Advancement in manufacturing technology and development of alternate materials are key factors enabling today’s process and product development.Diamondcutting tools have a long history started back in 1862, which has gone through tremendous change in last 50 years with the development of synthetic diamond and continuous exploration of alternate metal matrix materials.
For each specific application, powder for metal matrixesrequires careful selection based on its chemical composition, particle size, shape and thermal stability.
‘Cobalt powder’ was the most commonly used metal matrix powder. However, fluctuating price and health concerns associated with cobalt powder has compelled the industry to search for more economical and sustainable alternative. For that matter,iron and Iron based alloy powders turned out to be promising metal matrix powders alternatives for use in diamond cutting tools catering cutting, drilling, grinding, etc applications.
Lets’check these 4 iron powders for diamond cutting tools
Carbonyl Iron Powder
Diamond tool industry is moving towards cost effective solutions and adopting the process of free sintering where the fine form of iron is important. Hence, being fine form, Carbonyl iron powder is an excellent alternative and long-term term option for this industry. Its spherical shape helps for better flow in sintering. However, this is most expensive type of iron powder and totally depends on its import from various parts of world. Due to shortage/delayed, many tools manufacturers will not be able to use it even it is one of the best iron for diamond tool industries. Tools manufacturer now looking for cost alternative and being the best quality, carbonyl use is going towards down.
Atomized Iron Powder:
. Atomised Iron Powder is produced by disintegration of a thin stream of molten iron through the invasion of high energy water jets. It is then dried after atomisation. It has particle size limitation and could be get max 45 micron in sizes. It is spherical in size and mostly for PM industries where flow rate is very important. In Diamond cutting tool industry, it is use as an alternative for specific applications due to cost benefits. However, it has low compressibility and hardness. It needs more sintering temp due to its surface area as oxide is present more its surface. Due to coarser, it works for fast cutting tools. It holds diamond due to more porosity compare to other iron.
Reduced Iron Powders
This form of iron is rarely use in this industry since mechanically and chemically not more suitable for diamond cutting tools. Due to its very low cost and coarse particle sizes, few of specific applications use this powders with mix of other expensive metal powders
Electrolytic Iron Powder:
It is a special type of elemental iron that is marked by its high-level purity (more than 99.5%). It is produced through the chemical electrolysis. This is one of the best forms of iron available for the diamond cutting tool industries. Diamond cutting tool industries started using electrolytic iron way back in 18 centuries. Due to its consistent particle sizes, irregular shape, extremely high purity, excellent compressibility, electrolytic iron powder is the first choice of tools and abrasive manufacturers. It helps for better sintering properties, increasing the life of machines. It gets sintered @ low temperature due to its surface area. It is available from coarse to fine particle which enable the tools manufacturers to get the options based on their tools/abrasive’s requirement. It is most cost-effective iron with replacement for expensive metal powders.
Diamond tool industry using this iron for all types of tools and abrasives like segments, polishing tools, wire beads, core drills, etc. Electrolytic iron powder proves best in these parameters and is most suitable for diamond cutting tools.
Conclusion
Iron powder is one of the key elements for diamond cutting tool industry. Electrolytic iron powder is one of the most preferable Iron forms being use to make the various tools and abrasives. It helps manufacturers to make the tools equivalent to import segments and to support India to MAKE IN INDIA. Being the largest manufacturer, Industrial Metal Powders (I) Pvt Ltd has made this reputation to supply the quality @ economical costing, Imp always focus to create the options to the various industries and to support them by giving indigenous long term supplier for their need to happen make in India. Lets be vocal for local.
Â
