金刚石工具焊接技术原理及其应用OA

Significance:Diamond tools are irreplaceable advanced processing tools with ultra-high hardness,excellent wear resistance,high-temperature resistance,and corrosion resistance,which are widely used in machining hard-to-cut materials such as optical glass,engineering ceramics,and titanium alloys.High-quality bondings between diamond grits and matrix,as well as between diamond segments and steel substrates,are critical to exert the superior performances of diamond tools.As a key technology to realize high-strength metallurgical or mechanical joining,welding plays an indispensable role in the manufacturing of diamond tools,which directly determines the structural stability,service life,and machining accuracy of diamond tools.This work aims to clarify the fundamental principles of mainstream welding technologies of diamond tools,summarizes their technical characteristics and influencing parameters,and highlights their typical applications in high-end manufacturing fields,therefor providing theoretical and technical references for the performance optimization and engineering applications of diamond tools.Progress:This work systematically reviews three typical welding technologies of diamond tools:high-frequency welding,laser welding,and brazing.Introduces their working principles,characteristics,process parameters,and application boundaries.High-frequency welding realizes rapid heating and joining based on electromagnetic induction and skin effect,featuring high efficiency,low equipment cost,and suitability for mass production of large-size tools,but with relatively lower joint strength and a larger heat-affected zone compared to laser welding.Laser welding employs a high-energy-density laser beam as a heat source to form small-hole deep-penetration welding,with advantages of high bonding strength,small heat damage,high precision,and strong impact resistance,which is suitable for high-precision and thin-wall diamond tools,yet its equipment and maintenance costs are high.Brazing uses active filler metals containing Cr,Ti,Zr,and other elements to achieve chemical metallurgical bonding between diamond and matrix,which greatly improves the holding force to diamond grits and enables high protrusion height and good self-sharpening ability,making it ideal for grinding wheels and dressing tools.In addition,emerging technologies,including ultrasonic-assisted brazing and additive manufacturing,have effectively improved wettability,refined microstructures,and reduced thermal damage.This paper also summarizes the applications of welded diamond tools in aerospace,semiconductor,new energy,medical treatment,rail transit,and bearing machining.Analyzes the effects of welding and processing parameters on joint strength,surface quality,and tool wear mechanism.Conclusions and Prospects:Welding technologies significantly enhance the interfacial bonding strength and service performance of diamond tools.Reasonable selection of welding methods and optimization of process parameters can effectively reduce thermal damage,improve joint quality,and extend tool life.Welded diamond tools have become core of processing equipment in aerospace,semiconductor,new energy,and other high-end manufacturing fields,showing unique advantages in high-efficiency and high-precision machining of hard and brittle materials.Future research priorities include developing new filler metals matching with diamond and matrix to relieve residual stress,preparing fine-grained,low-melting-point,and high-sintering-activity pre-alloyed powders to suppress graphitization of diamond,developing multi-layer diamond tools with functional gradient design via integrating powder metallurgy,brazing,and additive manufacturing,and promoting intelligent,green,and low-carbon welding processes to meet the requirements of extreme working conditions and sustainable development.