Polycrystalline Diamond Composite Sheet With a Continuous Gradient Interface
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Solution Overview
Problem
Conventional manufacturing technologies struggle to produce polycrystalline diamond composite sheets with continuous gradient transition layers due to difficulties in achieving uniform and continuous material changes, leading to significant residual stress and poor bonding between diamond and cemented carbide layers, which limits their performance and service life.
Innovation Solution
A polycrystalline diamond composite sheet with a continuous gradient transition layer is fabricated using 3D printing, where the composition gradually transitions from 100% cemented carbide to 100% diamond, controlled by adjusting the feeding speeds of diamond and cemented carbide filament materials, eliminating the sudden change interface and optimizing the material structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder spreading or layer-by-layer stacking methods are used, then composition control is easy, but continuous and uniform material changes cannot be achieved
Solution Approach 1:
The patent changes the feeding speed parameters of diamond and cemented carbide filaments dynamically during the 3D printing process to achieve continuous material composition changes. By adjusting the ratio of feeding speeds, the material composition transitions continuously from 100% cemented carbide through gradient mixtures to 100% diamond, eliminating the need for complex pre-mixed powders and achieving uniform continuous material changes.
2Ease of manufacture
If sudden change interface between cemented carbide and diamond is used, then manufacturing is simple, but stress concentration and peeling occur
Solution Approach 1:
The patent applies local quality by creating a gradient transition layer with continuously changing material composition between the cemented carbide substrate and diamond layer. Each local region has a specific diamond content that gradually increases from the substrate toward the diamond layer, eliminating the sudden interface and reducing stress concentration while maintaining manufacturing simplicity through 3D printing.
3Reliability
If functionally graded materials with continuous gradient are used, then stress is minimized and performance is optimized, but conventional manufacturing cannot achieve continuous material changes
Solution Approach 1:
The patent replaces conventional mechanical powder spreading and stacking methods with 3D printing technology that uses digital modeling and automated filament feeding. This substitution enables continuous material composition changes through digital control of feeding speeds, achieving functionally graded materials with minimized stress while maintaining efficient production cycles.
Data Source
AI summary
The disclosure discloses a polycrystalline diamond composite sheet having a continuous gradient transition layer and a 3D printing preparation method thereof. The polycrystalline diamond composite sheet consists of a polycrystalline diamond layer, a continuous gradient transition layer, and a cemented carbide substrate from top to bottom, in which the continuous gradient transition layer consists of diamond and cemented carbide. Along a direction from the cemented carbide substrate to the polycrystalline diamond layer, a content of the cemented carbide in the continuous gradient transition layer decreases from 100% to 0, and a content of the diamond increases from 0 to 100%. By designing and combining the continuous gradient transition layer with 3D printing technology, the disclosure realizes a continuous change in the two materials of diamond and cemented carbide, thereby eliminating the sudden change interface of the materials inside the diamond composite sheet.