Manufacturing of Diamond Tool Segments via Microwave–Hybrid Sintering

Microwave (MW) sintering offers a promising alternative to conventional heating in powder metallurgy, providing faster processing, lower energy consumption, and improved microstructural control. In the diamond tool industry—where cost-efficiency and competitiveness are critical—MW–hybrid sintering shows strong potential for producing segments designed for cutting and polishing natural stone and construction materials. This study investigates the effects of sintering temperature, dwell time, and green density on the densification and mechanical properties of metal matrix composite (MMC) segments containing diamond particles. MW sintering reduced the optimum sintering temperature by 90–170 °C when compared to conventional free sintering. Under optimal conditions (57% green density, 820 °C, 5 min dwell), segments achieved ~95% densification and mechanical properties comparable to hot-pressed (HP) samples. Although MW–hybrid sintered matrices exhibited slightly lower Young’s modulus (~15%) and Vickers hardness (~20%), their flexural strength and fracture toughness remained comparable to HP counterparts. Overall, MW hybrid sintering provides a cost-effective, energy-efficient, and scalable route for fabricating high-performance diamond tool segments, supporting both economic viability and sustainable, competitive manufacturing.