Fabrication of a diamond impregnated tool using iron nanopowder binder

Abstract

To replace the high cost material of cobalt matrix, the feasibility of diamond impregnated tools using structure-modified Fe nanopowder was investigated in terms of its compaction and related sintering properties. The structure was controlled that the spherical agglomerate shape for the easily rearrangement at low pressure range and the bimodal typed porous agglomerate structure are principally responsible for the green density improvement. The structure modified Fe nanopowder showed higher compactability than the structure non-treated Fe nanopowder during the compaction process and homogeneously dispersed diamond in the segment. After sintering, the structure modified Fe nanopowder showed sound segment shape and reached 93.7% T.D. without substantial grain growth. The characteristics of compaction and the sintered segments were evaluated in terms of the microstructure. Moreover, a prototype product was made and core-drilling test was carried out using the structure modified Fe nanopowder. The results are discussed in comparison with the standard of commercial products.