Production of "Binderless" Diamond Compact Tools

Diamond Materials Incorporated, in partnership with Rutgers University and two large U.S. tool manufacturers, propose to develop a new class of high performance tools made from binderless compacts of polycrystalline diamond. This program will use advanced technology imported through ONR sponsorship. The technology to be implemented in this program will replace the present Polycrystalline Diamond Compacts (PCDs) technology, wherein sintered diamond pellets are produced commercially from 20-70 micron size diamond powder by high pressure compaction methods, using metal binders (Co, Si, Ni). Use of the metal binder reduces the thermal stability of the compacts. This limits the applications for the PCDs. The hardness and toughness of binderless Polycrystalline Diamond material is equivalent to those of naturally formed polycrystalline diamond - "carbonado". The result of this program will be development of an economical U.S. based manufacturing capability of superior machining and drilling tools. This will lead to stronger U.S. market leadership as well as improved manufacturing capabilities as a whole for commercial and military manufacturers. Anticipated Benefits: Binderless polycrystalline diamond compacts represent a new class of tool and rock drilling materials for a variety of military and civilian applications, with properties superior to those currently in use.