Active Braze Coated Diamond (ABCD)

Abstract

The thick braze alloy coating can hold diamond much firmer than thin element coatings (Ti, Cr, Si) of commercial saw diamond grits. Moreover, the braze alloy can form metallurgical bonding readily with the metal matrix of saw segments. As a result, diamond saws that employ ABCD can cut much faster and last much longer than conventional designs. ABCD can be planted in metal matrix to form three dimensional pattern, the chemical bonding of diamond and its controlled spacing can virtually eliminate diamond loss due to pullouts and diamond breakage due to excessive impact force. The greatly increased number of working crystals can extend the segment life by one order of magnitude. With the thick coating, ABCD can join together to form needles or plates that could not be possible with thinly coated diamond. The ABCD needles or plates can be planted or arranged in a metal matrix to form a three-dimensional structure. Such unique designs can greatly expand the functions of diamond saws.