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Nebel, 2012

Titel Detonationsspritzen von Diamant-Bronze-Verbundschichten für die Gesteinsbearbeitung
Autor/Autorin Nebel, Jan
Verleger Essen : Vulkan-Verl.
Erscheinungsjahr 2012
Gesamttitel Werkstofftechnologische Schriftenreihe ; Bd. 6
Hochschulschrift Zugl.: Dortmund, Techn. Univ., Diss., 2012
ISBN 978-3-8027-8814-7
Sprache Deutsch (ger)
Bezugsquelle 31,50 € beim Vulkan-Verlag


Diamond tools are utilized to a great extend for the machining of stone and show huge market potentials, especially in the field of rock sawing and surface grinding. However, continuously growing markets as well as new grinding applications lead to an increased demand for alternative manufacturing processes which enable the flexible and individual production of customized grinding tools.

The detonation spraying process (DGS) provides ideal preconditions as it shows a high geometric variability (tool design) and flexibility (substrate and matrix material). Furthermore, the atmospheric conditions and the low process complexity of the DGS process are some of the advantages. Grinding tools can be generated in one production step. Neither pressing tools nor subsequent joining processes are necessary.

Within the scope of this work, diamond-bronze composite coatings were produced successfully by using DGS. In fact, the DGS-process provides the relevant kinetic energies necessary to achieve a sufficient implantation into the simultaneously sprayed bronze layer. Indeed, the diamonds are accelerated to velocities up to 837 m/s in the spray jet. During the impact, they penetrate deep into the ductile matrix material. A high bonding strength of the diamond particles is given by the perfect mechanical interlocking.

Friability tests, fracture force tests, scanning electron microscopy, X-ray diffraction, and Raman spectroscopy were used to investigate the mechanical and thermal impact on the sprayed diamond superabrasives. It was found that under optimized detonation spraying conditions the thermal and mechanical impact remain low enough to ensure a good reliability of the processed diamonds. The diamond crystal structure endured the spraying process without detectable graphitization or oxidation. Furthermore, high durability and strength of the sprayed diamonds were confirmed. Optimized DGS parameters combined with controlled temperatures during the spraying process further guarantee a low oxidation, minimal porosity, and a high ductility of the bronze matrix which promise excellent retention and wear characteristics of the coating.

The performance and endurance of the DGS-sprayed diamond-bronze composites could be confirmed in a series of laboratory grinding tests. When compared with conventionally sintered grinding tools, the DGS-sprayed composites showed similar grinding properties and erosion rates.