutting?
 

Techniques of Manufacturing Diamond Blade

Galvanizing of diamond blade inserted in a metal shell using diamonds, typically nickel-plated on the steel base of the blade, can be very thin. Blades can be tens of micrometers thick for accurate cutting purposes.
 

Brazing Vacuum

In a vacuum brazing furnace, vacuum brazed diamond saw blades are formed by brazing synthetic diamond particles to the outer edge of a saw blade. Both the diamond fragments, without metal and diamond mixed in, are on the outer cutting edge of the blade. Vacuum brazed blades can cut a wide range of materials, including concrete, masonry, steel, different types of iron, plastics, bricks, wood, and glass, based on the recommended blade application from the manufacturer.

Tile chipping and burrs in the steel with a cleaner finish would be minimized by the finer synthetic diamond grit. Larger diamond grains have the greater cutting speed for diamonds but are more likely to cause chipping, burring, or cracking. To cut through the material easily, the fire service allows the blades to be made with extra-large diamond grit. Medium-size grains are used in the manufacturing industry.
 

Sintering of Diamond Blade

Sintered diamond blades with a metal bond are the most common blade type. These blades consist of a steel core (as opposed to the wires used in diamond cutters, the foundation is a steel plate) and diamond segments that are formed by mixing and then sintering synthetic diamond crystals with a metal powder. The diamond segments are also known as the blade's "cutting teeth".

The steel core can be different in nature. To provide cooling and sludge removal, some cores have gaps (called dimples) between the pieces, while others have a single continuous rim for a cleaner cut. The type of core that should be used depends on the type of stone that is supposed to be cut from the diamond cutter.

In general, according to their manufacturing techniques, three types of sintered metal bonded diamond wheels exist. They are Fully-sintered Diamond Blades, Silver-brazed Diamond Blades, and Laser-welded Diamond Blades.

Fully Sintered Diamond Blade
By putting a steel core together with diamonds and metal-binding materials in a mold and then sintering it in a sintering device, a completely sintered diamond blade is made. The diameter of absolutely sintered diamond wheels is therefore not very wide, typically not exceeding 400 millimeters (16 inches). The steel core will not be hardened, since it is used in the sintering process, so the core's hardness and strength are not too strong. It suggests that these types of diamond blades can deform during cutting processes under heavy loads and high intensity, and can show poor cutting performance.

As the diamond segments and steel heart are treated separately, platinum, brazed and laser-welded diamond blades do not have this limitation. The steel core can be hardened and cured with other heat additives, so its strength and durability can be high, which ensures that the blade can be used with high cutting performance and less deformation in high load and intensity cutting processes.

Silver-brazed Diamond Blade
Gold brazed diamond blade parts of silver braze are brazed to the steel core. Only for wet seedlings will these blades be used. Silver solder can melt and parts can fall off the steel core if used in dry cuts and become a severe safety threat.

Laser-welded Diamond Blade
To form a better weld that can keep the segments even at high temperatures, the laser melts and connects the metal of the diamond segment and the steel heart, which ensures that laser welded diamond blades can be used to break certain kinds of stone without water cooling. However when cutting very rough or abrasive materials, for example, concrete rebar reinforcement. With an adequate volume of water, laser-welded diamond blades can also be used. Failure to do so could lead to the failure of the diamond segment itself or the steel core below the wear and tear and crack segment, causing a significant safety threat.
 

Usage of Sintered Diamond Blades Bonded with Metal

Bond is the term used to characterize the metal powder's softness or stiffness used to shape the segments. The diamonds are kept in place by powdered metals. The bond governs how much the segments of the diamond wear off, causing the surface to be exposed to new diamonds and the grinding, to begin with, a 'sharp tip. The matching of the binder to the individual material being sliced is an important step in selecting a cutter.

Other variables to consider are the form of power of the Equipment to be used and the supply of water. To allow continuous diamond exposure, harder materials need a softer bonding section. To offset the increased wear that occurs in tougher abrasives, softer materials such as asphalt or freshly poured concrete may use a harder section. Furthermore, the diamond grit (size), intensity, and concentration should also be compatible with the quality of the cut content. When crushing hard materials, for instance, diamonds can be smaller.

When choosing a diamond blade for your particular use, there are other considerations to remember. This includes the blade form (production method), the presence of water in the cutting process, the strength of the saw, and the appropriate amount of noise that the saw makes. For example, if the strength of the saw is strong, the diamond concentration should be higher on the diamond blade or the bond should be harder.
 

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