Determination of the wear mechanism of the diamond tool matrix by analysis of wear particles
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2025-08-27 |
| Journal | Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu |
| Authors | O.P. Vynohradova, Viktoriia Vapnichna |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Diamond Tool Wear Mechanisms
Section titled âTechnical Documentation & Analysis: Diamond Tool Wear MechanismsâThis document analyzes the research paper, âDetermination of the Wear Mechanism of the Diamond Tool Matrix by Analysis of Wear Particles,â focusing on its implications for the design and manufacturing of high-performance diamond tools using 6CCVDâs advanced MPCVD materials.
Executive Summary
Section titled âExecutive SummaryâThis research provides critical insights into the brittle wear mechanisms governing the service life of diamond rock-breaking tools, directly informing material selection and design optimization for high-stress applications like geological drilling.
- Core Finding: The primary wear mechanism of the metallic matrix (Ni-Sn 6 wt%) is brittle chipping caused by microindentation from sharp rock edges (e.g., quartz grains, Mohs 7) under dynamic loading.
- Mechanism Confirmation: Wear particles exhibit a characteristic âdovetailâ configuration and contain elliptical grooves (4.2 ”m x 0.8 ”m) that serve as the epicenter for microcrack formation.
- Material Identity: Chemical analysis (EDX) confirmed the identity of the wear particles with the original matrix material, validating the use of sludge analysis as a diagnostic tool.
- Practical Value: Determining the chemical and morphometric features of wear particles allows for the development of quantitative wear resistance criteria, leading to significant resource savings in diamond tool production and operation.
- Relevance to 6CCVD: The findings underscore the need for highly robust, thermally stable diamond elements (PCD) and specialized bonding techniques (metalization) to resist the high-impact, brittle failure mode identified.
Technical Specifications
Section titled âTechnical SpecificationsâThe following hard data points were extracted from the experimental results and context provided in the research paper:
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Matrix Composition (Tin) | 6 | wt% | Ni-Sn bond system (experimental element) |
| Rock Indentor Hardness | 7 | Mohs scale | Sharp quartz grains in abrasive sandstone |
| Elliptical Groove Major Axis | 4.2 | ”m | Direct contact point of microindenter |
| Elliptical Groove Minor Axis | 0.8 | ”m | Direct contact point of microindenter |
| Small Microhole Width (aâ) | Up to 100 | ”m | Wear particle morphology |
| Large Microhole Width (aâ) | > 100 | ”m | Wear particle morphology |
| Small Microhole Step (hâ) | ~35 | ”m | Distance between microholes in chain |
| Large Microhole Step (hâ) | ~120 | ”m | Distance between microholes in chain |
| Diamond Grain Size (Example) | 200/160 | N/A | Used in comparative SEM analysis of tool bond |
Key Methodologies
Section titled âKey MethodologiesâThe experimental procedure focused on simulating dynamic drilling conditions and analyzing the resulting wear debris and surface morphology.
- Matrix Synthesis: The experimental element (diamond-free matrix) was fabricated using resistive electro-sintering based on the Ni-Sn (6 wt%) system.
- Dynamic Testing: Short-term contact tests were conducted on a specialized stand built upon a DIP-200 screw-cutting lathe, simulating the technological parameters of the drilling process.
- Friction Pair: The test involved dynamic contact between the experimental element surface and a block of abrasive sandstone (Torez deposit).
- Sludge Analysis (Chemical): Wear particles (sludge suspension) were analyzed using a ZEISS EVO 50 XVP Scanning Electron Microscope (SEM) coupled with an Oxford Instruments Ultim Max Energy Dispersive X-ray (EDX) analyzer to determine chemical composition (Ni, Sn, C, O, Si, Al, etc.).
- Surface Analysis (Morphometric): Worn surfaces and wear particles were examined using Lomo Metam R-1 and Bausch & Lomb Gemolite optical microscopes with a Digital KOCOM CCD video camera to characterize microgrooves, microholes, and crack systems.
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & CapabilitiesâThe research highlights that the integrity of the diamond tool relies heavily on the resistance of the matrix and the diamond elements to microindentation and brittle fracture. 6CCVD provides the advanced MPCVD diamond materials necessary to meet and exceed the demands of this high-wear environment.
Applicable Materials
Section titled âApplicable MaterialsâTo replicate or extend this research into functional tools, engineers require diamond materials optimized for extreme mechanical and thermal stability.
- Polycrystalline Diamond (PCD): Recommended for the active cutting elements in rock-breaking tools. MPCVD PCD offers superior toughness and thermal stability compared to traditional sintered PCD, directly mitigating the brittle chipping mechanism identified in the study.
- Single Crystal Diamond (SCD): Recommended for high-precision micro-indentors or specialized wear parts where ultra-low roughness and maximum hardness are critical (Ra < 1nm).
- Custom Thickness: 6CCVD supplies both SCD and PCD layers ranging from 0.1 ”m up to 500 ”m, allowing tool designers to specify the exact diamond volume required for optimal performance and resource efficiency.
Customization Potential
Section titled âCustomization PotentialâThe study emphasizes the importance of integrating the diamond element seamlessly into the metallic bond (like the Ni-Sn system). 6CCVD offers comprehensive services to facilitate this integration.
| Research Requirement | 6CCVD Customization Service | Benefit to Engineer |
|---|---|---|
| Large Tooling Formats | Custom Dimensions up to 125mm (PCD). | Enables the manufacture of large-diameter drill bits and inserts, accommodating industrial-scale geological exploration needs. |
| Robust Bonding Interface | In-House Metalization Services. | We apply custom metal layers (Au, Pt, Pd, Ti, W, Cu) directly to the diamond surface, ensuring superior wetting and adhesion to the metallic matrix (e.g., Ni-Sn bond) during high-temperature sintering or brazing. |
| Specific Grain Structure | Tailored MPCVD Synthesis. | Our process allows for control over the grain size and morphology of the PCD layer, enabling optimization against specific abrasive rock types (e.g., Mohs 7 quartz). |
| Precision Shaping | Laser Cutting and Machining. | We provide precise cutting and shaping of diamond plates to create the exact geometries required for tool inserts, ensuring optimal protrusion and contact geometry as discussed in the paper. |
Engineering Support
Section titled âEngineering SupportâThe complex interaction between the diamond element, the matrix, and the rock requires specialized knowledge.
- 6CCVDâs in-house PhD-level engineering team specializes in MPCVD diamond physics and material science. We offer consultation on material selection, surface preparation, and bonding strategies for similar Diamond Rock-Breaking Tool projects.
- We assist clients in defining the optimal diamond grade (SCD vs. PCD) and surface finish (Ra < 5nm for PCD) to minimize microcrack initiation and maximize tool life under dynamic loading conditions.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.
View Original Abstract
Purpose. Determining the contact zone of microindentors from the rock side with the surface of a non-diamond element based on the Ni-Sn system (6 wt%) and in comparison with the contact zone of the specified microindentors with the surface of a similar bond of a diamond-containing element, under dynamic loading. Methodology. To select the wear products of the experimental element material, made by resistive electro-sintering and the core of abrasive sandstone as a result of short-term contact between their surfaces, the tests were performed on a stand created on the basis of the screw-cutting lathe ĐĐĐ-200 according to the parameters of technological conditions that simulate the drilling process. The sludge suspension was selected and examined using a ZEISS EVO 50 XVP scanning electron microscope with an Oxford Instruments Ultim Max energy dispersive X-ray analyser. Also, the worn surface of the diamond-free element was subjected to microscopic examination using Lomo Metam R-1 microscopes with a Digital KOCOM CCD video camera and Bausch & Lomb, mod. Gemolite. Findings. The result of the study involves the determination of the direct point of contact between the microindenter on the rock side and the surface of the non-diamond element in the wear particle. The point of direct contact of the specified counterbodies has the form of an elliptical groove, which is the epicenter of the formation of a system of microcracks. The morphometric identity of the wear particles of the studied element and the diamond tool bond indicates the similarity of one of the mechanisms of microindentation from the side of the rock. Originality. Determination of one of the sources of damage to the working surface of the diamond tool element opens up prospects in the study of all stages of the bond wear mechanism depending on changes in its chemical composition or technological parameters of the tool use. Practical value. Determination of the chemical and morphometric features of the wear particles of the diamond tool bond will allow assessing its wear resistance and developing wear resistance criteria, which is reflected in the saving of resources.