A matrix powder for a diamond saw blade and a diamond saw blade

Abstract

The present application relates to the technical field of diamond saw blade, and particularly relates to a matrix powder for diamond saw blade and a diamond saw blade. The matrix powder comprises, in mass percentage, metal elements, iron-based pre-alloy powder, high-thermal-conductivity micro powder, and inevitable impurities; wherein the metal elements are selected from at least one of Fe, Sn, Cu and Ni; the iron-based pre-alloy powder is selected from an iron-based pre-alloy powder containing Fe and at least two of Cu, Ni, Co, Sn and P; and the high-thermal-conductivity micro powder is selected from a copper-tin alloy or a tungsten-copper alloy. The diamond saw blade comprises a steel base and a diamond cutter head, the diamond cutter head comprises a working layer and a transition layer; the transition layer is made of the above-mentioned matrix powder, and the working layer is made of the above-mentioned matrix powder and diamond. By adopting the synergistic design of the multi-layer matrix structure and the high-thermal-conductivity micro powder material, the peak temperature of the local chip groove of the multi-layer structure is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of diamond saw blade technology, and more specifically to a matrix powder for diamond saw blades and a diamond saw blade. Background Technology

[0002] Diamond saw blades are core tools for cutting hard and brittle materials such as building stone and concrete. They consist of two parts: the matrix and the cutting head. The matrix is ​​mostly made of high-strength alloy steel such as 65Mn and 30CrMo. After heat treatment, the yield strength is not less than 800MPa and the hardness is maintained at HRC40~45, providing structural support and fatigue resistance for the saw blade during high-speed rotary cutting. The cutting head is the core cutting unit, using diamond particles as the cutting phase and metal powder as the matrix binder. The diamond particles are consolidated through the mechanical holding and chemical bonding of the metal matrix. The particle size, crystal integrity, and interfacial bonding strength with the matrix directly determine the saw blade's cutting performance. Currently, the mainstream matrix systems for diamond saw blade cutting heads in the industry are iron-based, copper-based (including bronze-based), and cobalt-based metal binders. Different matrix systems are adapted to different cutting conditions based on their composition and performance differences. For cutting objects with high abrasiveness and high tensile strength, such as solidified concrete and reinforced concrete in construction projects, cobalt-based or cobalt bronze-based binder saw blades are required. The high cobalt content binder has excellent wettability and chemical bonding ability for diamond particles, resulting in high strength, high toughness, and outstanding wear coordination performance under high temperature conditions. It can effectively cope with the severe impact and high temperature conditions during the cutting of reinforced concrete, and prevent diamond particles from falling off or carbonizing prematurely.

[0003] In recent years, the prices of strategic metal raw materials such as copper and cobalt have continued to rise, significantly increasing the production and application costs of cobalt-based and cobalt bronze-based saw blades. The industry is gradually replacing them with lower-cost and more abundant iron-based matrices. However, conventional iron-based matrices have significant performance shortcomings: on the one hand, iron powder is easily oxidized, leading to reduced sintering activity, and at high temperatures, it can chemically corrode diamond, reducing the matrix's holding power over diamond and causing problems such as diamond particle shedding and insufficient wear resistance; on the other hand, the high-temperature strength, toughness, and interfacial bonding performance of iron-based matrices are difficult to match the high-requirement cutting scenarios involving reinforced concrete, resulting in cutting efficiency and saw blade service life far lower than cobalt-based matrices. Patent application CN102152407A discloses a cobalt-free, low-nickel pre-alloyed dry-cutting diamond circular saw blade, belonging to building material processing machinery parts, consisting of a steel matrix and a cutting head. The binder components of the cutting head include: pre-alloy, copper powder, tin powder, nickel powder, and paraffin wax; wherein the pre-alloy includes: iron powder, nickel powder, copper powder, tin powder, and cerium powder. Patent application CN102350738A discloses a pre-alloyed ultrafine powder matrix diamond tool, which consists of a steel matrix and a cutting head. The cutting head is composed of diamond and a matrix metal binder. The matrix binder contains the following components: pre-alloyed ultrafine powder, copper powder, tin powder, nickel powder, and paraffin wax.

[0004] In light of the current large-scale demand for concrete cutting in the building materials market, and the technological advantages of laser-welded saw blades in terms of structural stability and welding precision, developing a low-cost, high-sharpness laser-welded diamond saw blade suitable for cutting building materials is a key direction for resolving the contradiction between cost and performance in the industry, and has significant engineering application value and market promotion significance. Summary of the Invention

[0005] In view of the above-mentioned defects or improvement needs of the prior art, the present invention provides a matrix powder for diamond saw blades, diamond saw blades, and a method for preparing diamond saw blades.

[0006] Specifically, this is achieved through the following technical solution: In a first aspect, the present invention provides a matrix powder for a diamond saw blade, comprising, by weight percentage: The composition consists of 4%~15% metallic elements, 55%~90% iron-based pre-alloyed powder, 5%~30% high thermal conductivity micro powder, with the remainder being unavoidable impurities. The metallic element is selected from at least one of Fe, Sn, Cu, and Ni; The iron-based pre-alloyed powder is selected from iron-based pre-alloyed powders containing at least two elements selected from Fe, Cu, Ni, Co, Sn, and P; The high thermal conductivity micropowder is selected from copper-tin alloy or tungsten-copper alloy.

[0007] Furthermore, a diamond saw blade matrix powder, by weight percentage, comprises the following components: The composition consists of 5%~12% elemental metals, 65%~85% iron-based pre-alloyed powder, 8%~25% high thermal conductivity micro powder, with the balance being unavoidable impurities.

[0008] Furthermore, the mass percentage of tin in the copper-tin alloy is 15-25%, and the mass percentage of copper in the tungsten-copper alloy is 20-30%.

[0009] Furthermore, by mass percentage, when the high thermal conductivity micropowder is a tungsten-copper alloy, the tungsten-copper alloy accounts for 5% to 20% of the total matrix powder, and the copper-tin alloy accounts for 10% to 30% of the total matrix powder.

[0010] Furthermore, the iron-based pre-alloy powder is selected from at least one of iron-nickel pre-alloy powder, iron-copper-tin pre-alloy powder, iron-cobalt-copper-tin pre-alloy powder, iron-cobalt-nickel-phosphorus pre-alloy powder, and iron-copper-cobalt-tin-phosphorus pre-alloy powder.

[0011] Furthermore, the iron-based pre-alloyed powder includes iron-nickel pre-alloyed powder, iron-cobalt-nickel-phosphorus pre-alloyed powder, and iron-copper-cobalt-tin-phosphorus pre-alloyed powder.

[0012] Furthermore, the composition of the iron-nickel pre-alloyed powder includes: 4%~5% Ni, with the balance being Fe and unavoidable impurities; Furthermore, the composition of the iron-copper-tin pre-alloyed powder includes: Cu 20~30%, Sn 5~10%, with the balance being Fe and unavoidable impurities; Furthermore, the composition of the iron-cobalt-copper-tin pre-alloy powder includes: Co 10%~20%, Cu 15%~25%, Sn 3~6%, with the balance being Fe and unavoidable impurities; Furthermore, the composition of the iron-cobalt-nickel-phosphorus pre-alloyed powder includes: Co 10%~20%, Ni 5%~10%, P 2%~4%, with the balance being Fe and unavoidable impurities; Furthermore, the composition of the iron-copper-cobalt-tin-phosphorus pre-alloy powder includes: Cu 15%~25%, Co 8%~15%, Sn 3%~6%, P 0.5%~1.5%, with the balance being Fe and unavoidable impurities.

[0013] In this invention, the iron-based pre-alloyed powder uses Fe as the matrix. Cu and Sn are added to lower the sintering temperature and improve wettability; Co and Ni are added to improve toughness and diamond holding power; and P is added to deoxidize and form a hard phase. Those skilled in the art will understand that, without departing from the core concept of this invention, any elemental composition that meets the scope defined by this invention and achieves the aforementioned effects of lowering sintering temperature, improving wear resistance, and increasing holding power falls within the protection scope of this invention.

[0014] Furthermore, according to the medium particle size D50, the Sn powder has a particle size of 19~23 μm, the Cu powder has a particle size of 23~27 μm, and the Ni has a particle size of 9~11 μm; the iron-based pre-alloyed powder has a particle size of <50 μm; and the copper-tin alloy in the high thermal conductivity micro powder material has a particle size of 25-29 μm, and the tungsten-copper alloy has a particle size of 3-5 μm.

[0015] Furthermore, the matrix powder is used to prepare a multi-layered diamond saw blade matrix, the multi-layered structure including alternating working layers and transition layers, the transition layers being made of the matrix powder, and the working layers being made of the matrix powder and diamond.

[0016] Secondly, the present invention provides a diamond saw blade, comprising a steel substrate and a diamond cutting head, wherein the diamond cutting head has a five-layer composite structure along the thickness direction, and is sequentially configured from one side to the other as an edge diamond layer, a first interlayer, an inner diamond layer, a second interlayer, and an edge diamond layer; the edge diamond layer and the inner diamond layer are working layers, and the first interlayer and the second interlayer are transition layers. The transition layer is made of the matrix powder described in the first aspect, and the working layer is made of the matrix powder described in the first aspect and diamond.

[0017] Furthermore, the working layer contains 1-3% diamond particles by mass percentage, and the diamond particles have a particle size (D50) of 350-500 μm.

[0018] Furthermore, the first interlayer, the second interlayer, and the inner diamond layer have the same thickness, which is 0.5~0.7 mm; the edge diamond layer has a thickness that is 0.05~0.2 mm greater than the thickness of the first interlayer, the second interlayer, and the inner diamond layer.

[0019] Furthermore, the formula of the transition layer's matrix powder makes its hardness and wear resistance lower than that of the working layer, so as to facilitate the self-sharpening of chip removal grooves during the cutting process.

[0020] Furthermore, the diamond cutting head also has a bottom welding layer, through which the diamond cutting head is welded and fixed to the steel substrate; the bottom welding layer does not cover the entire layer, and its height (referring to the diameter direction of the saw blade after welding to the steel substrate) is 2~2.5 mm; the bottom welding layer is also called the bottom powder layer, and the bottom welding layer powder, by mass percentage, includes: copper 42~56%, nickel 18~32%, iron 8~20%, tin 3.5~14%, cobalt 0~5%, with the balance being unavoidable impurities. The bottom welding layer powder can also be other conventional alloy powders used in the art to achieve laser welding between the cutting head and the steel substrate.

[0021] Thirdly, the present invention provides a method for preparing a saw blade according to the second aspect above, comprising the steps of: Prepare the working layer powder, transition layer powder, and bottom welding layer powder separately: The working layer powder is composed of the matrix powder described in the first aspect and diamond particles, wherein the diamond particles account for 1-3% of the total mass of the powder; The transition layer powder is the matrix powder described in the first aspect above; The composition of the bottom welding layer powder, by mass percentage, includes: 42-56% copper, 18-32% nickel, 8-20% iron, 3.5-14% tin, 0-5% cobalt, with the balance being unavoidable impurities. Other alloy powders conventional in the art for laser welding of the cutting head to the steel substrate can also be used for the bottom welding layer powder.

[0022] The working layer powder, transition layer powder and bottom welding layer powder are respectively added to a granulating agent for granulation and drying to obtain working layer granulated powder and transition layer granulated powder respectively. Furthermore, within the mold, powder is applied in multiple layers according to the pre-designed cutter head structure. The equipment used has two powder loading cavities, each further divided into two areas: one area is filled with working layer powder or transition layer powder containing diamond, and the other area is filled with bottom welding layer powder. The configurations of the two cavities are identical. At the start of powder application, the two cavities work alternately, with the following order: the first cavity first applies "working layer powder containing diamond + bottom welding layer powder," then the second cavity applies "transition layer powder + bottom welding layer powder," and then the first cavity applies "working powder containing diamond + bottom welding layer powder," and so on, alternating until the required number of layers is completed. After powder application, pre-pressing and final pressing are performed sequentially to obtain the cutter head blank. The green cutter head is placed into a hot press mold and sintered to obtain the finished cutter head. The finished blade head is placed on a steel substrate and fixed by laser welding to obtain the saw blade.

[0023] Furthermore, the added granulating agent, by mass percentage, is 1-5 wt.% of the total mass of the powder. Furthermore, the drying temperature is 50~80℃, and the drying time is 4~6 hours; Furthermore, the pre-compression pressure is 1~3 T, and the pressure holding time is 0.2~0.5 s; the final compression molding pressure is 20~30 T, and the pressure release time is 0.3~1 s; Furthermore, observe and measure the fracture surface of the green blank with the cutting head, and control the error between the thickness of each layer of the green blank and the set thickness to be ≤0.2mm; Furthermore, the sintering temperature is 800~850℃, the sintering pressure is 20~40 kN, the heating time is 40~45min, and the temperature is held for 30~50min after reaching the maximum temperature. The hardness of the cutter head after sintering is 90~110 HRB, and the finished cutter head is obtained. Furthermore, the preparation method also includes a deburring step, in which the finished cutter head and abrasive are placed together in the deburring machine drum for rotation and grinding after hot pressing and sintering and before welding; Furthermore, the preparation method also includes a post-processing step: sharpening the welded saw blade and spraying anti-rust paint or protective coating onto the substrate surface.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention introduces highly thermally conductive micro-powder materials into the matrix powder, which can significantly improve the high temperature resistance, wear resistance and heat dissipation efficiency of the matrix, reduce the risk of thermal expansion mismatch, prevent premature diamond detachment and extend tool life; it can also form a hard and brittle composite phase in the matrix to achieve advanced wear to increase the diamond cutting edge height and optimize saw blade sharpness.

[0025] 2. This invention addresses the technical challenges of laser saw blades in extreme and harsh conditions such as dry cutting of reinforced concrete. It employs a synergistic design of a multi-layer matrix structure and a high thermal conductivity micropowder material. In existing technologies, while multi-layer structures provide chip removal channels, the instantaneous high temperatures (up to 800°C or higher) in the cutting zone during dry cutting of reinforced concrete cause the concrete silicate micropowder to melt and sinter within the chip removal channels, leading to blockage and failure of the multi-layer structure. This invention introduces a specific ratio of high thermal conductivity micropowder material, creating a significant synergistic effect with the multi-layer structure: the high thermal conductivity material rapidly draws away transient heat from the cutting interface and conducts it to the matrix, significantly reducing the local peak temperature of the chip removal channels and fundamentally eliminating the physical conditions for high-temperature sintering of concrete dust within the channels. The high thermal conductivity component ensures the sustained chip removal function of the multi-layer structure under dry cutting conditions. The combination of these two components solves the dry cutting blockage problem that cannot be overcome by a single structure or component.

[0026] 3. Under the alternating thermal shock of dry cutting followed by rapid heating and air cooling, multi-layered carcass structures are prone to thermal stress concentration at the interlayer interfaces due to the differences in the thermal expansion coefficients of the materials in each layer, leading to microcracks or even carcass peeling. This invention incorporates highly thermally conductive micropowder, compensating for the insufficient thermal shock resistance of multi-layered structures under extreme dry cutting conditions, and significantly improving the structural integrity and service life of multi-layered carcasses when cutting reinforced concrete. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a front view of the single-layer and multi-layer diamond saw blades in the embodiments and comparative examples of the present invention; Figure 2 These are front structural views and partial enlarged views of the cutting head of Embodiments 11-17 and Comparative Example 3 of the present invention; Figure 3 These are schematic diagrams of the cutter head structure of Embodiments 11-17 and Comparative Example 3 of the present invention; Figure 4 These are comparative examples 1 and 4 of the present invention, showing the cutter head structure. Figure 5 These are comparative examples 2, 5, 7, and 9 of the present invention, showing the cutter head structure. Detailed Implementation

[0029] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. It should also be understood that after reading this invention, those skilled in the art will be able to make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0030] The sources of some of the raw materials used in the following examples and comparative examples are as follows: The iron-nickel pre-alloyed powder was purchased from Hunan Fulong New Material Co., Ltd. (now renamed Nanyang Fulong New Material Co., Ltd.), with the grade FAM1050. By mass percentage, the composition of the iron-nickel pre-alloyed powder includes: approximately 95% iron (Fe), 4.0%–5.0% nickel (Ni), 0.4%–0.5% oxygen (O), and other trace impurities (C, Si, S, P, etc.): ≤0.1%. The iron-copper-tin pre-alloyed powder was purchased from Henan Taihe Huijin Powder Technology Co., Ltd. / Henan Shanghe Huijin Environmental Protection Technology Co., Ltd., with the grade X5-560. By mass percentage, the composition of the iron-copper-tin pre-alloyed powder includes: Cu 20~30%, Sn 5~10%, with the balance being Fe and unavoidable impurities. The iron-cobalt-copper-tin pre-alloy powder was purchased from Sichuan Lihe Micro-Aerospace Metal Materials Co., Ltd.; by mass percentage, the composition of the iron-cobalt-copper-tin pre-alloy powder includes: Co 10%~20%, Cu 15%~25%, Sn 3~6%, with the balance being Fe and unavoidable impurities; The iron-cobalt-nickel-phosphorus pre-alloyed powder was purchased from Henan Taihe Huijin Powder Technology Co., Ltd., and its grade is HJA. By mass percentage, the composition of the iron-cobalt-nickel-phosphorus pre-alloyed powder includes: Co 10%~20%, Ni 5%~10%, P 2%~4%, with the balance being Fe and unavoidable impurities. The iron-copper-cobalt-tin-phosphorus pre-alloyed powder was purchased from Henan Taihe Huijin Powder Technology Co., Ltd., with the grade X6600. By mass percentage, the composition of the iron-copper-cobalt-tin-phosphorus pre-alloyed powder includes: Cu 15%~25%, Co 8%~15%, Sn 3%~6%, P 0.5%~1.5%, with the balance being Fe and unavoidable impurities.

[0031] The copper-tin alloy was purchased from Changsha Tianqin Industrial Technology Development Co., Ltd. The tungsten-copper alloy was purchased from China Tungsten Online Technology Co., Ltd. In the following examples and comparative examples, the base powder layer material is Fe-Co-Ni-Cu-Sn pre-alloyed powder, which is formed by mixing and granulating elemental metals. Alternatively, other conventional alloy powders used in the art for laser welding of the cutting head to the steel substrate can also be used.

[0032] Example 1 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Fe 2%, Ni 4%, Fe-Ni pre-alloy powder 20%, Fe-Cu-Sn pre-alloy powder 20%, Fe-Co-Ni-P pre-alloy powder 44%, Cu-Sn15 alloy (Sn content 15 wt.%) 10%.

[0033] Example 2 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Fe 6%, Sn 4%, Cu 5%, Fe-Ni pre-alloy powder 15%, Fe-Cu-Sn pre-alloy powder 20%, Fe-Co-Cu-Sn pre-alloy powder 35%, Cu-Sn25 alloy (Sn content 25 wt.%) 15%.

[0034] Example 3 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Fe 5%, Fe-Cu-Sn pre-alloy powder 20%, Fe-Co-Ni-P pre-alloy powder 30%, Fe-Cu-Co-Sn-P pre-alloy powder 40%, W-Cu20 alloy (Cu content 20 wt.%) 5%.

[0035] Example 4 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Fe 5%, Sn 2%, Cu 3%, Fe-Ni pre-alloy powder 30%, Fe-Cu-Co-Sn-P pre-alloy powder 35%, Cu-Sn20 alloy (Sn content 20 wt.%) 25%.

[0036] Example 5 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Fe 5%, Cu 3%, Fe-Ni pre-alloy powder 30%, Fe-Co-Cu-Sn pre-alloy powder 52%, W-Cu30 alloy (Cu content 30 wt.%) 10%.

[0037] Example 6 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Sn 4%, Cu 4%, Fe-Cu-Co-Sn-P pre-alloy powder 77%, W-Cu25 alloy (Cu content 25 wt.%) 15%.

[0038] Example 7 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Ni 8%, Fe-Ni pre-alloyed powder, Fe-Co-Cu-Sn pre-alloyed powder 31%, Fe-Cu-Co-Sn-P pre-alloyed powder 31%, Cu-Sn20 alloy (Sn content 20 wt.%) 30%.

[0039] Example 8 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Sn 5%, Cu 5%, Fe-Ni pre-alloy powder 15%, Fe-Co-Ni-P pre-alloy powder 25%, Fe-Cu-Co-Sn-P pre-alloy powder 30%, W-Cu20 alloy (Cu content 20 wt.%) 20%.

[0040] Example 9 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Ni 4%, Fe-Ni pre-alloy powder 54%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 10%, Cu-Sn25 alloy (Sn content 25 wt.%) 30%.

[0041] Example 10 This embodiment provides a matrix powder for diamond saw blades, comprising the following components by weight percentage: Fe 6%, Sn 4%, Cu 5%, Fe-Ni pre-alloy powder 15%, Fe-Cu-Sn pre-alloy powder 20%, Fe-Co-Cu-Sn pre-alloy powder 35%, Cu-Sn25 alloy (Sn content 25 wt.%) 15%.

[0042] Example 11 In this embodiment, diamond saw blades are prepared using the matrix powder prepared in Example 1.

[0043] In this embodiment, the specifications of the laser-welded saw blade are: diameter 350mm, blade height 10mm, blade thickness 3.2mm, and base thickness 2.2mm. The blade has a five-layer structure with layer thicknesses of 0.7 / 0.6 / 0.6 / 0.6 / 0.7 (mm). The front structural diagram of the saw blade is shown below. Figure 1 As shown in the enlarged view of a portion of the cutting head, see below. Figure 2 , Figure 3 As shown. The cutter head also includes a bottom weld layer with a height of 2mm.

[0044] The preparation method includes the following steps: Prepare working layer powder, transition layer powder, and bottom welding layer powder separately: the working layer powder is composed of matrix powder and diamond particles, wherein the diamond particles account for 3% of the total mass of the powder; the transition layer powder is the matrix powder prepared in the aforementioned embodiment; granulate the working layer powder, transition layer powder, and bottom welding layer powder by adding 5 wt.% of granulating agent to each powder and drying at 50°C for 4 hours; thus obtaining the working layer granulated powder, transition layer granulated powder, and bottom welding layer granulated powder respectively.

[0045] In the mold, powder is layered multiple times according to a preset cutter head structure. The powder layering sequence, from the side closest to the steel substrate to the side furthest from the steel substrate, is as follows: edge diamond layer, first interlayer, inner diamond layer, second interlayer, and edge diamond layer. The equipment has two powder loading cavities, each further divided into two areas: one area is filled with working layer powder or transition layer powder containing diamond, and the other area is filled with bottom welding layer powder. The configurations of the two cavities are identical. At the start of powder layering, the two cavities work alternately, with the following sequence: the first cavity first lays "working layer powder containing diamond + bottom welding layer powder," then the second cavity lays "transition layer powder + bottom welding layer powder," and then the first cavity lays "working powder containing diamond + bottom welding layer powder," and so on, alternating until the required number of layers is completed. After the powder is spread, pre-pressing and final pressing are performed sequentially to obtain the green blank of the cutter head; after the powder is spread, pre-pressing and final pressing are performed sequentially, with a pre-pressing pressure of 3 T and a holding time of 0.5 s; the final pressing pressure is 20 T and the depressurization time is 0.3 s; thus obtaining the green blank of the cutter head.

[0046] The green cutter head is placed into a hot press mold and sintered at a temperature of 800°C and a pressure of 40 kN for 45 minutes. After reaching the maximum temperature, it is held for 30 minutes to obtain the finished cutter head.

[0047] The finished blade head is placed on a steel substrate and fixed by laser welding to obtain the saw blade.

[0048] Example 12 In this embodiment, diamond saw blades are prepared using the matrix powder prepared in Example 2.

[0049] The saw blade specifications are the same as in Example 1, and the preparation method includes the following steps: Prepare working layer powder, transition layer powder, and bottom welding layer powder separately: the working layer powder is composed of matrix powder and diamond particles, wherein the diamond particles account for 1% of the total mass of the powder; the transition layer powder is the matrix powder prepared in the aforementioned embodiment; granulate the working layer powder, transition layer powder, and bottom welding layer powder by adding 1 wt.% of granulating agent to each powder and drying at 80°C for 6 hours; thus obtaining the working layer granulated powder, transition layer granulated powder, and bottom welding layer granulated powder respectively.

[0050] In the mold, powder is applied in multiple layers according to a pre-set cutter head structure. The powder application sequence, from the side closest to the steel substrate to the side furthest from the steel substrate, is as follows: edge diamond layer, first interlayer, inner diamond layer, second interlayer, and edge diamond layer. Further, in the mold, powder is applied in multiple layers according to the pre-set cutter head structure. The equipment used has two powder loading chambers, each divided into two areas: one area is filled with working layer powder or transition layer powder containing diamond, and the other area is filled with bottom welding layer powder. The configurations of the two chambers are identical. At the start of powder application, the two chambers work alternately, with the following order: the first chamber first applies "working layer powder containing diamond + bottom welding layer powder," then the second chamber applies "transition layer powder + bottom welding layer powder," and then the first chamber applies "working powder containing diamond + bottom welding layer powder," and so on, alternating until the required number of layers is completed. After the powder is spread, pre-pressing and final pressing are performed sequentially to obtain the green blank of the cutter head; after the powder is spread, pre-pressing and final pressing are performed sequentially, with a pre-pressing pressure of 1 T and a holding time of 0.2 s; the final pressing pressure is 30 T and the pressure release time is 1 s; thus, the green blank of the cutter head is obtained.

[0051] The green cutter head is placed into a hot press mold and sintered at a temperature of 850°C and a pressure of 20 kN for 40 minutes. After reaching the maximum temperature, it is held for 50 minutes. The finished cutter head is then placed in a deburring machine drum along with the abrasive and rotated for grinding to obtain the finished cutter head.

[0052] The finished blade head is placed on a steel substrate and fixed by laser welding to obtain the saw blade.

[0053] Example 13 In this embodiment, diamond saw blades were prepared using the matrix powder prepared in Example 3.

[0054] The saw blade specifications and preparation method are the same as in Example 1.

[0055] Example 14 In this embodiment, diamond saw blades were prepared using the matrix powder prepared in Example 4.

[0056] The saw blade specifications and preparation method are the same as in Example 1.

[0057] Example 15 In this embodiment, diamond saw blades are prepared using the matrix powder prepared in Example 5.

[0058] The saw blade specifications and preparation method are the same as in Example 1.

[0059] Example 16 In this embodiment, diamond saw blades are prepared using the matrix powder prepared in Example 6.

[0060] The saw blade specifications and preparation method are the same as in Example 1.

[0061] Example 17 In this embodiment, diamond saw blades were prepared using the matrix powder prepared in Example 7.

[0062] The saw blade specifications and preparation method are the same as in Example 1.

[0063] Example 18 In this embodiment, diamond saw blades were prepared using the matrix powder prepared in Example 8.

[0064] The saw blade specifications and preparation method are the same as in Example 1.

[0065] Example 19 In this embodiment, diamond saw blades were prepared using the matrix powder prepared in Example 9.

[0066] The saw blade specifications and preparation method are the same as in Example 1.

[0067] Example 20 In this embodiment, diamond saw blades were prepared using the matrix powder prepared in Example 10.

[0068] The saw blade specifications and preparation method are the same as in Example 1.

[0069] Comparative Example 1 This comparative example does not add high thermal conductivity micro powder, and the diamond saw blade prepared is a single-layer structure.

[0070] The composition of the matrix powder used in diamond saw blades, by weight percentage, is as follows: Ni 8%, Cu 36%, Sn 4%, Fe-Ni pre-alloy powder 32%, Fe-Co-Ni-P pre-alloy powder 3%, Fe-Cu-Co-Sn-P pre-alloy powder 17%; The specifications of the laser-welded saw blade are: diameter 350mm, blade height 10mm, blade thickness 3.2mm, base thickness 2.2mm, and the blade head is a single-layer structure. The blade head also includes a bottom welding layer with a height of 2mm. The blade head structure is as follows... Figure 4 As shown.

[0071] The method for preparing the cutting head is the same as in Example 1.

[0072] Comparative Example 2 This comparative example does not add high thermal conductivity micropowder, and the diamond saw blade prepared is a three-layer structure.

[0073] The composition of the matrix powder used in diamond saw blades, by weight percentage, is as follows: Ni 8%, Cu 36%, Sn 4%, Fe-Ni pre-alloy powder 32%, Fe-Co-Ni-P pre-alloy powder 3%, Fe-Cu-Co-Sn-P pre-alloy powder 17%; The specifications of the laser-welded saw blade are: diameter 350mm, blade height 10mm, blade thickness 3.2mm, base thickness 2.2mm, and the blade head has a three-layer structure with layers of 1.1 / 1.0 / 1.1. The blade head also includes a bottom welding layer with a height of 2mm. The blade head structure is as follows... Figure 5 As shown.

[0074] The method for preparing the cutting head is the same as in Example 1.

[0075] Comparative Example 3 This comparative example does not add high thermal conductivity micropowder, and the diamond saw blade prepared has a five-layer structure.

[0076] The composition of the matrix powder used in diamond saw blades, by weight percentage, is as follows: Ni 8%, Cu 36%, Sn 4%, Fe-Ni pre-alloy powder 32%, Fe-Co-Ni-P pre-alloy powder 3%, Fe-Cu-Co-Sn-P pre-alloy powder 17%; The specifications of the laser-welded saw blade are the same as in Example 1.

[0077] The method for preparing the cutting head is the same as in Example 1.

[0078] Comparative Example 4 In this comparative example, high thermal conductivity micro-powder was added to prepare a diamond saw blade with a single-layer structure.

[0079] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Ni 4%, Cu-Sn alloy (Sn content 25 wt.%) 30%, Fe-Ni pre-alloy powder 44%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 20%; The specifications of the laser-welded saw blade are the same as those in Comparative Example 1.

[0080] The method for preparing the cutting head is the same as in Example 1.

[0081] Comparative Example 5 In this comparative study, highly thermally conductive micro-powder was added to prepare a diamond saw blade with a three-layer structure.

[0082] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Ni 4%, Cu-Sn alloy (Sn content 25 wt.%) 30%, Fe-Ni pre-alloy powder 44%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 20%; The specifications of the laser-welded saw blade are the same as those in Comparative Example 2.

[0083] The method for preparing the cutting head is the same as in Example 1.

[0084] Comparative Example 6 In this comparative example, high thermal conductivity micro-powder was added to prepare a diamond saw blade with a single-layer structure.

[0085] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Sn 3%, Cu 20%, W-Cu alloy (Cu content 20 wt.%) 8%, Fe-Ni pre-alloy powder 47%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 20%; The specifications of the laser-welded saw blade are the same as those in Comparative Example 1.

[0086] The method for preparing the cutting head is the same as in Example 1.

[0087] Comparative Example 7 In this comparative study, highly thermally conductive micro-powder was added to prepare a diamond saw blade with a three-layer structure.

[0088] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Sn 3%, Cu 20%, W-Cu alloy (Cu content 20 wt.%) 8%, Fe-Ni pre-alloy powder 47%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 20%; The specifications of the laser-welded saw blade are the same as those in Comparative Example 2.

[0089] The method for preparing the cutting head is the same as in Example 1.

[0090] Comparative Example 8 In this comparative example, high thermal conductivity micro-powder was added to prepare a diamond saw blade with a single-layer structure.

[0091] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Sn 6%, Cu 31%, Ni 15%, W-Cu alloy (Cu content 20 wt.%) 8%, Fe-Ni pre-alloy powder 7%, Fe-Co-Ni-P pre-alloy powder 3%, Fe-Cu-Co-Sn-P pre-alloy powder 30%; The specifications of the laser-welded saw blade are the same as those in Comparative Example 1.

[0092] The method for preparing the cutting head is the same as in Example 1.

[0093] Comparative Example 9 In this comparative study, highly thermally conductive micro-powder was added to prepare a diamond saw blade with a three-layer structure.

[0094] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Sn 6%, Cu 31%, Ni 15%, W-Cu alloy (Cu content 20 wt.%) 8%, Fe-Ni pre-alloy powder 7%, Fe-Co-Ni-P pre-alloy powder 3%, Fe-Cu-Co-Sn-P pre-alloy powder 30%; The specifications of the laser-welded saw blade are the same as those in Comparative Example 2.

[0095] The method for preparing the cutting head is the same as in Example 1.

[0096] Comparative Example 10 In this comparative study, highly thermally conductive micro-powder was added to prepare a diamond saw blade with a seven-layer structure.

[0097] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Ni 4%, Cu-Sn alloy (Sn content 25 wt.%) 30%, Fe-Ni pre-alloy powder 44%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 20%; The specifications of the laser-welded saw blade are as follows: diameter 350mm, blade height 10mm, blade thickness 3.2mm, base thickness 2.2mm, and the blade has a seven-layer structure with layers arranged in a ratio of 0.5 / 0.4 / 0.5 / 0.4 / 0.5 / 0.4 / 0.5. The blade also includes a bottom welding layer with a height of 2mm.

[0098] The method for preparing the cutting head is the same as in Example 1.

[0099] Comparative Example 11 In this comparative example, high thermal conductivity micro-powder was added to prepare a diamond saw blade with a seven-layer structure.

[0100] In this comparative example, the composition of the matrix powder used for the diamond saw blade, by mass percentage, is as follows: Sn 3%, Cu 20%, W-Cu alloy (Cu content 20 wt.%) 8%, Fe-Ni pre-alloy powder 47%, Fe-Co-Ni-P pre-alloy powder 2%, Fe-Cu-Co-Sn-P pre-alloy powder 20%; The specifications of the laser-welded saw blade are the same as those in Comparative Scale 10.

[0101] Experimental Example The cutting performance of the saw blades prepared in Examples 11-20 and Comparative Examples 1-11 was tested: 1. The object to be cut is a C45 reinforced concrete block with dimensions of 600mm×270mm×100mm, containing 3 Φ16mm threaded steel bars inside.

[0102] 2. Test equipment and operating conditions: A TS800 handheld saw was used for manual cutting, with a power of 5.5KW and a rotation speed of 4700r / min. The cutting process was purely dry cutting without water cooling.

[0103] 3. Evaluation indicators: The results of the cutting experiment are as follows:

[0104] As can be seen from Comparative Examples 1-3, even with a high content of elemental Cu, the cutting speed is low and the raw material cost is high without the addition of highly thermally conductive micro-powder materials. Furthermore, although increasing the number of layers in the cutting head can improve the cutting speed to some extent, the cutting speed of the five-layer structure cutting head is still far lower than that of the technical solution of this invention due to the limitations of the material system.

[0105] The results of Comparative Examples 4 and 5 show that adding copper-tin alloy, a highly thermally conductive micropowder material, and controlling its content within the optimal range can significantly improve the cutting speed of the saw blade head; however, due to the insufficient number of layers in the blade head, the effect of improving the cutting speed was not fully realized, and the best cutting performance was not yet achieved.

[0106] The results of Comparative Examples 6 and 7 show that adding tungsten-based alloy with high thermal conductivity micropowder material and controlling its content within the optimal range can significantly improve the cutting speed of the saw blade head; however, due to the insufficient number of layers in the blade head, the effect of improving the cutting speed was not fully realized, and the best cutting performance was not yet achieved.

[0107] The test results of Comparative Examples 8 and 9 show that, even with a high elemental copper content of 30% in the matrix powder (resulting in high raw material costs), the cutting speeds of single-layer and three-layer cutting heads significantly improved compared to Comparative Examples 1-7 after adding the optimal amount of tungsten-based alloy high thermal conductivity micropowder. However, compared to the five-layer structure cutting head, there is still a significant difference in cutting speed, indicating that the five-layer structure is crucial for fully utilizing the performance advantages of high thermal conductivity materials.

[0108] The test results of Comparative Examples 10 and 11 show that the cutting speed does not increase with the increase of the number of layers on the cutter head. Therefore, the optimal number of layers needs to be determined based on the cutter head thickness, and a suitable layering scheme should be selected for different cutting objects. Increasing the number of layers means that more steps are formed on a single cutter head, and changes in the number of steps may affect chip handling and chip removal performance. For the cutting object targeted by this invention—concrete for building materials—more layers result in a smaller contact area between the diamond cutter head and the material being cut, which reduces the continuity and stability of the cutting, thereby reducing the cutting speed.

Claims

1. A matrix powder for use in diamond saw blades, characterized in that, By weight percentage, including components: The composition consists of 4%~15% metallic elements, 55%~90% iron-based pre-alloyed powder, 5%~30% high thermal conductivity micro powder, with the remainder being unavoidable impurities. The metallic element is selected from at least one of Fe, Sn, Cu, and Ni; The iron-based pre-alloyed powder is selected from iron-based pre-alloyed powders containing at least two elements selected from Fe, Cu, Ni, Co, Sn, and P; The high thermal conductivity micropowder is selected from copper-tin alloy or tungsten-copper alloy.

2. The carcass powder according to claim 1, characterized in that, By weight percentage, including components: The composition consists of 5%~12% elemental metals, 65%~85% iron-based pre-alloyed powder, 8%~25% high thermal conductivity micro powder, with the balance being unavoidable impurities.

3. The carcass powder according to claim 1 or 2, characterized in that, The copper-tin alloy contains 15-25% tin by mass, and the tungsten-copper alloy contains 20-30% copper by mass.

4. The carcass powder according to claim 1 or 2, characterized in that, The iron-based pre-alloyed powder is selected from at least one of iron-nickel pre-alloyed powder, iron-copper-tin pre-alloyed powder, iron-cobalt-copper-tin pre-alloyed powder, iron-cobalt-nickel-phosphorus pre-alloyed powder, and iron-copper-cobalt-tin-phosphorus pre-alloyed powder.

5. The carcass powder according to claim 3, characterized in that, The iron-based pre-alloyed powder includes iron-nickel pre-alloyed powder, iron-cobalt-nickel-phosphorus pre-alloyed powder, and iron-copper-cobalt-tin-phosphorus pre-alloyed powder.

6. The carcass powder according to claim 3, characterized in that, The composition of the iron-nickel pre-alloyed powder, by mass percentage, includes: 4%~5% Ni, with the balance being Fe and unavoidable impurities; The composition of the iron-copper-tin pre-alloyed powder includes: Cu 20~30%, Sn 5~10%, with the balance being Fe and unavoidable impurities; The composition of the iron-cobalt-copper-tin pre-alloy powder includes: Co 10%~20%, Cu 15%~25%, Sn 3~6%, with the balance being Fe and unavoidable impurities; The composition of the iron-cobalt-nickel-phosphorus pre-alloyed powder includes: Co 10%~20%, Ni 5%~10%, P 2%~4%, with the balance being Fe and unavoidable impurities; The composition of the iron-copper-cobalt-tin-phosphorus pre-alloy powder includes: Cu 15%~25%, Co 8%~15%, Sn 3%~6%, P 0.5%~1.5%, with the balance being Fe and unavoidable impurities.

7. The carcass powder according to claim 1 or 2, characterized in that, The matrix powder is used to prepare a multi-layered diamond saw blade matrix, the multi-layered structure including alternating working layers and transition layers, the transition layers being made of the matrix powder, and the working layers being made of the matrix powder and diamond.

8. A diamond saw blade, comprising a steel substrate and a diamond cutting head, characterized in that, The diamond cutting tip has a five-layer composite structure along its thickness direction, consisting of an edge diamond layer, a first interlayer, an inner diamond layer, a second interlayer, and an edge diamond layer, arranged sequentially from one side to the other. The edge diamond layer and the inner diamond layer are the working layers, and the first interlayer and the second interlayer are the transition layers. The transition layer is made of the matrix powder as described in any one of claims 1 to 7, and the working layer is made of the matrix powder as described in any one of claims 1 to 7 and diamond.

9. The saw blade according to claim 7 or 8, characterized in that, The working layer contains, by mass percentage, 97-99% matrix powder and 1-3% diamond particles, wherein the diamond particles have a particle size of 350-500 μm.

10. The saw blade according to claim 7 or 8, characterized in that, The first interlayer, the second interlayer, and the inner diamond layer have the same thickness, which is 0.5~0.7 mm; the edge diamond layer has a thickness that is 0.05~0.2 mm greater than the thickness of the first interlayer, the second interlayer, and the inner diamond layer.

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