Development of a novel polycrystalline diamond composite using tantalum as a binder

Abstract

Polycrystalline diamond (PCD) is widely applied in the cutting and drilling industries due to its excellent mechanical properties. Currently, several researchers have been studying the use of different binders in its manufacturing, seeking to improve their properties and reduce the use of traditional metals that are harmful to human health and the environment. This work aimed to study the applicability of tantalum as a novel binding agent of PCD. The products developed here were processed using powder metallurgy and High Pressure-High Temperature (HPHT) sintering. The effect of different tantalum concentrations (2.5, 5.0, 7.5, and 10.0 wt. %) was investigated using X-ray diffraction (XRD), Confocal Microscopy, Density measurement, Particle Size Analysis, and Scanning Electron Microscopy (SEM). Mechanical properties and failure behavior were employed to evaluate the products. The PCD-Ta system was also tribologically tested against ferrous and ceramic materials, in order to simulate their applicability in industrial machining conditions. The results suggest that increasing Ta quantity on PCD mixtures promoted reduction of milling contaminations and enhanced the mechanical properties of the as-sintered bodies by modifying the fracture mechanism predominance. No occurrence of chemical reactions between the two compounds was observed on the milling, but the formation of TaC resulting from a reaction between the free carbon and the metallic Ta was identified on all as-sintered compositions. The PCD-Ta ratio directly influences the tribological behavior of the present system with ceramic and ferrous materials, and severest wear was provoked by samples with the lowest binder content. Furthermore, abrasive and adhesive were the predominant wear mechanisms detected in all studied compositions. Finally, the overall microstructural, mechanical, and tribological outcomes demonstrated that the developed composites presented satisfactory performance, which indicates that tantalum can be a viable alternative to act as a PCD binder.