Diamond saw blade is produced by 2 parts: the steel core blade and diamond segment.
Steel Core Blade Part:
The core blade is typically a circular iron disk used to support the diamond segments. The diamond segments are welded on the core edge by using sintering, brazing or laser welding.
Laser welding
Of the three most common method of welding diamond segments to the steel blade, and by far the method that yields the strongest bond to the core blade is laser welding. As the pioneer in laser welding machine, ChinShine continues to develop and perfect laser welding techniques. The more aggressive applications for diamond saw blades involve the use of higher horsepower equipment wet and dry cutting harder materials to much greater cut depths. The steel blade cores for these aggressive applications are thicker, heat-treated, precision-ground, and tensioned. The additional thickness and heat treatment allows the core to withstand the flexing stress of the heavier equipment and higher horsepower. The precision grind on the surface minimizes the drag while the tensioning establishes the flatness of the diamond saw blade at a specific rpm range.
Diamond Segment Part
Diamond segment is made up of two components: diamond and metal bonds.
Diamond Grits
The diamond used is manufactured or synthetic as opposed to natural. Manufactured diamond is preferred over natural diamond because key characteristics like crystal shape, size, and strength can be closely controlled through the manufacturing process. The ability to control the key characteristics of the synthetic diamond allow for accurate prediction of cutting speed and blade life as well as consistent repeatability. Some other important factors to consider about diamond are the:
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• amount of diamond in the segment
• quality of the diamond in the segment
• size of the diamond in the segment
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Amount of Diamond:
The amount of diamond in the segment is variable and requires more horsepower as the content of diamond is increased in the segment. Simply put it means that as more diamond is added to the segment more horsepower is needed to make the diamond saw blade cut. In practical terms this means that diamond saw blades for high horsepower saws will have more diamond in the diamond segment.
Quality of the Diamond:
The quality of the diamond determines the ability of the individual diamond to resist heat and maintain a sharp point. Better diamonds can hold a point longer at higher temperatures.
Size of the Diamond:
Finally the last thing to consider is the size of the diamond. The individual’s diamond sizes are specified in mesh ranges like 25-35 or 50-60. The higher the numbers the finer the individual particles. In practical application finer diamond is used for critically-hard material like Chert or Quartz while the larger more coarse diamond is used for soft materials like asphalt and soft red clay bricks.
Bonding System (Wears)
The bond is a mixture of metal powders used in various combinations to achieve specific wear rates. A correctly-formulated bond holds the diamond in place, just long enough to get maximum use from the diamond segments before releasing the stone and exposing the next layer of diamond.
The wear rate for the diamond segment can be simplified to the ability of a metal to resist wear from abrasion. Metals with low abrasion resistance like bronze are considered soft. The soft bonds are mostly made up of soft metals like Bronze and are common when cutting very hard less abrasive material like porcelain. The hard bonds are mostly made up of hard metals like Tungsten Carbide and are common when cutting very soft abrasive materials like asphalt or freshly poured concrete.
The best way to remember bond-to-material application is “opposites attract” - hard bonds for soft abrasive materials while soft bonds are used for hard less abrasive materials. In some extreme cases, it is possible to simply judge the hardness of the diamond saw blade by noticing the color of the diamond segment. Because soft diamond blades contain a majority of Bronze, the soft blades for extremely hard materials will have a yellow tint to the diamond segment.
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