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A close-up of a diamond blade, showing worn metal behind the diamonds on the bladeA diamond blade is a saw blade which has diamonds fixed on its edge for cutting hard or abrasive materials. There are many types of diamond blade, and they have many uses, including cutting stone, concrete, asphalt, bricks, coal balls, glass, and ceramics in the construction industry; cutting semiconductor materials in the semiconductor industry; and cutting gemstones, including diamonds, in the gem industry.
Types
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Diamond blades are available in different shapes:
Diamond blades designed for specific uses include marble, granite, concrete, asphalt, masonry, and gem-cutting blades. General purpose blades are also available.
Manufacturing methods
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Electroplating
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Blades using diamonds embedded in a metal coating, typically of nickel electroplated onto a steel blade base, can be made to be very thin'blades can be tens of micrometres thick, for use in precise cuttings.
Vacuum brazing
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Vacuum brazed diamond saw blades are manufactured by brazing synthetic diamond particles to the outside edge of the circular saw blade in a vacuum brazing furnace. All of the diamond particles are fully exposed and fastened on the exterior cutting edge of the blade instead of being embedded within a metal-diamond mixture. Depending on the manufacturer's recommended blade application, vacuum brazed blades will cut a wide variety of material including concrete, masonry, steel, various irons, plastic, tile, wood and glass.
Finer synthetic diamond grits will reduce the chipping of tile and burring of steel and provide a smoother finish. Larger diamond grits will provide a higher cutting speed, but will be more likely to cause chipping, burring, or cracking. Fire departments sometimes use vacuum brazed saw blades and require blades to be made with a very large diamond grit, to tear through material quickly. An intermediate grit size is used by the production industry.[1]
Sintering
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Sintered metal-bonded diamond blades are the most common type of blade. These blades consist of a steel core (the base is steel plate, unlike that of the wires used in diamond wire saws) and diamond segments, which are made by combining synthetic diamond crystals with metal powder and then sintering them. The diamond segments are also known as the "cutting teeth" of the blade.[2]
The steel core can vary in design. Some cores have spaces (known as gullets) between segments to provide cooling and slurry removal, while others have a single continuous rim for smoother cutting. The type of core that can be used depends on the type of materials that the diamond blade is designed to cut.
Generally, there are three types of sintered metal-bonded diamond blades according to their manufacturing methods: wholly sintered diamond blades, silver brazed diamond blades and laser welded diamond blades.
A wholly sintered diamond blade is made by putting the steel core, together with the diamonds and the metal bond materials, into a mold and then sintering it in a sintering furnace equipment. Consequently, the diameter of wholly sintered diamond blades is not very large, normally not more than 400 millimetres (16 in). Because it is participating in the sintering process, the steel core cannot be quenched, so the hardness and strength of the core are not very high. This means that these types of diamond blade may deform in high-load and high-intensity cutting processes and can exhibit low cutting efficiency.
Silver brazed and laser welded diamond blades do not have this weakness because their diamond segments and steel core are treated separately. The steel core can be quenched and processed with other heat treatments, so its hardness and strength can be high, meaning that the blade can be used in high-load and high-intensity cutting processes with high cutting efficiency and a smaller degree of deformation.
Silver brazed diamond blades' diamond segments are brazed to the steel core using a silver solder. These blades can only be used in wet cuttings. If they are used in dry cuttings, the silver solder may melt and the segments can break from the steel core and become a serious safety hazard. A laser melts and combines the metal of the diamond segment and the steel core creating a stronger weld, which can hold the segments even in high temperatures, meaning that laser welded diamond blades can be used to cut many types of stone without water cooling. However, when cutting very hard or abrasive materials, e.g., concrete containing reinforcing rebar, laser welded diamond blades should also be used with adequate water. Otherwise, it is possible for the diamond segment itself to break or the steel core below the segment to wear and break, creating serious safety hazards.
Application of sintered metal-bonded diamond blades
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A diamond blade grinds, rather than cuts, through material. Blades typically have rectangular teeth (segments) which contain diamond crystals embedded throughout the segment for grinding through very hard materials.
The bond is a term used for the softness or hardness of the powder metal being used to form the segments. The powdered metals hold the diamonds in place. The bond controls the rate at which the diamond segments wear down allowing new diamonds to become exposed at the surface to continue grinding with a "sharp" edge. An important step in choosing a blade is to match the bond to the specific material to be cut. Additional factors to consider are the type and power of the equipment to be used and the availability of water. Harder materials need a softer bonded segment to allow for continuous diamond exposure. Softer materials like asphalt or freshly poured concrete can use a harder segment to resist the increased wear that softer, abrasive materials create.[clarification needed] In addition, the diamonds' grit (size), toughness, and concentration should also match the nature of the material to be sawed. For example, when hard materials are cut, the diamonds should be smaller.
There are other factors that should be considered when choosing a diamond blade for a particular application. These include the type (manufacturing method) of the blade, the availability of water in the cutting process, the horsepower of the saw, and the acceptable level of noise created by the saw. For example, if the horsepower of a saw machine is large, the diamond concentration of the diamond blade should be higher, or the bond should be harder. Higher diamond concentration will decrease the impact on each single diamond in working, while a harder bond will hold the diamonds more firmly.
Cutting with or without water
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Many blades are designed to operate either wet or dry. However, diamond tools and blades work better when wet, and dry cutting should be limited to situations in which water cannot or should not be used. Water will prevent the blade from overheating, greatly reduce the amount of harmful dust created by cutting, remove the slurry from the cut, and extend the life of the blade, since diamond is unable to withstand the forces involved at the elevated temperatures involved in dry cutting ceramic and abrasive materials, and will be subject to rapid tool wear and possible failure.
When water cannot be used (in, for example, electrical saws), measures should be taken to ensure that the operator does not inhale the dust created by the process, which can cause silicosis, a serious lung disease. When dry cutting, the blade should be allowed to cool off periodically. Cooling can be increased by allowing the blade to spin freely out of the cut. The OSHA has strict regulations regarding silica dust and requires a N95 NIOSH-approved respirator in work sites where dangerous amounts of silica dust are present.[3][4]
References
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In today's modern day and age, structures and buildings are often built and with the likes of concrete and other hard metals.
These materials aren't easy to cut.
You can't just grab any regular old saw'
Hard materials need to be cut with an even tougher and stronger material.
That's where diamond comes in.
Diamond, if you don't know already, is the hardest naturally occurring substance known to man, which is why it's used to cut hard materials like tile, steel, and concrete.
On the mineral hardness scale, diamond comes out on top, have a rating of 10 on the Mohs Hardness scale.
But diamonds are also pretty rare, making them rather pricey.
So when you buy a diamond blade, the blade is actually synthetic (man-made) diamond.
Without a synthetic diamond, it would be virtually impossible to cut hard materials'
These blades also offer multiple advantages over other metal and abrasive blades:
Yes, certain diamond blades can cut through metal, but this will depend entirely on the blades application.
Most diamond blades are used to cut through concrete, brick, tile, and asphalt.
But, not all blades are the same.
Different blades mean different applications'
Each blade comes with a different styles, shape, and grooves which come into play in it's ability to cut.
Are you interested in learning more about customized diamond cutting blade manufacturers? Contact us today to secure an expert consultation!
Usually, each blade is specialized to cut a certain material or hardness of materials.
Take for example, the difference in concrete vs asphalt diamond blades.
'Because asphalt is softer than surfaces like concrete, or granite, soft bonded blades won't be effective and typically don't result in clean cuts. Instead, the best tool for asphalt cutting is a diamond blade with a hard bond.'
Some blades are universal and can be used to cut through almost all materials.
Before buying any blade, always be sure to do your research and figure out it's application.
Check the product packaging. If you're not sure, ask someone for help in identifying the application/specialization.
Steel is one of the strongest metals on the planet.
When it comes to diamond blades, there are a few that can cut through steel.
Certain blades like the Husqvarna High Pro 3 and 5 series are acceptable for cutting through steel bars.
But in general, abrasive saws are betting for cutting steel, not diamond.
Abrasive saws are made of 'aluminum oxide grain that is reinforced with two sheets of fiberglass or other insulting material' which is better for grinding through steel.
Believe it or not, but diamond blades don't actually cut.
Instead, they use the friction force to 'grind' away at the material.
'Harder materials are best cut when the bond of the diamond blade is softer. As the diamond particles are dulled and broken, the bond releases so that more of the synthetic diamond can be exposed grinding away at the material.'
'The reverse is true for cutting softer materials. The bond is stronger to ensure that the diamond is exposed long enough to be fully utilized.'
Essentially, the blades scratches away at the particles of each material.
Size of the blade will also have an impact on what your cutting and the project your working on.
You're not going to walk into the kitchen to cut some tile with a 30' diamond blade and a massive cut off saw. You'll probably use a much smaller, electric saw with a more applicable 4' blade.
Keep this in mind next time you begin a home renovation project.
The size you choose will depend on the sizing that fits your saw.
In order to find this out, read the saws manufacturers manual or product packaging and find out the diameter of the blade it takes.
It depends.
The material you're cutting and the usage will be the greatest determinants of your blades life expectancy.
That being said, it's generally known that a diamond blade can be used about 100 times longer than other abrasive type blades.
The quality of the blade will also play a factor:
Remember, buying cheap is often more expensive in the long run.
Any blade and saw is dangerous.
Saws spin at a couple thousand Revolutions Per Minute (RPM). Combine that with the fact the blade is made of the hardest material on earth and you have a pretty serious cutting machine.
There's no way you want your hand or any other body part anywhere near that blade'
Here are a few tips to keep you safe out there:
Cutting with a circular saw, road saw, or anything with a high speed blade will cause debris to go flying everywhere.
That means you need to wear gear the protects you, especially your face:
Just like a car needs specific gas, saws and blades have their own instructions that need to be followed.
Always check the manufacturers manual as well as the product packaging for the proper safety and handling of the product.
Whenever operating saws, it's a bad idea to force the saw. Avoid pushing it too hard.
Even diamond blades have their limits and will crack, chip, and break
Simply put, do not cut with the blade at such an angle that the sides of the saw does any of cutting.
The blades are only designed to cut at the edges of the saw and not the flat sides.
Saws get really hot, really fast.
There's a lot of power, friction, and force that go into grinding away the likes of concrete, brick, and asphalt.
If your saw doesn't use water for cool down, you should take a break time.
The harder the material you're cutting, the more cool down time you'll need.
Like stated above, many blades are only designed to cut certain materials.
Don't cut materials you're not supposed to!
Reading the manufacturers manual and following the recommendations is a must.
These instructions are designed to prevent the diamond blade from wearing down or ripping through material.
Before operating any saw with a diamond blade, it's a good idea to make sure nothing is already damaged.
Check both sides and the edges of the blade to ensure it's ready to go.
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