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2023
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Applications of Diamond Coatings on Cutting Tools
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Diamond’s exceptional properties—such as high hardness, excellent thermal conductivity, a low coefficient of friction, a low coefficient of thermal expansion, and superior chemical stability—make it an ideal choice for tool coatings. However, natural diamond is scarce and costly, rendering it impractical for use as a coating. Through sustained research efforts, polycrystalline diamond (PCD) tools were successfully developed in the 1950s. Although diamond‑based cutting tools exhibit outstanding machining performance, they still suffer from several limitations: the addition of binders reduces both hardness and wear resistance; achieving high dimensional accuracy when machining workpieces remains challenging; and the high cost restricts their application to tools with relatively simple geometries.
Applications of Diamond Coatings on Cutting Tools
Diamond’s exceptional properties—such as its high hardness, excellent thermal conductivity, low coefficient of friction, low thermal expansion, and superior chemical stability—make it an ideal choice for tool coatings. However, natural diamond is scarce and costly, rendering it impractical for use as a coating. Through sustained research efforts, polycrystalline diamond (PCD) tools were successfully developed in the 1950s. Although diamond‑based tools exhibit outstanding cutting performance, they still suffer from several limitations: the addition of binders reduces their hardness and wear resistance; machining accuracy is difficult to ensure; and their high cost restricts their application to only simple‑shaped tools.
The principle underlying the preparation of CVD diamond involves first evacuating the resonant cavity and maintaining its airtight seal. Microwaves generated by a microwave generator are coupled into the resonant cavity via a waveguide, while a mixed reaction gas consisting of a carbon source and hydrogen is introduced. Under microwave excitation, a glow discharge is initiated within the cavity, ionizing the reactant gases and generating various reactive species. These reactive species then undergo a series of chemical reactions on the seed crystal, leading to adsorption, desorption, migration, diffusion, and deposition at the seed‑crystal surface, ultimately resulting in diamond formation. Because this process relies on electromagnetic energy to activate the reaction gases, it constitutes an electrodeless discharge with a highly pure plasma. Moreover, the microwave‑induced discharge region is localized rather than spreading, enabling the efficient generation of diverse atomic species such as atomic hydrogen. The ions produced possess low kinetic energy, thereby avoiding etching of the already formed diamond.
CVD diamond overcomes the limitations of single-crystal diamond by enabling deposition on substrates of arbitrary shapes, thereby facilitating the fabrication of diamond tools with complex geometries, such as drill bits, milling cutters, and inserts with chip‑breaking grooves. Currently, CVD diamond is primarily used in two forms: thick‑film welded cutting tools and diamond‑coated cutting tools; coatings thinner than 30 μm are classified as thin films, while those thicker than 300 μm are considered thick films. Diamond‑coated cutting tools produced via CVD are cost‑effective, well suited for high‑volume manufacturing, and hold significant market potential.
Diamond coating
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