Ceramic grinding wheels containing transition metals exhibit significant advantages over traditional wheels when processing diamonds. However, during sintering and processing, transition metals are prone to oxidation, particularly in high-temperature and high-humidity environments. To address the issue of oxidation-induced failure in ceramic grinding wheels containing transition metals, the work aims to develop a diamond ceramic grinding wheel that integrates both antioxidant and interface reinforcement functions. By coating iron with silicon, the wheel effectively isolates oxygen, protecting the active iron layer and achieving oxidation protection for the wheel matrix and interface reinforcement between the abrasive grains and matrix under conventional sintering conditions (air, ambient pressure). In the study, scanning electron microscopy (SEM) and X-ray diffraction (XRD) were used to analyze the microstructure and composition of the silicon-coated iron powder. The results showed that after high-temperature sintering, the composition of the silicon-coated iron powder remained unchanged, confirming its excellent anti-oxidation properties. Subsequently, N68 vitrified binder powder, PMMA pore-forming agents, 2000# diamond abrasives, and silicon-coated iron powder were mixed in different ratios (silicon-coated iron powder: diamond powder = 1∶2, 1∶1, 2∶1), along with dextrin solution, sieved, cold-pressed, and sintered to produce wheel blocks. Comparative experiments were conducted to test the bending strength and block composition of traditional ceramic wheels containing transition metals and silicon-coated iron wheels with different powder ratios. The results showed that, under the same ratio, the silicon-coated iron ceramic wheel had higher strength and did not undergo oxidation after sintering, proving that the silicon-coated iron powder not only had strong anti-oxidation ability but also significantly enhanced the structural strength of the wheel. To further validate the effectiveness of the grinding wheel, grinding experiments were conducted with single-crystal diamond (7 mm×7 mm×0.3 mm) as the workpiece. The spindle speed was initially set to 1 250 r/min, and the feed rate was 0.2 μm/s for diamond processing. Surface roughness, material removal rate, and Raman spectral characteristics were used to screen and optimize the wheel formula. Based on this optimized formula, the effect of different spindle speeds (1 000, 1 250, 1 500, 1 750 r/min) and feed rates (0.1, 0.2, 0.3, 0.4 μm/s) on single-crystal diamond processing was investigated. The best processing conditions were determined through surface roughness, material removal rate, and Raman spectra, and the subsurface damage of the processed diamond was analyzed through X-ray photoelectron spectroscopy (XPS) and transmission electron microscopy (TEM), revealing the material removal mechanisms. Experimental results indicated that the fabricated wheel not only demonstrated excellent anti-oxidation performance but also significantly improved structural strength. Under the optimized formula, the material removal rate for single-crystal diamond (100) reached 10.69 μm/h, the surface roughness (Sa) was 0.82 nm, and the thickness of the subsurface amorphous carbon layer was only 1.913 nm. Raman and XPS spectra confirmed that material removal occurred due to the catalytic effect of the iron active component in the grinding wheel, leading to the formation of Fe3C layer on the diamond surface. This process, combined with mechanical grinding by hard abrasives, effectively improved the surface quality of the material. The study demonstrates that, under normal sintering conditions, the silicon-coated iron gradient oxidation structure ceramic grinding wheel successfully achieves interface reinforcement and oxidation protection. The mechanical-chemical synergistic removal mechanism significantly improves the processing efficiency and surface quality of single-crystal diamonds, providing a new solution for efficient, low-damage processing of diamond substrates. This method shows great industrial application potential in the manufacturing of diamond-based electronic devices.
Key words
ceramic grinding wheel /
mechanical-chemical polishing /
single-crystal diamond /
self-rotating grinding
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Funding
The Major Science and Technology Project of Xiamen (3502Z20231047); The Open Research Fund of Academy of Advanced Carbon Conversion Technology, Huaqiao University
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