Novel process for manufacturing Higher performance And LOwer cost synthetic industrial diamond (HALO)

制造更高性能和更低成本的合成工业金刚石 (HALO) 的新工艺

• 批准号: 10030745
• 金额: $ 21.09万
• 依托单位: GULL CORPORATION LIMITED
• 依托单位国家: 英国
• 项目类别: Investment Accelerator
• 财政年份: 2022
• 资助国家: 英国
• 起止时间: 2022 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=10030745
• 关键词: Novel; process; manufacturing; Higher; performance

Industrial machining processes such as cutting, grinding, polishing, drilling, and wire-drawing require mechanically robust diamonds for durable, productive and precise machining. Industrial diamond performance is gauged by diamond wear distance. Wear distance is a measure of the amount of material a diamond component can process effectively before wearing out. Diamond wear distance is dependent on diamond properties such as hardness, fracture toughness and (friction) heat resistance and the machining process conditions.The US$13.38B global industrial diamond stone market is mainly addressed by widely available synthetic single crystal and polycrystalline diamonds. The mechanical properties of these two synthetic diamond types differ significantly, with each type having its own specific performance attributes and limitations.Sumitomo Corp. in Japan have developed a new, synthetic polycrystalline diamond material with exceptional mechanical properties, which addresses the limitations of commercial industrial diamonds. However, this state-of-the-art diamond material is not commercially available, since it cannot be manufactured in commercial volumes using conventional production methods.In this project, we will further develop our innovative, patent-pending diamond process cell and diamond synthesis process for commercial scale volume production of this state-of-the-art synthetic polycrystalline diamond. Once we establish our new production process, we will conduct performance assessments with real tool end-users.Our disruptive approach uses thermal expansion to achieve the required ultra-high process pressures. This enables us to produce 6x the amount of diamond per process cell, compared to conventional production methods. Furthermore, owing to the compact nature of our process cell (approximately 200x smaller than conventional equipment), we can thermally process 10 individual process cells in parallel boosting our production volumes to full commercial scale.The advantages of this new, state-of-the-art, synthetic polycrystalline diamond material are well known and much sought after in the global industrial diamond market. Our unique production approach will unlock its commercial availability. Successful delivery of this project will ensure we are first to market with this superior, UK manufactured, industrial diamond product. Following production scale up, we will distribute our new product via our global diamond distributors E.I.D. Ltd.

切割、磨削、抛光、钻孔和拉丝等工业加工工艺需要机械坚固的金刚石来实现耐用、高效和精确的加工。工业金刚石的性能是通过金刚石磨损距离来衡量的。磨损距离是金刚石部件在磨损之前可以有效加工的材料量的量度。金刚石磨损距离取决于金刚石特性，如硬度、断裂韧性和（摩擦）耐热性以及加工工艺条件。US$13.38B 全球工业金刚石石市场主要由广泛使用的合成单晶和多晶金刚石解决。这两种合成金刚石类型的机械性能差异很大，每种类型都有其特定的性能属性和局限性。日本住友公司开发了一种新型合成多晶金刚石材料，具有卓越的机械性能，解决了商业工业金刚石的局限性。然而，这种最先进的金刚石材料尚未商业化，因为它无法使用传统的生产方法进行商业批量生产。在这个项目中，我们将进一步开发我们正在申请专利的创新金刚石加工单元和金刚石合成工艺，以商业规模批量生产这种最先进的合成多晶金刚石。一旦我们建立了新的生产工艺，我们将与真实的工具最终用户进行性能评估。我们的颠覆性方法利用热膨胀来实现所需的超高工艺压力。与传统生产方法相比，这使我们每个工艺单元生产的金刚石数量增加了 6 倍。此外，由于我们的加工单元结构紧凑（比传统设备小约 200 倍），我们可以并行热处理 10 个单独的加工单元，从而将我们的产量提高到完全商业规模。这种新型、最先进的合成多晶金刚石材料的优势众所周知，并且在全球工业金刚石市场上备受追捧。我们独特的生产方法将释放其商业可用性。该项目的成功交付将确保我们率先将这种英国制造的优质工业钻石产品推向市场。扩大生产规模后，我们将通过我们的全球钻石经销商 E.I.D. 分销我们的新产品。有限公司