CN102712478B - 多晶金刚石及其制造方法 - Google Patents

多晶金刚石及其制造方法 Download PDF

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CN102712478B
CN102712478B CN201180005940.4A CN201180005940A CN102712478B CN 102712478 B CN102712478 B CN 102712478B CN 201180005940 A CN201180005940 A CN 201180005940A CN 102712478 B CN102712478 B CN 102712478B
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diamond
polycrystalline diamond
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lonsdaleite
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角谷均
山本佳津子
佐藤武
有元桂子
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Abstract

本发明涉及一种多晶金刚石，其包含：立方金刚石；以及六方金刚石，所述六方金刚石的(100)面的X射线衍射峰强度与所述立方金刚石的(111)面的X射线衍射峰强度的比值不低于0.01%。此外，本发明制造多晶金刚石的方法包括以下步骤：制备石墨化度小于或等于0.58的非金刚石碳材料；以及在不添加任何烧结剂和结合剂的情况下，在金刚石呈热力学稳定的压力和温度条件下将所述非金刚石碳材料直接转化为立方金刚石和六方金刚石，并进行烧结。

Description

多晶金刚石及其制造方法
技术领域
本发明涉及多晶金刚石及其制造方法，尤其涉及适用于诸如切削钻头、修整器和模具之类的工具以及钎头的、具有高硬度和高强度的多晶金刚石以及这种多晶金刚石的制造方法。
背景技术
对于用于诸如切削钻头、修整器和模具之类的工具以及钎头的常规多晶金刚石，采用铁族元素金属（例如，Fe、Co和Ni）、碳酸盐（例如，CaCO3）等作为促进原料烧结的烧结剂，并且采用陶瓷（例如，SiC）等作为使原料结合的结合剂。
通过在金刚石呈热力学稳定的高压和高温条件（通常，压力为约5GPa至8GPa，温度为约1300℃至2200℃）下，将作为原料的金刚石粉末与烧结剂一同烧结，从而获得上述多晶金刚石。
如此获得的多晶金刚石中含有所使用的烧结剂。这种烧结剂对多晶金刚石的诸如硬度和强度之类的机械特性以及对耐热性存在较大的影响。
还已知通过酸处理而除去了上述烧结剂的多晶金刚石、以及将具有耐热性的SiC用作结合剂的耐热性优异的烧结金刚石，然而，这些金刚石的硬度和强度较低，并且作为工具材料的机械特性不足。
同时，可以在不使用烧结剂等情况下，在超高压和超高温条件下将非金刚石碳材料（例如，石墨、玻璃碳或无定形碳）直接转化成为金刚石。通过将非金刚石相直接转化成金刚石相并且同时进行烧结，获得了单相的多晶金刚石。
F.P.Bundy,J.Chem.Phys.,38(1963)第631-643页（非专利文献1）、M.Wakatsuki,K.Ichinose,T.Aoki,Japan.J.Appl.Phys.,11(1972)第578-590页（非专利文献2）和S.Naka,K.Horii,Y.Takeda,T.Hanawa,Nature,259(1976)第38页（非专利文献3）公开了这样的多晶金刚石，该多晶金刚石是通过在14GPa至18GPa的这种超高压和3000K或更高的超高温下直接转化作为原料的石墨而获得的。
然而，以上各种多晶金刚石均是通过进行直接电加热而制得的，其中在直接电加热过程中，通过使电流直接流过诸如石墨之类的导电性非金刚石碳材料从而将其加热，这样不可避免地存在未转化的石墨。此外，金刚石的粒度不均匀，并且烧结往往在局部上并不充分。因此，诸如硬度和强度之类的机械特性不足够高，并且仅获得片状多晶，因而未曾实现实际应用。
T.Irifune,H.Sumiya,“NewDiamondandFrontierCarbonTechnology(新型金刚石和前沿碳技术),”14(2004)第313页（非专利文献4）和Sumiya,Irifune,SEITechnicalReview,165(2004)第68页（非专利文献5）公开了一种通过使用高纯度、高结晶度的石墨作为原料，并通过在不低于12GPa且不低于2200℃的超高压超高温条件下间接加热从而进行直接转化和烧结，由此获得致密且高纯度的多晶金刚石的方法。尽管以这种方法获得的金刚石具有非常高的硬度，但是其实际特性（例如，耐磨性、耐崩裂性和抗裂纹扩展性）不足且不稳定。
天然形成的多晶金刚石（黑金刚石、半刚石等）也是已知的，一些这种多晶金刚石被用于钎头。另一方面，这些金刚石的材质差异较大，并且产量较低，因而没有在工业上大量使用。
在一些应用中使用单晶金刚石。然而，因尺度和成本方面的限制，其使用限于超精密工具或精密耐磨工具，并且用途和使用条件受单晶金刚石的劈裂性和机械特性的各向异性的限制。
引用列表
非专利文献
非专利文献1：F.P.Bundy,J.Chem.Phys.,38(1963)第631-643页
非专利文献2：M.Wakatsuki,K.Ichinose,T.Aoki,Japan.J.Appl.Phys.,11(1972)第578-590页
非专利文献3：S.Naka,K.Horii,Y.Takeda,T.Hanawa,Nature,259(1976)第38页
非专利文献4：T.Irifune,H.Sumiya,"NewDiamondandFrontierCarbonTechnology,"14(2004)第313页
非专利文献5：Sumiya,Irifune,SEITechnicalReview,165(2004)第68页
发明内容
技术问题
为了解决现有技术中的上述问题而进行了本发明，并且本发明的目的是提供具有高硬度和高强度的多晶金刚石以及制造这种多晶金刚石的方法，其中该多晶金刚石适于用作诸如切削钻头、修整器和模具之类的工具以及钎头。
解决问题的方案
本发明借助以下研究发现而得以完成：对于包含立方金刚石和六方金刚石、且六方金刚石与立方金刚石的比值处于规定范围内的多晶金刚石，其硬度和强度要高于六方金刚石与立方金刚石比值不在该规定范围内的多晶金刚石。
即，本发明涉及了一种包含立方金刚石和六方金刚石的多晶金刚石，其中所述六方金刚石的(100)面的X射线衍射峰强度与所述立方金刚石的(111)面的X射线衍射峰强度的比值（h/c比值）不低于0.01%。
此外，本发明借助以下研究发现而得以完成：在不添加任何烧结剂和结合剂的情况下，通过在金刚石呈热力学稳定的压力和温度条件下直接烧结石墨化度不高于规定值的非金刚石碳材料，从而制造出上述h/c比值处于上述规定范围内的多晶金刚石。
即，本发明涉及一种制造多晶金刚石的方法，其包括以下步骤：制备石墨化度小于或等于0.58的非金刚石碳材料；以及在不添加任何烧结剂和结合剂的情况下，在金刚石呈热力学稳定的压力和温度条件下将所述非金刚石碳材料直接转化为立方金刚石和六方金刚石，并进行烧结。
本发明的有益效果
如上文所述，本发明提供了具有高硬度和高强度的多晶金刚石以及制造这种多晶金刚石的方法，该多晶金刚石适于用作诸如切削钻头、修整器和模具之类的工具以及钎头。
具体实施方式
（第一实施方案）
根据本发明的一个实施方案的多晶金刚石包含立方金刚石（下文称作c-金刚石）和六方金刚石（下文称作h-金刚石），并且h-金刚石的(100)面的X射线衍射峰强度与c-金刚石的(111)面的X射线衍射峰强度的比值（下文称作h/c比值）不低于0.01%。
与不含有h-金刚石（即，h/c比值为0%）的多晶金刚石、或h/c比值低于0.01%的多晶金刚石相比，本发明实施方案中的h/c比值不低于0.01%的多晶金刚石具有更高的硬度和强度，具体而言具有更高的强度、抗裂强度、耐磨性等。
这里，c-金刚石指具有立方晶体结构的金刚石，并且h-金刚石指具有六方晶体结构的金刚石。可根据通过X射线衍射测得的衍射峰图案来区分c-金刚石和h-金刚石。即，在含有c-金刚石和h-金刚石的多晶金刚石的X射线衍射中，获得了c-金刚石衍射峰图案和h-金刚石衍射峰图案混合在一起的图案。在本专利申请中，h-金刚石与c-金刚石的比值由h/c比值表述，该h/c比值为h-金刚石的(100)面的X射线衍射峰强度与c-金刚石的(111)面的X射线衍射峰强度的比值。
(第二实施方案)
本发明另一实施方案的多晶金刚石的制造方法包括以下步骤：制备石墨化度不高于0.58的的非金刚石碳材料；以及在不添加任何烧结剂和结合剂的情况下，在金刚石呈热力学稳定的压力和温度条件下将所述非金刚石碳材料直接转化为立方金刚石和六方金刚石，并进行烧结。
根据本实施方案中多晶金刚石的制造方法，获得了具有高硬度和高强度（具体而言具有高强度、高横向强度、高耐磨性等）的多晶金+刚石，该多晶金刚石包含c-金刚石(立方金刚石)和h-金刚石(六方金刚石)，并且h/c比值(h-金刚石的(100)面的X射线衍射峰强度与c-金刚石的(111)面的X射线衍射峰强度的比值)不低于0.01％。
(非金刚石碳材料的制备步骤)
本发明实施方案中的多晶金刚石制造方法首先包括制备石墨化度不高于0.58的非金刚石碳材料的步骤。对本发明制备步骤中制得的非金刚石碳材料没有特别的限制，只要其石墨化度不高于0.58、并且为除金刚石之外的其他碳材料即可。具有低石墨化度的石墨(例如，粉碎的石墨)、无定形碳材料(例如，无定形碳和玻璃碳)或其混合物均是适用的。
这里，通过如下方法确定非金刚石碳材料的石墨化度P。对非金刚石碳材料进行X射线衍射，测得作为非金刚石碳材料的石墨的(002)面的晶面间距d002，并且基于以下方程式(1)计算非金刚石碳材料的乱层结构部分的比值p。
d002＝3.440-0.086×(1-p2)...(1)
基于以下方程式(2)，由如此获得的乱层结构部分的比值p计算石墨化度P。
P＝1-p...(2)
从抑制晶粒生长的角度看，非金刚石碳材料优选不含有作为杂质的铁族元素金属。此外，从抑制晶粒生长和促进向金刚石转化的角度看，作为杂质的氢(H)、氧(O)等的含量优选较低。
(将非金刚石碳材料转化为c-金刚石和h-金刚石并且烧结非金刚石碳材料的步骤)
本发明实施方案中的多晶金刚石制造方法还包括以下步骤：在不添加任何烧结剂和结合剂的情况下，在金刚石呈热力学稳定的压力和温度条件下将上述非金刚石碳材料直接转化为立方金刚石和六方金刚石，并进行烧结。
通过在不添加任何烧结剂和结合剂的情况下，将上述非金刚石碳材料置于金刚石呈热力学稳定的压力和温度条件下，所述非金刚石碳材料直接转化成c-金刚石和h-金刚石，同时被烧结，由此获得h/c比值不低于0.01%的、具有高硬度和高强度的多晶金刚石。
这里，烧结剂指促进充当原料的材料烧结的催化剂，可列举铁族元素金属（例如，Co、Ni和Fe）、碳酸盐（例如，CaCO3）等。结合剂指用于使充当原料的材料结合的材料，可列举陶瓷，例如SiC。
金刚石呈热力学稳定的压力和温度条件指在碳系材料中，金刚石相为热力学稳定相的压力和温度条件。可以在不添加任何烧结剂和结合剂的情况下进行烧结的这种压力和温度条件尤其是指这样的条件：压力不低于12GPa且温度为2000℃至2600℃，并且优选为压力不低于16GPa且温度为2200℃至2300℃。
对本发明实施方案中的多晶金刚石制造方法中所用的高压高温发生装置没有特别的限制，只要其为能够达到金刚石相呈热力学稳定相的压力和温度条件的装置即可，然而从提高生产率和可操作性的角度来看，优选带式发生装置或多顶砧式（multi-anviltype）发生装置。另外，对用以容纳作为原料的非金刚石碳材料的容器没有特别的限制，只要其由耐高压和高温的材料制成即可，例如，可适当地使用Ta等。
实施例
（实施例1至6，对比例1至2）
如表1中所示，制备了具有不同的石墨化度和粒度的多种石墨粉末以作为非金刚石碳材料。
随后，使用高压高温发生装置，在不添加任何烧结剂和结合剂的情况下，于压力为16GPa且温度为2200℃的条件下（其为金刚石呈热力学稳定的压力和温度）对上述多种非金刚石碳材料中的每一种进行高温高压处理。
对所获得的多种多晶金刚石中的每种多晶金刚石的硬度、横向强度和耐磨性加以评价。硬度是通过使用Knoop硬度计，在施加4.9N的负荷并持续10秒的条件下测得的Knoop硬度。横向强度通过借助三点弯曲强度测试仪而测得的。耐磨性是通过使用金刚石研磨机，在负荷设定为3kg/mm2的条件下而测得的，其以将实施例1中的值定义为1.0时的相对值示出。这里，相对值越高，表示耐磨性越高。结果汇总于表1中。
表1
参照表1，发现与h/c比值低于0.01%的多晶金刚石（对比例1至2）相比，h/c比值不低于0.01%的多晶金刚石（实施例1至6）具有更高的硬度、横向强度和耐磨性，并且具有优异的强度特性和耐磨性。
此外，对实施例1、3、6中的样品和对比例1、2中的样品在高温下的抗裂强度和硬度进行了评价。各项测量均在氩气流中进行。结果汇总于表2中。
表2
参照这些结果，h/c比值不低于0.01%的多晶金刚石（实施例1、3、6）即使在高温下仍实现了高抗裂强度和硬度，并且与h/c比值低于0.01%的多晶金刚石（对比例1、2）相比，其抗裂强度和硬度随温度升高而降低的速率更小。与室温（25℃）下的抗裂强度数值相比，前者（实施例1、3、6）在大于或等于800℃且小于或等于1200℃的温度范围内的抗裂强度的下降幅度不超过10%；并且与室温（25℃）下的硬度相比，其在800℃下的硬度的下降幅度不超过20%。此外，实施例1、3、6在1200℃下的抗裂强度高于室温下（25℃）的抗裂强度。
（实施例7）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石钎焊至由金属制成的钎柄上，并制成在前端部分具有4个尖端（具有四边形平面）的划片器。使用制得的各划片器以20g的负荷在蓝宝石衬底中形成200条50mm长的划槽。随后，利用电子显微镜观察位于各划片器前端部分处的多晶金刚石的磨损量。由此得到，与根据对比例1至2的多晶金刚石制成的划片器的磨损量相比，由根据实施例1至6的多晶金刚石制成的划片器的磨损量为其0.80倍以下。
（实施例8）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石埋于由金属制成的钎柄中，并制成在前端部分具有单个尖端（为锥形）的修整器。通过使用WA（白刚玉）磨石，由湿法对所制得的各修整器进行打磨，其中打磨条件为：磨石的圆周速度为30m/秒，切削深度为0.05mm。随后，用高度仪测量各修整器的磨损量，与根据对比例1至2的多晶金刚石制成的修整器的磨损量相比，由根据实施例1至6的多晶金刚石制成的修整器的磨损量为其0.85倍以下。
（实施例9）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石埋于由金属制成的圆形框架中，并且制得孔径为20μm的模具。使用制得的各模具，以500m/分钟的线速度进行Cu线拉丝。这里，直至孔径磨损至20.2μm时，由根据实施例1至6的多晶金刚石制成的模具所花费的拉丝时间是由对比例1至2的多晶金刚石制成的模具所花费时间的1.12倍或更长时间。
（实施例10）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石埋于由金属制成的圆形框架中，并制成孔径为200μm、孔高为5mm且孔表面的算术平均粗糙度Ra为290nm的孔。使用所制得的每个孔以形成排水压为200MPa的水射流喷嘴，并且评价其在切削厚度为10mm的不锈钢板时的性能。直至孔直径增至300μm时，由根据实施例1至6的多晶金刚石制成的孔所花费的切削时间是由对比例1至2的多晶金刚石制成的孔所花费时间的1.15倍或更长时间。
（实施例11）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石钎焊至超硬基体金属，并且制得前端角度为90°、前端曲率半径（R）为100nm的切削工具。使用所制造的各切削工具来加工金属板，以形成深5μm、间距为5μm的凹槽，其中该金属板是通过在厚度为30mm的铜板上镀覆20μm厚的镍而获得的。直至切削工具的前端磨损量达1μm时，由根据实施例1至6的多晶金刚石制成的切削工具所花费的切削时间是由对比例1至2的多晶金刚石制成的切削工具所花费时间的1.30倍或更长时间。
（实施例12）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石钎焊至超硬钎柄，并制成直径为1mm且刃长度为3mm的钻头。使用所制造的各钻头对由硬质合金（WC-Co）制成的1.0mm厚板材进行钻孔，其中钻孔条件为：钻头转速为400rpm，进给量为2μm/时间。直至钻头磨损或破裂时，由根据实施例1至6的多晶金刚石制成的钻头的钻孔数量为由对比例1至2的多晶金刚石制成的钻头的钻孔数量的1.20倍以上。
（实施例13）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石钎焊至超硬钎柄，并制成直径为3mm且磨削刃角度为60°的圆盘形磨削工具。使用所制造的各磨削工具在由硬质合金（WC-Co）制成的表面中形成V形槽，加工时间为2小时，加工条件为：转速为4000rpm，切削深度为2μm，检查此时磨削刃的磨损量。由根据实施例1至6的多晶金刚石制成的磨削工具的磨削刃磨损量为由对比例1至2的多晶金刚石制成的磨削工具的0.7倍以下。
（实施例14）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石接合至由金属制成的框架，由此制成放电加工电极导向器。将线直径为70μm的电极线以10m/分钟的速率供入，并检查100小时后导向孔部分的磨损量。由根据实施例1至6的多晶金刚石制成的钻头的磨损量为由对比例1至2的多晶金刚石制成的钻头磨损量的0.8倍以下。
（实施例15）
将上述实施例1至6和对比例1至2中获得的各多晶金刚石用来制造直径为3.5且厚度为0.6mm的划线轮。利用所制造的各划线轮，在进给速率为100mm/秒，挤压负荷为2.5kg的条件下利用陶瓷衬底进行划线试验，并且检查50小时的磨损量。由根据实施例1至6的多晶金刚石制成的划线轮的磨损量为由对比例1至2的多晶金刚石制成的划线轮磨损量的0.75倍以下。
参考上述实施例7至15，发现本发明的多晶金刚石（实施例1至6）的硬度、强度和耐磨性均明显优于常规多晶金刚石（对比例1至2），因此，本发明的多晶金刚石尤其可用作划片器、修整器、模具、孔、切削工具、旋转切削工具（如钻头或端铣刀）、磨削工具、电极导向器和划线轮的材料。
应当理解，本文所公开的实施方案和实施例为示例性的，并在各个方面为非限制性的。本发明的范围是通过权利要求书的权项、而非上述说明书来进行限定的，并且意图包含与权利要求书的权项等同的范围和含义内的任何改变。

Claims (14)

1.一种制造多晶金刚石的方法，包括如下步骤：
制备石墨化度小于或等于0.58的非金刚石碳材料；以及
在不添加任何烧结剂和结合剂的情况下，在金刚石呈热力学稳定的压力和温度条件下将所述非金刚石碳材料直接转化为立方金刚石和六方金刚石，并进行烧结，
其中所述六方金刚石的(100)面的X射线衍射峰强度与所述立方金刚石的(111)面的X射线衍射峰强度的比值不低于0.01％且不高于0.5％。
2.一种多晶金刚石，其是通过权利要求1所述的方法制造的，包含：
立方金刚石；以及
六方金刚石，
所述六方金刚石的(100)面的X射线衍射峰强度与所述立方金刚石的(111)面的X射线衍射峰强度的比值不低于0.01％且不高于0.5％。
3.根据权利要求2所述的多晶金刚石，其在大于或等于800℃且小于或等于1200℃的温度范围内的抗裂强度为其在室温下的抗裂强度的90％以上。
4.根据权利要求3所述的多晶金刚石，其在大于或等于1000℃且小于或等于1200℃的温度范围内的抗裂强度大于其在室温下的抗裂强度。
5.根据权利要求2所述的多晶金刚石，其在800℃下的硬度为其在室温下的硬度的80％以上。
6.一种划片器，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的前端部分，
所述前端部分具有三个或四个尖端。
7.一种划线轮，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的轮。
8.一种修整器，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的前端部分。
9.一种拉丝模具，包含根据权利要求2至5中任一项所述的多晶金刚石。
10.一种喷嘴，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的孔。
11.一种磨削工具，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的磨削刃。
12.一种切削工具，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的切削刃。
13.一种旋转切削工具，包括由根据权利要求2至5中任一项所述的多晶金刚石构成的切削刃。
14.一种捆丝导向器，由根据权利要求2至5中任一项所述的多晶金刚石构成。
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