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Why Vacuum Brazing?

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.

Experience the excellence in vacuum brazing with PINPOWER's advanced PP series. Our machines are meticulously engineered to meet the diverse demands of modern industries, offering unparalleled performance and reliability. The PP series includes three models: PP-S, PP-SPLUS, and PP-H, each designed to provide optimal brazing solutions.

Models Overview

Function/Product No. PP-S PP-SPLUS PP-H
Vacuum Chamber Diameter (mm) 150 150 184
Human Machine Interface (HMI) 9" 10" 10"
Resolution 800 x 480 1,280 x 800 1,280 x 800
Energy Management － ◎ ◎
Remote Access and Data Collection* － ◎ ◎
Temperature Discrepancy Alert ◎ ◎ ◎
Annual Maintenance Reminder ◎ ◎ ◎
Cooling System Monitoring － ◎ ◎

* Optional

Technical Specifications

Power 380 V, 3 Phases, 60 A, 5 wires, 40 KVA
Cooling Water 50 L/min, 19,200 BTU/hr
Control System PLC control integrated with 20 programming recipes
Vacuum Chamber
Quartz inner
Ø 150 mm (PP-S and PP-SPLUS)
Ø 184 mm (PP-H)
Heating System 24 kW, heating rate of 800 ℃/min, accuracy ± 3 ℃
maximum operating temperature 950 ℃
Vacuum System High vacuum pump 1,100 L/sec ultimate vacuum pressure
< 9 x 10⁻⁶ torr

Features and Benefits

Vacuum Chamber Diameter

Available in 150 mm for PP-S and PP-SPLUS, and 184 mm for PP-H, accommodating various workpiece sizes.

10" Siemens HMI

Large, high-resolution display for enhanced user interaction and precise control, with potential multilingual support.

High-Resolution Display

The 1,280 x 800 resolution ensures clear and detailed visuals, improving accuracy and user experience.

Energy Management by MID Energy Meter

Provides precise tracking of energy consumption promoting sustainability and cost savings.

Remote Access and Data Collection

Facilitates efficient internet-based diagnostics and troubleshooting, while also enabling user data collection and analysis, minimizing downtime and optimizing equipment performance.

Temperature Discrepancy Alert

Alerts for discrepancies between set and actual temperatures, ensuring precise control.

Annual Maintenance Reminder

Timely reminders for maintenance based on machine usage, ideal for both standard and intensive operations.

Cooling System Monitoring

Real-time monitoring prevents overheating, ensuring machine protection and operational efficiency.

Advantages

1

Automation

Minimizes the need for skilled labor, providing consistent, high-quality brazing that is independent of operator expertise, resulting in reduced labor costs and efficient operation.

2

Consistent Quality

Ensures consistently high-strength joints, preserving diamond integrity with minimal thermal impact.

3

Energy Efficiency

High throughput per brazing cycle significantly reduces energy consumption and CO₂ emissions.

4

Environmentally Friendly

Low noise (< 65 dB) and zero emissions provide a safe and clean working environment.

5

Material Versatility

Suitable for a wide range of superhard materials, including PCD, PCBN, MCD, CVD diamond, natural diamond, and potentially sintered diamond segments.

6

Time-Saving

Shorter brazing cycles (1 - 2 hours) compared to traditional methods, enhancing productivity.

7

No Post-Brazing Cleanup

Eliminates the need for post-brazing cleaning, saving significant time and effort.

8

Superior Appearance

Produces smooth and flawless braze lines with no voids or pits, enhancing product aesthetics and end-user satisfaction.

9

High Reliability

Built with high-quality well known brand components, ensuring durability and low maintenance.

10

Clean and Safe

Applying brazing paste at room temperature and moist ensures a cleaner and safer environment compared to high-temperature molten braze applications.

11

Easy Maintenance

Designed for ease of maintenance, allowing operators to perform routine checks and maintenance, reducing overall downtime.

Brazing Procedure

STEP 1

After ultrasonic cleaning, apply the paste

STEP 2

Set diamond tip on the shank

STEP 3

Dry the workpiece in the drying oven

Temperature : 100 ~ 120 ℃
Time : 10 ~ 20 minutes approximately
Atmosphere : Air

STEP 4

Shave off excess paste as necessary

STEP 5

Place into the high-speed vacuum brazing machine

STEP 6

Complete brazing

High-Speed Vacuum Brazing
vs Conventional Brazing
High-Speed Vacuum Brazing Conventional Brazing
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
  • PCD, PCBN, tungsten carbide: low temperature brazing
  • PCBN, CVD, CBN, mono crystal diamond, natural diamond: high temperature brazing
 Only PCD and PCBN: low temperature brazing
Capacity Around 80 pcs/hr, depending on the tool size Max. 20 pcs/hr
Brazing Quality Automatic process, consistent quality and complete repeatability Manual process, quality depending on worker’s skill level
Additional Benefit
  • No need for experienced labor. Operator can perform other jobs while machine is running
  • Lower production cost
  • No dangerous fume inhalation
  • Need flux and extra cleaning
  • Need experienced labor
  • Dangerous fumes
  • No more variables of manual brazing, be free from labors’ skill
  • Guaranteed consistent brazing quality and tip retention
  • Protects PCD/ PCBN/ CVD/ diamonds from oxidation and reduces graphitization
  • 1 Machine = for all types of superabrasive cutting tool products
  • Improves your brazing capacity and quality

Comparison with Induction
or Torch Brazing for ISO Inserts
High-Speed Vacuum Brazing Induction or Torch Brazing
Brazing Temperature Available up to 900 ℃ Below 750 ℃
Diamond Type
  • PCD, PCBN
  • CVD, CBN, mono crystal diamond, natural diamond
 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 ~ 150 pcs/hr depending on the insert size. The smaller the tool, the more you can braze
  • Brazing one by one
  • Manual process
  • 15 ~ 20 pcs/hr
Capacity 2
(reamers, PCD tipped drills)		 10 ~ 30 pcs/hr depending on size of drill and PCD tip
  • 5 pcs max (longer time due to cleaning, sanding, etc)
  • Graphitizes PCD
Flux Cleaning No flux, no need cleaning before and after brazing
  • Cleaning before and after brazing
  • Sanding after brazing
Fixing No need fixing. One time braze due to capillary action Fixing is necessary. Operator must maintain pressure. Possible re-heating necessary

Comparison with Vacuum Furnace
Brazing for ISO Inserts
High-Speed Vacuum Brazing Vacuum Furnace Brazing
Cycle time 1.5 hr 8 ~ 10 hr
Precision No movement of tips because of rapid heating and cooling Tips are moving at some cases due to long process time

Comparison with Induction Brazing
for Reamers (4 edges and above)
High-Speed Vacuum Brazing Induction Brazing
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