Development of a Diamond Composite in the NI-CO-FE3P-SN-WC System Via Free Sintering for Use in Multi-Find Diamond Pearls

Objective: The main objective of this study is to manufacture a diamond composite with a metallic matrix based on Ni-Co-Fe3P-Sn-WC, using the Free Sintering process through cold uniaxial compaction, intended for the production of pearls for diamond wire saws, used in cutting ornamental stones. Theoretical Framework: The multi-wire technology represents an advancement in cutting ornamental stone blocks, allowing the simultaneous production of multiple slabs. Powder metallurgy is the predominant technique used in the manufacturing of pearls for diamond wire saws. Through testing, including scanning electron microscopy (SEM) and shear tests, it is possible to evaluate the alloy's strength, diamond crystal adhesion, and failure behavior of the alloy. Methodology: The adopted methodology involves the processing and characterization of pearls for diamond wire saws, following the techniques of powder metallurgy. Initially, parametric calculations were performed using Excel, providing a basis for subsequent analyses. Diamond-coated pearls were produced with different proportions of constituent elements, and uniaxial compressive strength tests and microstructural characterization were conducted to evaluate the results. Results and Discussion: In the adhesion tests to the metal tube, the pearls produced with the NICOFE alloy showed similar performance to the commercial pearls "A" and "B," with satisfactory direct shear strength values. However, some point defects were observed, such as porosity in the transition zone, creating a weaker bond, negatively impacting the final strength of the composite. Analysis of the commercial samples indicated that diamond abrasion was not related to the composition of the sintered alloy. Research Implications: This research suggests significant economic and technological implications, such as the development and nationalization of technology for the ornamental stone industry. The use of the NICOFE alloy could strengthen the local industry by providing a viable and more accessible alternative for the production of diamond pearls. Originality/Value: The NICOFE blend presents technical advantages for manufacturing diamond wire pearls, highlighting the environmental benefits from reduced cobalt use and economic advantages by offering more accessible materials for the ornamental stone industry.