Vacuum brazing is a highly effective method for joining diamond tools and is preferred over traditional soldering methods for several reasons. First, vacuum brazing produces high-strength joints that are difficult to wet by materials such as diamonds, PCD, and PCBN. This results in a more secure bond between the diamond and the tool body, leading to increased tool life and durability.
Second, the process of vacuum brazing is very clean and environmentally friendly, as it does not require the use of fluxes or other chemicals. This is particularly important for diamond tools, as the presence of impurities in the soldering process can negatively impact their performance.
Third, the constant and even distribution of temperature across all components during vacuum brazing helps to avoid residual stresses in the components that can result from heating and subsequent cooling. This helps to retain the thermal and mechanical properties of the diamond tool, and can even improve them in some cases.
Finally, vacuum brazing allows for multiple components with multiple brazing points to be joined simultaneously in one brazing process, as all workpieces are exposed to the same brazing temperature due to radiant heat. This increases efficiency and reduces production time, making it a cost-effective option for diamond tool manufacturers.
CPE | Power | 380V 3P 4 wires or 480V 3P 3 wires |
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CDA | Ø8 mm, 5 ~ 7 kg/cm2 | |
Cooling Water | 40 L/min, 19200 BTU/hr | |
Specification | Control System | |
PLC | One touch control integrated 10 programming recipes | |
HMI | 9” | |
Vacuum Chamber | ||
Quartz Chamber | Quartz inner Ø 150 mm | |
Quartz plate 285 x 140 mm | ||
H75 mm Max | ||
Heating System | ||
Heating Lamp | 2 kw x 12 = 24 kw | |
Heating Rate | 800 ℃ /min | |
Accuracy | ±3 ℃ | |
Maximum Operating Temperature | 950 ℃ | |
Vacuum System | ||
High Vacuum Pump | 1100 L/sec, cold trap, ultra-high vacuum valve | |
Rotary Pump | 670 L/min | |
Ultimate Vacuum Pressure | 20 min < 9x10-6 torr | |
Pumping Speed | 5 min < 5x10-5 torr | |
Dimension | ||
Main Frame | 1400L x 880W x 1670H mm |
Temperature : 100 ℃ ~ 120 ℃
Time : 10~20 min approximately
Atmosphere : Air
High Speed Vacuum Brazing | Conventional Brazing | |
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Usage | Brazing Natural diamond, CVD, PCD, PCBN and related materials on to tool body | Some limitations on substrate materials due to thermal coefficient |
Brazing Temperature | Available up to 900 ℃ | Limit up to 750 ℃ |
Applicable Material |
|
Only PCD and PCBN: low temperature |
Capacity | Around 80pcs per hour, depending on the tool size | Max. 20pcs per hour |
Brazing Quality | Automatic process, consistent quality and complete repeatability | Manual process, quality depending on worker’s skill level |
Additional Benefit |
|
|
High Speed Vacuum Brazing | Induction or Torch Brazing | |
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Brazing Temperature | Available up to 900 ℃ | Below 750 ℃ |
Diamond Type |
|
Only PCD and PCBN |
Brazing Alloy | Liquid metal (paste): higher melting point (stable at high temperature machining) | Silver alloy : melting point between 600~700 ℃ |
Capacity 1 (ISO inserts) |
40~150pcs per hour depending on the insert size. The smaller the tool, the more you can braze |
|
Capacity 2 (reamers, PCD tipped drills) |
10~30pcs per hour depending on size of drill and PCD tip |
|
Flux Cleaning | No flux, no need cleaning before and after brazing |
|
Fixing | No need fixing. One time braze due to capillary action | Fixing is necessary. Operator must maintain pressure. Possible re-heating necessary |
High Speed Vacuum Brazing | Vacuum Furnace Brazing | |
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Cycle time | 1.5 hours | 8~10 hours |
Precision | No movement of tips because of rapid heating and cooling | Tips are moving at some cases due to long process time |
High Speed Vacuum Brazing | Induction Brazing | |
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Brazing Speed | No difference for more edges | Longer time for more edges |
Staff | 1 entry-level worker can perform other jobs while machine is running | At least 1 dedicated experienced worker |
Brazing Quality and Yield Rate | Automatic process with one simple touch, consistent good quality and yield rate, even for more edges | Manual process, quality and yield rate depending on worker’s skill level and will become worse if more edges |