Ultra-fine-diameter diamond wire saw and preparation method therefor

Abstract

An ultra-fine-diameter diamond wire saw having a low wire breakage rate and a preparation method therefor. The saw comprises a wire core; diamond particle inlays; a first alloy coating layer, a second alloy coating layer, and a third alloy coating layer which are coaxially arranged from the surface of the wire core outwards in the radial direction of the wire core. The first alloy coating layer is a rigid inner shell and is used for preventing high-cycle fatigue cracks from penetrating through the second alloy coating layer and then expanding to the wire core. The second alloy coating layer is a flexible interlayer and is used for preventing instantaneous impact cracks or low-cycle fatigue cracks from penetrating through the third alloy coating layer and then extending to the first alloy coating layer. The third alloy coating layer is a rigid outer shell and is used for resisting against abrasion with a material being cut and penetration by instantaneous impact cracks.

Description

Ultra-fine diameter diamond wire saw and preparation method thereof Technical Field

[0001] The invention relates to the technical field of electrolysis or electrophoresis production process for coatings, and in particular to an ultra-fine diameter diamond wire saw with a low wire breakage rate and a preparation method thereof. Background Art

[0002] Diamond wire saws, also known as diamond wire, are made by attaching diamond abrasives to a metal wire using electroplating or resin bonding. In the 1990s, wire sawing technology was adopted to cut silicon ingots into wafers to address the processing challenges of large silicon wafers. Early wire sawing techniques employed bare metal wire and free abrasives. During the machining process, the abrasives were inserted between the wire and the workpiece to create a cutting action. This technique was successfully used to machine silicon and silicon carbide. To further shorten machining times and to enable machining of other hard materials and difficult-to-machine ceramics, the diamond abrasives were fixed to the wire in a specific manner, resulting in the fixed diamond wire saw.

[0003] Fixed diamonds mainly include electroplating type and resin type: the electroplating type is a linear superhard material tool made by depositing a layer of metal (usually nickel and nickel-cobalt alloy) on the metal wire by electroplating, and consolidating diamond abrasives in the metal; while the resin type uses resin as a binder to consolidate the diamond abrasives on the metal wire.

[0004] Electroplated diamond wire saws can be manufactured in various diameters and lengths to meet specific needs. They can be mounted on various machines to create various processing methods, such as reciprocating (saw frame), high-speed band saw, and wire cutting. Electroplated diamond wire saws are suitable for cutting thin sheets, processing curved surfaces, and drilling small holes in hard and brittle materials, offering a broad range of applications.

[0005] As silicon material prices continue to fall, customers have more stringent requirements on the wire breakage rate and overall yield rate during the slicing process, and require an increase in the single-knife wafer output rate to reduce production costs. At the same time, with the advancement of photovoltaic power generation technology, the size of silicon wafers has gradually shifted to half-wafer cutting, and the demand for diamond wire saw quality is increasing. With the advancement of wire thinning and the narrowing of client cutting groove pitch, the steel wire must have a low wire breakage rate, high cutting force, and strong silicon powder removal ability; factors affecting wire breakage include the performance of the busbar itself, the accuracy and stability of the processing equipment operation, the stable control of the electroplating process parameters, and the auxiliary material diamond plating process technology; the wire drawing process will produce drawing grooves, which will affect the surface quality of the steel wire. Defective steel wire will cause internal wire breakage and external customer cutting breakage during the subsequent electroplating process; the precision of diamond wire production equipment reduces scratches on the steel wire, and hidden mechanical damage caused by oblique pulling, which leads to wire breakage at the end of use; the auxiliary material diamond abrasive plating process determines the diamond sanding capacity and arrangement shape, and thus determines the cutting force of the wire saw; therefore, how to reduce the wire breakage rate of fine-diameter steel wire and improve the stability of wire saw manufacturing is a technical challenge in the current industry.

[0006] Related technologies are disclosed in the prior art:

[0007] Chinese patent publication number CN112192459B discloses a process for preparing a diamond wire saw suitable for cutting large-size semiconductors. Specifically, the disclosure states that the diamond wire saw is composed of diamond abrasive grains, a busbar steel wire, and a coating. The preparation process includes material preparation, busbar pretreatment, core wire pre-plating, composite sanding, abrasive grain consolidation, wire spiraling, drying, and wire winding. The process is suitable for cutting semiconductor wafers larger than 8 inches. The process reduces wire breakage, surface damage layers, wire marks, and fragmentation, effectively improves the wire's chip removal capability, and reduces anomalies during the cutting process. Furthermore, the process enhances cutting efficiency and improves wafer surface quality, resulting in excellent economic and practical value.

[0008] Chinese patent publication number CN111979572A discloses a method for quickly adjusting the thickness of the thickened coating of electroplated diamond wire; specifically, the method discloses: first, calculating the electroplating reaction time of the steel wire linear speed, then calculating the current density of the electroplating reaction and the reaction surface area of ​​the diamond wire, and finally calculating the electroplating current based on the calculated current density and the reaction surface area of ​​the diamond wire. The electroplating current and steel wire linear speed corresponding to the target thickened coating thickness can be quickly obtained, which can be used as a reference for experimental design to achieve rapid adjustment of the actual electroplating current and steel wire linear speed in the thickening electroplating process, and obtain a diamond wire with a target thickened coating thickness in the electroplating thickening process. The method of the present invention is simple, the data is accurate through experimental verification, and a large amount of experimental verification is not required, which saves materials and time, and can achieve rapid adjustment of the coating thickness of the electroplated diamond wire to meet the different requirements of different customers for the coating thickness, blade height and blade rate of the diamond wire.

[0009] Chinese patent publication number CN116536731A discloses a highly wear-resistant, low-loss diamond wire saw containing a nickel-cobalt alloy coating and a method for preparing the same. Specifically, the invention comprises a wire saw substrate and two metal coatings wrapped around the surface, wherein the inner layer of the two metal coatings is a nickel-phosphorus alloy coating, and the outer layer is a nickel-cobalt alloy coating. The coating structure is optimized to be double-layered, with the outermost layer optimized from pure nickel to a nickel-cobalt alloy, which further enhances strength and coating hardness, reduces stress, and achieves the goals of increasing particle consolidation, reducing wire breakage rates, and reducing wire loss. The preparation method utilizes a combination of chemical plating and electroplating, resulting in a fast reaction speed, low coating stress, good physical properties, and excellent performance of the finished wire saw.

[0010] Chinese patent publication number CN218666357U discloses a pre-plating tank, specifically comprising a tank body; a conductive assembly, the conductive assembly comprising a conductive rod having an annular groove group formed thereon, the annular groove group comprising multiple annular grooves extending circumferentially along the conductive rod; a metal wire mesh, the ends of which are respectively wound around the multiple annular grooves of the conductive rod; and an anode assembly, the anode assembly being disposed within the tank body. In the present invention, multiple annular grooves extending circumferentially along the conductive rod are formed on the conductive rod, providing mounting locations for the metal wire mesh, thereby increasing the contact area between the metal wire mesh and the plating solution within the tank body. The present invention is not limited by current density, resulting in a thick nickel layer formed on the metal wire, a strong bond between the diamond coating of the diamond wire and the metal wire, stable and reliable cutting of the diamond wire, and a low wire breakage rate during cutting. Furthermore, the present invention can increase the travel speed of multiple metal wires, reducing overall production costs and increasing production efficiency.

[0011] A Chinese patent with the announcement number CN113500252B discloses a method for reducing the breakage rate of fine-diameter diamond wire. Specifically, the method includes: preparing semi-finished steel wire, subjecting carbon steel wire rods of appropriate specifications to saponification, heat treatment, quenching, alkaline degreasing, pickling, copper plating, galvanizing, surface quenching, and water washing to obtain semi-finished brass steel wire of target specifications; drawing the obtained semi-finished brass steel wire to produce an ultra-fine steel wire busbar of target specifications; and subjecting the obtained ultra-fine steel wire busbar to pre-treatment, pre-nickel plating, sanding, sand consolidation, and post-treatment to produce a fine-diameter diamond wire. By increasing the copper-zinc coating ratio, the uniformity of the steel wire coating after drawing is improved, the electrical conductivity and sanding capacity of the steel wire are improved, and the mechanical properties of the steel wire are improved. Secondly, by optimizing the pre-treatment process in step three and adding a rhodine slow-release agent, the corrosion of the steel wire by the acid solution and the generation of hydrogen embrittlement are reduced, and the flexibility of the wire saw is improved to reduce the brittle breakage of the diamond wire.

[0012] The Chinese patent with announcement number CN218314490U discloses a directionally distributed high-strength and high-hardness diamond wire; specifically, it discloses: it includes a busbar and an abrasive, a resin layer and a carbon fiber layer are arranged between the busbar and the abrasive from the inside to the outside, the abrasive includes a metal layer and diamonds arranged on the metal layer, the metal layer is evenly distributed on the outside of the carbon fiber layer, a positioning layer and a reinforcement layer are also arranged on the outside of the carbon fiber layer, the metal layer partially protrudes from the reinforcement layer, and a discharge film is arranged on the outer surface of the reinforcement layer between the metal layers. It has the properties of high strength and high hardness. The directional and uniform distribution of diamonds solves the problem of poor cutting ability due to uneven distribution. At the same time, the positioning layer and reinforcement layer on the outside also ensure that the diamonds will not fall off easily during use.

[0013] However, the prior art based on the above patent document still has the following technical problems:

[0014] 1. The diamond wire in the prior art has a single coating. Even if the prior art discloses a pre-plating or re-plating process, it usually adopts a single pure nickel coating, nickel-cobalt coating, nickel-iron coating, or nickel-cobalt-iron coating. After multiple electroplating steps, the coating has the same composition, resulting in a single coating performance.

[0015] 2. In the existing ultra-fine diamond wire saw, the busbar is usually made of tungsten wire. Tungsten wire is a thin filament made by forging and drawing tungsten bars or rods. It is a typical tungsten product with advantages such as high melting point, good flexibility, high tensile strength, strong fatigue resistance, high temperature resistance, corrosion resistance and oxidation resistance. However, the cost of tungsten wire busbar is 4-5 times that of high-carbon steel busbar. In the existing technology, there is still a lack of reports on how to use low-cost high-carbon steel busbar to prepare diamond wire with a low breakage rate.

[0016] 3. Existing diamond wires with composite coatings of different compositions only provide different properties based on their respective coatings, such as the first coating is wear-resistant and the second coating is sand-fixing. They cannot utilize the direct synergistic effect of different coatings to jointly resist the main situations that cause wire breakage, such as instantaneous impact, low-cycle fatigue, and high-cycle fatigue faced by diamond wires during work.

[0017] Summary of the Invention

[0018] To achieve the purpose of the present invention, the present invention is implemented through the following technical solutions: an ultra-fine diameter diamond wire saw with a low wire breakage rate, comprising:

[0019] A busbar; a diamond inlay; a first alloy coating, a second alloy coating, and a third alloy coating coaxially distributed from the inside to the outside of the busbar surface along the radial direction of the busbar;

[0020] The busbar is made of high carbon steel wire instead of tungsten wire, and the wire diameter is 35 microns (μm);

[0021] The first alloy coating, the second alloy coating and the third alloy coating form a "sandwich" structure;

[0022] The first alloy plating layer and the second alloy plating layer both have a higher hardness and Young's modulus than the second alloy plating layer;

[0023] The first alloy coating has a higher hardness and Young's modulus than the third alloy coating;

[0024] The second alloy coating has a yield strength higher than that of the first alloy coating and the second alloy coating;

[0025] That is, HV1>HV3>HV2 E1>E3>E2 σs2>σs1 and σs2>σs3

[0026] Wherein, HV1, HV2 and HV3 represent the micro Vickers hardness of the first alloy coating, the second alloy coating and the third alloy coating, respectively; E1, E2 and E3 represent the Young's modulus of elasticity of the first alloy coating, the second alloy coating and the third alloy coating, respectively; σs1, σs2 and σs3 represent the yield strength of the first alloy coating, the second alloy coating and the third alloy coating, respectively;

[0027] The third alloy coating is a hard shell used to resist friction and instantaneous impact crack penetration of the cut material;

[0028] The second alloy coating is a flexible interlayer, which is used to prevent instantaneous impact cracks or low cycle fatigue cracks from penetrating the third alloy coating and then extending to the first alloy coating;

[0029] The first alloy coating is a hard inner shell, which is used to prevent high cycle fatigue cracks from penetrating the second alloy coating and then extending toward the busbar.

[0030] Furthermore, the first alloy coating is a nickel-cobalt alloy.

[0031] Furthermore, the second alloy coating is a nickel-iron alloy.

[0032] Furthermore, the third alloy coating is a nickel-iron-cobalt alloy.

[0033] Furthermore, the third alloy coating is a nickel-iron-cobalt-zinc alloy.

[0034] Furthermore, the first alloy plating layer, the second alloy plating layer, and the third alloy plating layer are not pure nickel plating layers.

[0035] The present invention also provides a method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate, which is used to prepare the ultra-fine diameter diamond wire saw with a low wire breakage rate, and is characterized in that it comprises the following steps: wire laying, alkali washing, acid washing, water washing, pre-plating, sanding, sand consolidation, secondary plating, tertiary plating, water washing, hot water washing, and wire winding;

[0036] The pre-plating step forms a first alloy plating layer of a nickel-cobalt alloy on the busbar, the second plating step forms a second alloy plating layer of a nickel-iron alloy on the busbar, and the third plating step forms a third alloy plating layer of a nickel-iron-cobalt alloy on the busbar;

[0037] The first alloy plating layer and the second alloy plating layer both have a higher hardness and Young's modulus than the second alloy plating layer;

[0038] The first alloy coating has a higher hardness and Young's modulus than the third alloy coating;

[0039] The second alloy coating has a yield strength higher than that of the first alloy coating and the second alloy coating;

[0040] The third alloy coating is a hard shell used to resist friction and instantaneous impact crack penetration of the cut material;

[0041] The second alloy coating is a flexible interlayer, which is used to prevent instantaneous impact cracks or low cycle fatigue cracks from penetrating the third alloy coating and then extending to the first alloy coating;

[0042] The first alloy coating is a hard inner shell, which is used to prevent high cycle fatigue cracks from penetrating the second alloy coating and then extending toward the busbar.

[0043] Furthermore, the pickling step includes: 30 g / L composite acid salt, temperature is 20 ° C, treatment time is 5 s

[0044] The water washing step comprises: using pure water with a conductivity of less than 10 μs / cm, controlling the water temperature at 25 to 30° C., and washing three times by spraying, immersing, or a combination of spraying and immersing;

[0045] The hot water washing step includes: using pure water with a conductivity of less than 10μs / cm and controlling the water temperature at 65-70℃ for immersion washing.

[0046] Each 1L pre-plating solution includes 150-200 grams of hydrated NiSO4, 25-30 grams of hydrated NiCl2, 5-20 grams of hydrated CoSO4, 30-50 grams of H3BO3, 0.5-1 gram of N,N-dimethylpropargylamine or diethylaminopropargylamine, 0.1-0.5 grams of C3H3NaO3S or C3H5SO3Na, and 0.1-0.5 grams of carboxyethylisothiouronium salt;

[0047] Each 1L of the second plating solution contains 170-210 grams of nickel sulfamate and 20-40 grams of ferrous sulfate; the plating temperature is 60-65°C and the pH is 3.0-4.0;

[0048] The three plating solutions are prepared by mixing the pre-plating solution and the second plating solution in a ratio of 1:1, and then adding hydrated NiSO4, hydrated NiCl2, and hydrated CoSO4 in proportion. In the three plating solutions after preparation, the weight ratio of nickel-cobalt-iron is (30-40):(20-25):(20-25).

[0049] The present invention also provides a device for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate, which is used to implement the method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate. The device is characterized in that the device is a rewinding multi-wire electroplating device with an integrated traction wheel frame platform. The integrated traction wheel frame platform is provided with a pay-off wheel, a pre-cleaning station, a pre-plating station, a sand-loading and consolidating station, a second plating station, a third plating station, a post-cleaning station, and a take-up wheel.

[0050] The beneficial effects of the present invention are:

[0051] 1. The present invention uses electroplating to prepare ultrafine diamond wire saws based on carbon-based busbars, which significantly reduces costs and improves market competitiveness compared to tungsten-based busbars.

[0052] 2. The present invention prepares a composite multilayer coating with different components based on pre-plating, secondary plating and triple plating instead of using pure nickel plating, thereby improving the comprehensive performance of the coating, especially the use of nickel-iron alloy, reducing the amount of nickel used and reducing the cost of the coating.

[0053] 3. The three-layer coating of the present invention has different hardness, elastic modulus and yield limit, forming a "sandwich" structure, which can synergistically provide high-reliability anti-wire breakage performance for the diamond wire saw. Specifically, the outermost third alloy coating has a higher hardness and can provide wear resistance, but the high-hardness material is relatively brittle. The present invention provides a second alloy coating with lower hardness as a back support, which can absorb the instantaneous impact of the third alloy coating and avoid the brittle fracture of the third alloy coating. At the same time, even if the instantaneous impact breaks the third coating, it will be significantly weakened when penetrating the second alloy coating because it is softer and less likely to penetrate the first alloy coating, thereby reducing the instantaneous impact short-line rate.

[0054] 4. The second alloy coating of the present invention has a lower Young's modulus and a higher yield strength than the third alloy coating, that is, the nickel-iron alloy of the second alloy coating is "softer" in terms of hardness and Young's modulus compared to the nickel-chromium alloy or the nickel-iron-cobalt alloy. When the cutting force of the diamond wire is greater and closer to the wire-breaking force, the diamond wire saw is in a low-cycle fatigue cycle state and is prone to low-cycle fatigue fracture. In the low-cycle fatigue state, the deformation of the material is closer to plastic deformation, and the expansion of the crack is closer to tearing. Since the soft material has a lower Young's modulus, it can undergo greater deformation under the large load of the low-cycle cycle, giving up deformation space, thereby resisting the expansion of low-cycle fatigue cracks. In the present invention, the second alloy coating of the nickel-iron material plays a role in resisting the progression of low-cycle cracks, thereby reducing the low-cycle fatigue wire breakage rate of the diamond wire saw of the present invention.

[0055] 5. The first alloy coating and the second alloy coating of the present invention are both nickel-chromium-based high-hardness coatings. When the diamond wire saw faces high-speed and stable cutting, the force fluctuation is small and it is in a high-cycle fatigue cycle state. (High-cycle fatigue refers to the fatigue caused by a material under a cyclic stress lower than its yield strength after 10,000 to 100,000 cycles). In the high-cycle fatigue cycle state, the initial crack will not be torn at all, but local stress concentration will cause crack expansion under high-frequency stress. Hard materials can effectively resist the expansion of high-cycle fatigue initial cracks and avoid high-cycle fatigue fracture, thereby improving the high-cycle fatigue fracture resistance of the metal wire saw of the present invention and reducing the high-cycle fatigue wire breakage rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] FIG1 is a schematic structural diagram of a busbar and a coating of a diamond wire saw according to the present invention;

[0057] FIG2 is a flow chart of the preparation of a diamond wire saw according to the present invention;

[0058] FIG3 is a front view schematic diagram of the structure of the integrated traction wheel frame platform of the present invention;

[0059] FIG4 is a schematic diagram of the top view of the integrated traction wheel frame platform of the present invention. DETAILED DESCRIPTION

[0060] In order to deepen the understanding of the present invention, the present invention will be further described in detail below with reference to the examples. The examples are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0061] Example 1

[0062] An ultra-fine diameter diamond wire saw with a low wire breakage rate, comprising:

[0063] A busbar; a diamond inlay; a first alloy coating, a second alloy coating, and a third alloy coating coaxially distributed from the inside to the outside of the busbar surface along the radial direction of the busbar;

[0064] The busbar is made of high carbon steel wire instead of tungsten wire;

[0065] The first alloy coating, the second alloy coating and the third alloy coating form a "sandwich" structure;

[0066] The first alloy plating layer and the second alloy plating layer both have a higher hardness and Young's modulus than the second alloy plating layer;

[0067] The first alloy coating has a higher hardness and Young's modulus than the third alloy coating;

[0068] The second alloy coating has a yield strength higher than that of the first alloy coating and the second alloy coating;

[0069] That is, HV1>HV3>HV2 E1>E3>E2 σs2>σs1 and σs2>σs3

[0070] Wherein, HV1, HV2 and HV3 represent the micro Vickers hardness of the first alloy coating, the second alloy coating and the third alloy coating, respectively; E1, E2 and E3 represent the Young's modulus of elasticity of the first alloy coating, the second alloy coating and the third alloy coating, respectively; σs1, σs2 and σs3 represent the yield strength of the first alloy coating, the second alloy coating and the third alloy coating, respectively;

[0071] The third alloy coating is a hard shell used to resist friction and instantaneous impact crack penetration of the cut material;

[0072] The second alloy coating is a flexible interlayer, which is used to prevent instantaneous impact cracks or low cycle fatigue cracks from penetrating the third alloy coating and then extending to the first alloy coating;

[0073] The first alloy coating is a hard inner shell, which is used to prevent high cycle fatigue cracks from penetrating the second alloy coating and then extending toward the busbar.

[0074] Furthermore, the first alloy coating is a nickel-cobalt alloy.

[0075] Furthermore, the second alloy coating is a nickel-iron alloy.

[0076] Furthermore, the third alloy coating is a nickel-iron-cobalt alloy.

[0077] Furthermore, the third alloy coating is a nickel-iron-cobalt-zinc alloy.

[0078] Furthermore, the first alloy plating layer, the second alloy plating layer, and the third alloy plating layer are not pure nickel plating layers.

[0079] Example 2:

[0080] A method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate, for preparing the ultra-fine diameter diamond wire saw with a low wire breakage rate, characterized in that it comprises the following steps: wire laying, alkali washing, acid washing, water washing, pre-plating, sanding, sand consolidation, secondary plating, tertiary plating, water washing, hot water washing, and wire winding;

[0081] The pre-plating step forms a first alloy plating layer of a nickel-cobalt alloy on the busbar, the second plating step forms a second alloy plating layer of a nickel-iron alloy on the busbar, and the third plating step forms a third alloy plating layer of a nickel-iron-cobalt alloy on the busbar;

[0082] The first alloy plating layer and the second alloy plating layer both have a higher hardness and Young's modulus than the second alloy plating layer;

[0083] The first alloy coating has a higher hardness and Young's modulus than the third alloy coating;

[0084] The second alloy coating has a yield strength higher than that of the first alloy coating and the second alloy coating;

[0085] The third alloy coating is a hard shell used to resist friction and instantaneous impact crack penetration of the cut material;

[0086] The second alloy coating is a flexible interlayer, which is used to prevent instantaneous impact cracks or low cycle fatigue cracks from penetrating the third alloy coating and then extending to the first alloy coating;

[0087] The first alloy coating is a hard inner shell, which is used to prevent high cycle fatigue cracks from penetrating the second alloy coating and then extending toward the busbar.

[0088] Furthermore, the pickling step includes: 30 g / L of complex acid salt, temperature of 20°C, and treatment time of 5 s;

[0089] The water washing step comprises: using pure water with a conductivity of less than 10 μs / cm, controlling the water temperature at 25 to 30° C., and washing three times by spraying, immersing, or a combination of spraying and immersing;

[0090] The hot water washing step includes: using pure water with a conductivity of less than 10μs / cm and controlling the water temperature at 65-70℃ for immersion washing.

[0091] The electroplating current is: cathode current density is 2-10A / dm2.

[0092] Furthermore, each 1L of the pre-plating solution includes 150-200 grams of hydrated NiSO4, 25-30 grams of hydrated NiCl2, 5-20 grams of hydrated CoSO4, 30-50 grams of H3BO3, 0.5-1 gram of N,N-dimethylpropargylamine or diethylaminopropargylamine, 0.1-0.5 grams of C3H3NaO3S or C3H5SO3Na, and 0.1-0.5 grams of carboxyethylisothiouronium salt;

[0093] Each 1L of the second plating solution contains 170-210 grams of nickel sulfamate and 20-40 grams of ferrous sulfate; the plating temperature is 60-65°C and the pH is 3.0-4.0;

[0094] The three plating solutions are prepared by mixing the pre-plating solution and the second plating solution in a ratio of 1:1, and then adding hydrated NiSO4, hydrated NiCl2, and hydrated CoSO4 in proportion. In the three plating solutions after preparation, the weight ratio of nickel-cobalt-iron is (30-40):(20-25):(20-25).

[0095] The present invention also provides a device for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate, which is used to implement the method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate. The device is characterized in that the device is a rewinding multi-wire electroplating device with an integrated traction wheel frame platform. The integrated traction wheel frame platform is provided with a pay-off wheel, a pre-cleaning station, a pre-plating station, a sand-loading and consolidating station, a second plating station, a third plating station, a post-cleaning station, and a take-up wheel.

[0096] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. An ultra-fine diameter diamond wire saw with low wire breakage rate, characterized in that: include: A busbar; a diamond inlay; a first alloy coating, a second alloy coating and a third alloy coating coaxially distributed from the inside to the outside of the busbar surface along the radial direction of the busbar; The busbar uses high carbon steel wire instead of tungsten wire; The first alloy coating, the second alloy coating and the third alloy coating form a "sandwich" structure; The first alloy coating and the second alloy coating both have a higher hardness and a higher Young's modulus of elasticity than the second alloy coating; The first alloy coating has a higher hardness and Young's modulus than the third alloy coating; The second alloy coating has a yield strength higher than that of the first alloy coating and the second alloy coating; That is to satisfy: HV1>HV3>HV2 E1>E3>E2 σs2>σs1 and σs2>σs3 Wherein, HV1, HV2 and HV3 represent the micro-Vickers hardness of the first alloy coating, the second alloy coating and the third alloy coating, respectively; E1, E2 and E3 represent the Young's modulus of elasticity of the first alloy coating, the second alloy coating and the third alloy coating, respectively; σs1, σs2 and σs3 represent the yield strength of the first alloy coating, the second alloy coating and the third alloy coating, respectively; The third alloy coating is a hard shell, which is used to resist the friction and instantaneous impact crack penetration of the cut material; The second alloy coating is a flexible interlayer, which is used to prevent instantaneous impact cracks or low cycle fatigue cracks from penetrating the third alloy coating and then extending to the first alloy coating; The first alloy coating is a hard inner shell, which is used to prevent high cycle fatigue cracks from penetrating the second alloy coating and then extending to the busbar.

2. The ultra-fine diameter diamond wire saw with low wire breakage rate according to claim 1, characterized in that: The first alloy coating is a nickel-cobalt alloy.

3. The ultra-fine diameter diamond wire saw with low wire breakage rate according to claim 2, characterized in that: The second alloy coating is a nickel-iron alloy.

4. The ultra-fine diameter diamond wire saw with low wire breakage rate according to claim 3, characterized in that: The third alloy coating is a nickel-iron-cobalt alloy.

5. The ultra-fine diameter diamond wire saw with low wire breakage rate according to claim 3, characterized in that: The third alloy coating is a nickel-iron-cobalt-copper alloy.

6. An ultra-fine diameter diamond wire saw with low wire breakage rate according to any one of claims 2 to 5, characterized in that: The first alloy plating layer, the second alloy plating layer, and the third alloy plating layer are not pure nickel plating layers.

7. A method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate, for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate according to any one of claims 1 to 6, characterized in that: The following steps are involved: Paying off, alkali washing, pickling, water washing, pre-plating, sanding, sand consolidation, secondary plating, tertiary plating, water washing, hot water washing, and taking up; The pre-plating step forms a first alloy plating layer of a nickel-cobalt alloy on the busbar, the second plating step forms a second alloy plating layer of a nickel-iron alloy on the busbar, and the third plating step forms a third alloy plating layer of a nickel-iron-cobalt alloy on the busbar; The first alloy coating and the second alloy coating both have a higher hardness and a higher Young's modulus of elasticity than the second alloy coating; The first alloy coating has a higher hardness and Young's modulus than the third alloy coating; The second alloy coating has a yield strength higher than that of the first alloy coating and the second alloy coating; The third alloy coating is a hard shell, which is used to resist the friction and instantaneous impact crack penetration of the cut material; The second alloy coating is a flexible interlayer, which is used to prevent instantaneous impact cracks or low cycle fatigue cracks from penetrating the third alloy coating and then extending to the first alloy coating; The first alloy coating is a hard inner shell, which is used to prevent high cycle fatigue cracks from penetrating the second alloy coating and then extending to the busbar.

8. The method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate according to claim 7, characterized in that: The pickling steps include: 30g / L composite acid salt, temperature of 20℃, treatment time of 5s The water washing step includes: using pure water with a conductivity of less than 10 μs / cm, controlling the water temperature at 25 to 30° C., and washing three times by spraying, or immersing, or a combination of spraying and immersing; The hot water washing step includes: using pure water with a conductivity of less than 10 μs / cm and controlling the water temperature at 65-70° C. for immersion washing.

9. The method for preparing an ultra-fine diameter diamond wire saw with a low wire breakage rate according to claim 8, characterized in that: Each 1L pre-plating solution includes 150-200 grams of hydrated NiSO4, 25-30 grams of hydrated NiCl2, 5-20 grams of hydrated CoSO4, 30-50 grams of H3BO3, 0.5-1 grams of N,N-dimethylpropargylamine or diethylaminopropargylamine, 0.1-0.5 grams of C3H3NaO3S or C3H5SO3Na, and 0.1-0.5 grams of carboxyethylisothiouronium salt; Each 1L of the second plating solution includes 170-210 grams of nickel sulfamate and 20-40 grams of ferrous sulfate; the plating temperature is 60-65°C and the pH is 3.0-4.0; The three-plating solution is prepared by mixing the pre-plating solution and the second plating solution in a ratio of 1:1, and then adding hydrated NiSO4, hydrated NiCl2, and hydrated CoSO4 in proportion. In the three-plating solution after preparation, the components of nickel-cobalt-iron are in a weight ratio of (30-40):(20-25):(20-25).

10. A manufacturing device for an ultra-fine diameter diamond wire saw with a low wire breakage rate, used for implementing the manufacturing method for an ultra-fine diameter diamond wire saw with a low wire breakage rate according to any one of claims 7 to 9, characterized in that: The preparation device is a rewinding multi-wire electroplating device, which is equipped with an integrated traction wheel frame platform, on which a pay-off wheel, a pre-cleaning station, a pre-plating station, a sanding and consolidation station, a second plating station, a third plating station, a post-cleaning station, and a take-up wheel are arranged.

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