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Effect of Sintering Temperature and Boron Carbide Content on the Wear Behavior of Hot Pressed Diamond Cutting Segments

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Effect of Sintering Temperature and Boron Carbide Content on the Wear Behavior of Hot Pressed Diamond Cutting Segments Science of Sintering, 47 (2015) 131-143 ________________________________________________________________________ doi: 10.2298/SOS1502131I UDK 546.261; 622.785 Effect of Sintering Temperature and Boron Carbide Content on the Wear Behavior of Hot Pressed Diamond Cutting Segments S. Islak1,*), H. Çelik2 1 Kastamonu University, Faculty of Engineering and Architecture, Department of Materials Science and Nanotechnology Engineering, 37000, Kastamonu, Turkey 2 Firat University, Faculty of Technology, Department of Metallurgy and Materials Engineering, 23100, Elazig, Turkey Abstract: The aim of this study was to investigate the effect of sintering temperature and boron carbide content on wear behavior of diamond cutting segments. For this purpose, the segments contained 2, 5 and 10 wt.% B4C were prepared by hot pressing process carried out under a pressure of 35 MPa, at 600, 650 and 700 °C for 3 minutes. The transverse rupture strength (TRS) of the segments was assessed using a three-point bending test. Ankara andesite stone was cut to examine the wear behavior of segments with boron carbide. Microstructure, surfaces of wear and fracture of segments were determined by scanning electron microscopy (SEM-EDS), and X-ray diffraction (XRD) analysis. As a result, the wear rate decreased significantly in the 0-5 wt.% B4C contents, while it increased in the 5-10 wt.% B4C contents. With increase in sintering temperature, the wear rate decreased due to the hard matrix. Keywords: Diamond cutting segments, B4C, sintering temperature, wear, TRS 1. Introduction Diamond cutting tools are commonly used for cutting, drilling, grinding, and polishing natural stone [1]. Diamond cutting tools are comprised of a metallic matrix and cutting grain (generally diamond). The hot pressing method enables the synthetic diamond to bond with the metallic matrix [2-4]. The two basic functions of the metallic matrix are to hold the diamond tight and to wear at a rate compatible with the diamond loss. Carbides were added to the matrix in order to increase the wear resistance of the metallic matrix. The number of subject-related studies in literature is limited. Meszaros and Vadasdi [5] produced Co-2% WC matrix diamond cutting tools. The study reported that WC controlled the weight loss of the matrix with abrasion and ultimately increased the wear resistance. Oliveira et al [6] used Fe-Cu-SiC powders as a matrix for diamond cutting tools. There was a 14% rate of increase at the hardness level that has a controlling effect on the rate of wear with the addition of SiC. In this investigation, the effect of boron carbide content, known to be the hardest material with the best mechanical properties after diamond and cubic boron nitride [7-10], and the sintering temperature on the bending strength and wear behavior of diamond cutting segments were studied. _____________________________ *) Corresponding author: [email protected] 132 S. Islak et al. /Science of Sintering, 47 (2015) 131-143 ___________________________________________________________________________ 2. Materials and Experimental Studies The raw materials used in experiments were bronze powder (85 wt.% Cu + 15 wt.% Sn, purity 99.9%, grain size 45-50 µm), boron carbide powder (79 wt.% B + 21 wt.% C, purity 99.5%, grain size 20 µm), and synthetic diamond grain (grain size 40/50 US mesh). Boron carbide grains were added to the bronze at the amount of 2, 5 and 10 wt.% percents. The amount of diamond was selected as concentrations of 30. Fig. 1 illustrates the SEM micrographs of bronze powder, boron carbide powder, and the diamond grain. As illustrated in the SEM micrographs, bronze powder has an irregular shape, boron carbide powder has a variable structure and is sharp-edged, and diamond grains have a cubic octahedral structure. Fig. 1. SEM micrographs of (a) bronze powder, (b) boron carbide powder and (c) synthetic diamond grains. S. Islak et al./Science of Sintering, 47 (2015) 131-143 133 ___________________________________________________________________________ Bronze, boron carbide powders and diamond grain were homogeneously mixed by the adding paraffin wax in a mixer. The powder mixtures prepared were directly hot pressed in graphite moulds for 3 min at 600, 650 and 700 °C with an applied pressure of 35 MPa on an automatic hot pressing machine. The circular diamond saw blade used in the present tests had a diameter of 300 mm and a steel core of thickness 1.8 mm, 21 pieces of diamond impregnated segments (size 40 x 7 x 3.2 mm) were brazed to the periphery of circular steel core with a standard narrow radial slot. Fig. 2 illustrates the completed circular diamond cutting tool. Fig. 2. The completed diamond cutting tool. The relative density, hardness and transverse rupture strength of the segment matrix were determined. The relative densities of segments were measured by Archimedes’ principle. Hardness measurements were performed using a Brinell scale with a ball diameter of 2.5 mm and a load of 62.5 kg. The three-point bending tests were performed to determine the transverse rupture strength (TRS) of the segments. The size of the hot-pressed segment for the three-point bending test was 40 x 7 x 3.2 mm. The wear behaviour of diamond cutting segments was tested by cutting a 500 x 150 x 30 mm andesite using a stone cutting machine. The amount of andesite cut during the cutting process was calculated by multiplying the cut length with the cut depth. The diameters of the circular diamond saw blades were measured before and after the cutting procedure using a digital caliper with a resolution of 10-2 mm. The wear rate (mm/m2) of each segment was calculated by dividing the radial wear (mm) of each segment with the amount of andesite cut (m2) [11, 12]. A scanning electron microscope (SEM) fitted with an energy dispersion X-ray spectroscopy (EDS), an X-ray diffractometer were used to investigate the fractured and wear surfaces, and identify the phase structures, and how the microstructure of segments changed based on the sintering temperature and boron carbide content. 3. Results and discussion 3.1. Microstructure The segments containing B4C were successfully produced using the hot pressing method together with a sintering time of three minutes at 600, 650, and 700°C, under a pressure of 35 MPa. Fig. 3 illustrates the XRD pattern of the segments manufactured in the present study. As illustrated, α-Cu, ε-bronze (Cu3Sn) and B4C phases formed in the microstructure of the segment matrix. The formation of α-Cu and ε-bronze phases was 134 S. Islak et al. /Science of Sintering, 47 (2015) 131-143 ___________________________________________________________________________ supported with the Cu-Sn binary phase diagram (Fig. 4). 800 ο α−Cu Δ Cu Sn (ε−bronze) ο 3 600 ο ο Δ 700 oC 400 o Lin (Counts) 650 C 200 600 oC 0 20 30 40 50 60 70 80 90 (a) 2-Theta-Scale 1000 Δ Cu Sn (ε−bronze) 3 ο α−Cu Β C ο 4 800 ο 600 ο Δ 700 oC 400 Lin (Counts) 650 oC 200 o 0 600 C 20 30 40 50 60 70 80 90 (b) 2-Theta-Scale Fig. 3. XRD pattern of the segments: (a) bronze and (b) 5 wt.% B4C. Fig. 4. Cu-Sn binary phase diagram [13]. S. Islak et al./Science of Sintering, 47 (2015) 131-143 135 ___________________________________________________________________________ Fig. 5 illustratess the SEM images of the microstructure of segments without boron carbide. As illustrated, the amount of pores in the segments sintered at 600 °C was more in comparison to that of 700 °C. The amount of pores decreased at a high sintering temperature, which lead to high speed solid-state diffusion [14]. The pores formed at the grain boundary. Fig. 5. The SEM image of CuSn (no B4C added) segment, (a) 600 °C and (b) 700 °C. Fig. 6 illustrates the SEM images of the segments produced by adding 2%, 5%, and 10% B4C in weight to bronze powder. The B4C grains were relatively homogeneously distributed throughout the microstructure, and surrounded by bronze. In micrographs, light grey areas indicate bronze matrix, and the dark grey and cornered shapes indicate the reinforcement component B4C. As illustrated in Fig. 6, as the sintering temperature and B4C addition increases, B4C grains spread towards the bronze grain boundaries, like a homogenous network. The XRD patterns illustrate that there was no chemical reaction between bronze and B4B C. The level of porosity increased together with the increased rate of boron carbide because boron carbide had an adverse effect on sinterability [15]. Table 1 illustrates the EDS analysis of regions identified in the SEM images illustrated in Fig. 6. The region 1, 2, and 3 illustrate B4B C, CuSn and Cu3Sn phases, respectively. 136 S. Islak et al. /Science of Sintering, 47 (2015) 131-143 ___________________________________________________________________________ Fig. 6. SEM images of the segments containing boron carbide: (a) 2 wt.% B4C - 600 °C, (b) 5 wt.% B4C - 600 °C, (c) 10 wt.% B4C - 600 °C, (d) 2 wt.% B4C - 700 °C, (e) 5 wt.% B4C - 700 °C and (f) 10 wt.% B4C - 700 °C. Tab. I EDS analysis of regions identified in the SEM images illustrated in Fig. 6 Chemical Composition (wt.%) Regions B C Cu Sn 1 79.18 19.80 0.00 1.02 2 0.00 0.00 85.89 14.11 3 0.00 0.00 62.28 37.72 S. Islak et al./Science of Sintering, 47 (2015) 131-143 137 ___________________________________________________________________________ 3.2. Density and hardness Tab. II illustrates the effect of sintering temperatures and boron carbide on densities of segments. When boron carbide was introduced to the CuSn, it decreased the sintered density. This was due to the fact that the density of boron carbide was lower than that of 3 3 bronze.
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