The objective of the present work was to determine the suitability of a new iron-based Mn-Cu-Sn matrix alloy for the manufacture of diamond-impregnated tool components. A number of specimens were consolidated by the hot press route from ball-milled powders. Density, microstructural features, phase composition, bending properties and hardness were evaluated. The results revealed excellent mechanical properties, including σ 0.2 > 850 MPa in 3-point bending and HK0.5 > 300. A commercial Co-WC reference matrix alloy was also produced for comparison purposes. Diamond-impregnated specimens with different matrices were tested for wear rate on abrasive sandstone using a test rig specially designed to simulate tool application conditions. The tests that involved 3-and 2-body abrasion ranked the alloys in different orders. Statistical analysis showed that the wear rate of diamondimpregnated composites was mainly affected by diamond concentration, but statistically significant contribution of the matrix resistance to 3-body abrasion was also found.
In this work, Fe-Mn-Cu-Sn-C alloys were prepared by means of powder metallurgy (PM). Powder mixtures were ball-milled for 8, 30 and 120 h and densified to < 1% porosity using spark plasma sintering (SPS) at 900°C and 35 MPa. After consolidation, all samples of the Fe alloys were characterized by x-ray diffraction (XRD), scanning electron microscopy (SEM), hardness and flexural strength tests. Resistance to abrasive wear was evaluated in both three-body abrasion and two-body abrasion tests. The SEM observations revealed an evident dependence of grain size and microstructural homogeneity on milling time. The XRD analysis showed a marked increase in austenite content in the as-sintered specimens with milling time. Although the proportion of deformation-induced martensite was small, the strengthening effect of abrasion on the subsurface layer of the investigated alloys was clearly indicated by Knoop hardness measurements.
The possibility of the use of inexpensive iron-base powders in the production of sintered diamond tools is again explored. Ball-milled Fe-Ni-Cu-Sn-C and Fe-Mn-Cu-Sn-C powders were consolidated to a virtually pore-free condition by hot pressing at 900• C. The resultant materials are characterised by a combination of high Knoop hardness, 260-440 and yield strength, 780-1350 MPa, and resistance to abrasion. These properties can be significantly modified by changing the milling time.Keywords: ball milling, sintered diamond tools, matrix powder, Fe-Ni-Cu-Sn-C, Fe-Mn-Cu-Sn-C, hot pressing W artykule zamieszczono wyniki badań nad możliwością zastosowania tanich proszków na bazie żelaza do produkcji spiekanych narzędzi metaliczno-diamentowych. Mielone proszki Fe-Ni-Cu-Sn-C i Fe-Mn-Cu-Sn-C poddano prasowaniu na gorąco w temperaturze 900• C. Otrzymane spieki posiadają gęstość zbliżoną do teoretycznej, wysoką twardość (260-400 HK0.5), granicę plastyczności (780-1350 MPa) oraz dużą odporność na zużycie ścierne. Wymienione własności są w dużym stopniu uzależnione od czasu mielenia proszków wyjściowych.
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