Production Process of PCD blanks

17 March 2024
PCD blanks is mainly used in tooling industry for machining non-ferrous metals, composite materials, and wear resistant parts. 
More SuperHard PCD cutting tool blanks are produced by sintering selected quality diamond particles at high pressure and high temperature, and consist of diamond layer and tungsten carbide substrate.
Mixing, Cup Loading, Assembly, Insertion into Pressure Medium, Placement into Press, High-Temperature High-Pressure Processing, Depackaging, Pressure Release, Surface Treatment, Grinding, Polishing, Completion of Composite Insert, Final Cutting as per Requirements.
PCD  blanks
Mixing, Cup Loading
Due to the necessity of high-temperature and high-pressure processing for PCD, to prevent equipment damage and ensure stable product quality caused by impurities or moisture during the pressing process, it is essential to use an ultrasonic cleaner to clean the molybdenum cup and steel ring, followed by drying after assembly.
First, mix the fine diamonds or micro-powders, then place the preformed hard alloy substrate (with 13-16% cobalt) into the molybdenum cup, spread evenly on the substrate (to prevent uneven product quality or porosity cracking), fill the molybdenum cup with the mixed material, insert the steel ring, and place 2-6 pieces in one set (the number of pieces per set depends on specifications and quality requirements; the fewer pieces produced per press, the smaller the specifications, and the more stable the quality).
PCD blanks
Insertion into Pressure Medium, Placement into Press
To ensure uniform pressure, the outer metal cup needs to be covered with a softer pressure medium such as talc or salt. Wrap the prepared medium around the cup and place it in the press.
The pressed blanks are depackaged by tapping to remove the talc blocks, steel rings, and molybdenum cups.
PCD Blanks
Pressure Release
The PCD composite insert blanks are placed in a vacuum high-temperature furnace and gradually cooled from high temperatures to release stress (the blanks formed under high temperature and high pressure are fragile and of unstable quality).
Removal of Surface Impurities
The surface of the blanks is processed using methods such as sandblasting.
Through grinding (e.g., grinding wheel grinding, such as double-sided grinding) and polishing (polishing pad, etc.), process to the required dimensions.
Inspection, to check uniformity, flatness, etc., of the composite inserts.
According to requirements, the surface of the composite inserts is cut and then inspected using measuring instruments.
PCD blank
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