聚晶金刚石复合体界面及复合机理的研究
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摘要
聚晶金刚石复合体作为一种特殊的复合材料，以其特有的性能在非金属及硬脆材料的加工方面获得了愈来愈广泛的应用。然而金刚石属于非金属材料，它与金属(或合金)之间在强度、硬度、弹性模量及结构等方面存在着较大的差异，特别是二者之间的界面能很高，使得绝大多数的单质金属或合金都难以有效地润湿和粘结金刚石颗粒，界面结合弱，限制了其应用范围。因此，研究金刚石与粘结金属间的界面结合问题及其复合机理具有特别重要的意义。
鉴于目前国内外聚晶金刚石复合体的研究现状及存在的问题，以湖南省自然科学基金项目《聚晶金刚石复合体界面及复合机理的研究》(项目编号为00JJY2044)为依托，在导师的指导和前人工作的基础上展开本论文的研究。采用SEM、EDS、XRD、TEM、TG-DTA等研究方法，主要开展了以下几方面的研究：
1、在六面顶压机上高温高压合成φ20mm聚晶金刚石复合体。并对合成φ34mm聚晶金刚石复合体所需的φ40mm的反应腔体进行了设计。
2、在前人工作的基础上，系统地分析了PDC材料在超高温高压烧结过程中金刚石-钴的相互作用，进而提出PDC材料超高压液相活化强化烧结机理为：聚晶金刚石超高压液相烧结的塑性流动机理；聚晶金刚石超高压液相烧结的再结晶生长机理和聚晶金刚石超高压液相烧结的中介结合机理。
3、以钴作为粘结相，分析研究了钴扩散规律及作用机理，并对超高压烧结材料的界面精细结构、界面结合、界面反应、界面结构及对PDC复合材料性能的影响。研究结果表明：
(1)WC-Co基底与金刚石层没有明显的结合界面，界面结合主要以WC-Co-D结合；混合烧结系统中界面处钴的富积区域较金刚石的原位烧结系统中大。
(2)金刚石的原位烧结系统中，金刚石颗粒间大部分形成了牢固的D-D直接结合，结构较致密；金刚石与钴粉的混合烧结系统中，主要以D-Co-D结合，钴基本上沿晶界呈叶脉状分布。
(3)原位烧结样品的晶界中的WC、Co_2C、Co_3C和η—Co_3W_3C含量较高；随着烧结温度的升高，钴-碳的共晶化合物Co_xC含量逐渐降低。
(4)金刚石-金刚石界面实际上就是原始金刚石颗粒表面与析出
金刚石的生长相遇的界面，这种晶界呈大角度倾斜晶界结构;在界面
处存在大量的晶体缺陷，主要表现为孪晶、位错、包裹体。
(5)聚晶金刚石复合体的热应力、耐热性主要取决于结合剂种
类及结合剂与金刚石形成的晶界物相。
4、本文研究了WC一C。层与金刚石层的复合、金刚石颗粒之间的
复合机理。研究结果表明:
(1) WC一CO与金刚石层界面的结合强度不仅与界面上钻含量有
关，而且与界面上钻的组织结构、合成PDC的金刚石原料颗粒粒度、
界面形状有关。
(2)WC一CO基体在超高温高压烧结后的脆性相刁一刃。撇C明显减
少;WC一C。基体在超高温高压烧结后出现了碳的石墨峰。
(3)原位烧结样品中WC一C。基底侧往界面方向钻含量明显减少，
W含量有逐渐增加趋势;而金刚石与钻粉的混合烧结样品中这一现象
不太明显。
(4)D--D结合区域和D一Co一D结合区域的晶粒间界中钻的存在
形式是不同的。D一Co一D结合区域的晶粒间界上的钻大部分是烧结过
程结束后残留下来的钻熔体，而D目一D结合界面上的钻是以包裹体或
钻一碳的共晶化合物的形式存在。
(5)金刚石粉末只在压力作用下，加压前后，金刚石粉末粒度
基本不变化，超高压下金刚石颗粒破碎并不是造成界面处晶粒细小的
主要原因。
5、任何技术的最终目的是为了产品的实际应用。为此，本文将
所合成的PDC做成钻头，在钻探的实际应用中对其性能进行了评估，
取得了较好的试验效果。
论文创新点在于:
(1)设计了合成。34mm的金刚石聚晶复合体所需的中40nUn的叶
腊石反应腔体，为合成大直径PDC材料提供了必要条件;
(2) wc一co基底与金刚石层没有明显的结合界面，界面结合主
要以WC一Co一D结合;
(3)原位烧结样品晶界中的we、eoZe、Co3C和粉一Co3w3C含量较
金刚石与钻粉的混合烧结样品高;随着烧结温度的升高，钻一碳的共
晶化合物CoxC含量逐渐降低;
(4) wC一 Co基体在超高温高压烧结后的脆性相叮一Co凡C明显减
少;WC一Co基体在超高温高压烧结后出现了碳的石墨峰;
(5)聚晶金刚石复合体的热应力、耐热性主要取决于结合剂种
类及结合剂与金刚石形成的晶界物相。
(6)WC一C。与金刚石界面的结合强度不仅与界面上钻含量有关，
而且与界面上的钻的组织结构、合成PDC的金刚石原料颗粒粒度、界
面形状结构有关;
(7)金刚石粉末加压前后粒度基本不变化，加压后，金刚石出
现脆性断裂，颗粒破碎基本上是穿晶式的;并提出了造成界面处晶粒
细小的原因。
T
As a type of special composite, Polycrystalline Diamond Compacts(PDC) has been increasingly applied in machining hard and abrasive materials, because of its superior physical properties. However, diamond is a non-metal materials, it is different from metals or alloys in intensity, hardness, elastic modulus and structure. Especially the interfacial energy is high between diamond and metals or alloys, resulting in the difficulty of most of metals or alloys to effectively wet. Due to feeblish interfacial bonding, Polycrystalline Diamond Compacts often ruptured and broke off during its application, thus increase drilling cost and reducing its range of application. Therefore, to study interface bonding between diamond and metals or alloy and its compounding mechanism are of great importance.
In light of the present state and existing problems of PDC study at home and abroad, on the basis of tutor's right guidance and the predecessor's studying, The author conducts an investigation into the research topic in this paper by relying on Hunan province natural science fund item-A study on interface and it's compounding mechanism of Polycrystalline Diamond Compacts(serial number:OOJJY2044). The following research work has been completed by SEM analysis, EDS analysis, XRD analysis, TEM analysis, TG-DTA analysis. It shows that:
1.Φ20mm PDC have been synthesized at ultra-high temperature and ultra-high pressure, And the reaction vessels of 4Φ 40mm for synthesizingΦ 34mm PDC is designed.
2. Based on the analysis of the past sintering theories, the paper has summarized and analyzed the reciprocity of diamond-cobalt in the process of ultra-high pressure and ultra-high temperature sintering, and advanced systemic theory on diamond fluid activated strengthen sintering under ultra-high pressure and temperature, namely, the plastic flowing, the Recrystallization and regrowth of diamond, the medi-bonding.
3. Cobalt acts as the binder. The paper has studied s interfacial microstructure, interfacial reaction, the diffusing rule and action mechanism of cobalt and the interface influence on performances of PDC.
It shows that:
(1) The bonding interface between WC-Co matrix and diamond layer was not clear, and occurs in the form of WC-Co-D bonding, that is to say, there is a thin cobalt-enriched area. The cobalt content in the interface is higher by the process of mixture sintering of diamond and cobalt than by the process of Sweep Through Catalyzed Recrystallization sintering(STCR).
(2) Cobalt distributes equably between diamond grains by sintering of Sweep Through Catalyzed Recrystallization, the intergranular has formed firm bonding of D-D; but the intergranular has formed firm bonding of D-Co-D by mixture sintering of diamond and cobalt, and cobalt is basically distributed as laminated gangue along grain boundary.
(3) The contents of WC, Co2C, Co3C, 77-Co3W3C in grain boundary are higher by sintering of Sweep Through Catalyzed Recrystallization than by mixture sintering of diamond and cobalt, with sintering temperature increasing, the eutectic mixture of cobalt and graphite CoxC is reduced gradually.
(4) The grain boundary is simply the surface at which the regrowth fronts expanding from the original grains met during manufacture of the compact. The grain boundary is quite irregular, and there is no simple orientation relationship, exists in a high-angle grain boundary. The small-angle grain boundary can be observed in a high-angle grain boundary, and it is made up of dislocations. There are a lot of crystal defects in grain boundary, this defects are dislocations and twins. At the same time, there is a trivial cobalt inclusions and graphite inclusions.
(5) The heat stress and the heat resistance of PDC depend on the binder and the structure of reactants which were formed by reaction of the binders to diamond in grain boundary.
4. This paper deals with two types of compounding between WC-Co and PCD, and compounding between diamond and diamond. It shows that:
(1) The bonding strength betwe
鉴于目前国内外聚晶金刚石复合体的研究现状及存在的问题，以湖南省自然科学基金项目《聚晶金刚石复合体界面及复合机理的研究》(项目编号为00JJY2044)为依托，在导师的指导和前人工作的基础上展开本论文的研究。采用SEM、EDS、XRD、TEM、TG-DTA等研究方法，主要开展了以下几方面的研究：
1、在六面顶压机上高温高压合成φ20mm聚晶金刚石复合体。并对合成φ34mm聚晶金刚石复合体所需的φ40mm的反应腔体进行了设计。
2、在前人工作的基础上，系统地分析了PDC材料在超高温高压烧结过程中金刚石-钴的相互作用，进而提出PDC材料超高压液相活化强化烧结机理为：聚晶金刚石超高压液相烧结的塑性流动机理；聚晶金刚石超高压液相烧结的再结晶生长机理和聚晶金刚石超高压液相烧结的中介结合机理。
3、以钴作为粘结相，分析研究了钴扩散规律及作用机理，并对超高压烧结材料的界面精细结构、界面结合、界面反应、界面结构及对PDC复合材料性能的影响。研究结果表明：
(1)WC-Co基底与金刚石层没有明显的结合界面，界面结合主要以WC-Co-D结合；混合烧结系统中界面处钴的富积区域较金刚石的原位烧结系统中大。
(2)金刚石的原位烧结系统中，金刚石颗粒间大部分形成了牢固的D-D直接结合，结构较致密；金刚石与钴粉的混合烧结系统中，主要以D-Co-D结合，钴基本上沿晶界呈叶脉状分布。
(3)原位烧结样品的晶界中的WC、Co_2C、Co_3C和η—Co_3W_3C含量较高；随着烧结温度的升高，钴-碳的共晶化合物Co_xC含量逐渐降低。
(4)金刚石-金刚石界面实际上就是原始金刚石颗粒表面与析出
金刚石的生长相遇的界面，这种晶界呈大角度倾斜晶界结构;在界面
处存在大量的晶体缺陷，主要表现为孪晶、位错、包裹体。
(5)聚晶金刚石复合体的热应力、耐热性主要取决于结合剂种
类及结合剂与金刚石形成的晶界物相。
4、本文研究了WC一C。层与金刚石层的复合、金刚石颗粒之间的
复合机理。研究结果表明:
(1) WC一CO与金刚石层界面的结合强度不仅与界面上钻含量有
关，而且与界面上钻的组织结构、合成PDC的金刚石原料颗粒粒度、
界面形状有关。
(2)WC一CO基体在超高温高压烧结后的脆性相刁一刃。撇C明显减
少;WC一C。基体在超高温高压烧结后出现了碳的石墨峰。
(3)原位烧结样品中WC一C。基底侧往界面方向钻含量明显减少，
W含量有逐渐增加趋势;而金刚石与钻粉的混合烧结样品中这一现象
不太明显。
(4)D--D结合区域和D一Co一D结合区域的晶粒间界中钻的存在
形式是不同的。D一Co一D结合区域的晶粒间界上的钻大部分是烧结过
程结束后残留下来的钻熔体，而D目一D结合界面上的钻是以包裹体或
钻一碳的共晶化合物的形式存在。
(5)金刚石粉末只在压力作用下，加压前后，金刚石粉末粒度
基本不变化，超高压下金刚石颗粒破碎并不是造成界面处晶粒细小的
主要原因。
5、任何技术的最终目的是为了产品的实际应用。为此，本文将
所合成的PDC做成钻头，在钻探的实际应用中对其性能进行了评估，
取得了较好的试验效果。
论文创新点在于:
(1)设计了合成。34mm的金刚石聚晶复合体所需的中40nUn的叶
腊石反应腔体，为合成大直径PDC材料提供了必要条件;
(2) wc一co基底与金刚石层没有明显的结合界面，界面结合主
要以WC一Co一D结合;
(3)原位烧结样品晶界中的we、eoZe、Co3C和粉一Co3w3C含量较
金刚石与钻粉的混合烧结样品高;随着烧结温度的升高，钻一碳的共
晶化合物CoxC含量逐渐降低;
(4) wC一 Co基体在超高温高压烧结后的脆性相叮一Co凡C明显减
少;WC一Co基体在超高温高压烧结后出现了碳的石墨峰;
(5)聚晶金刚石复合体的热应力、耐热性主要取决于结合剂种
类及结合剂与金刚石形成的晶界物相。
(6)WC一C。与金刚石界面的结合强度不仅与界面上钻含量有关，
而且与界面上的钻的组织结构、合成PDC的金刚石原料颗粒粒度、界
面形状结构有关;
(7)金刚石粉末加压前后粒度基本不变化，加压后，金刚石出
现脆性断裂，颗粒破碎基本上是穿晶式的;并提出了造成界面处晶粒
细小的原因。
T
As a type of special composite, Polycrystalline Diamond Compacts(PDC) has been increasingly applied in machining hard and abrasive materials, because of its superior physical properties. However, diamond is a non-metal materials, it is different from metals or alloys in intensity, hardness, elastic modulus and structure. Especially the interfacial energy is high between diamond and metals or alloys, resulting in the difficulty of most of metals or alloys to effectively wet. Due to feeblish interfacial bonding, Polycrystalline Diamond Compacts often ruptured and broke off during its application, thus increase drilling cost and reducing its range of application. Therefore, to study interface bonding between diamond and metals or alloy and its compounding mechanism are of great importance.
In light of the present state and existing problems of PDC study at home and abroad, on the basis of tutor's right guidance and the predecessor's studying, The author conducts an investigation into the research topic in this paper by relying on Hunan province natural science fund item-A study on interface and it's compounding mechanism of Polycrystalline Diamond Compacts(serial number:OOJJY2044). The following research work has been completed by SEM analysis, EDS analysis, XRD analysis, TEM analysis, TG-DTA analysis. It shows that:
1.Φ20mm PDC have been synthesized at ultra-high temperature and ultra-high pressure, And the reaction vessels of 4Φ 40mm for synthesizingΦ 34mm PDC is designed.
2. Based on the analysis of the past sintering theories, the paper has summarized and analyzed the reciprocity of diamond-cobalt in the process of ultra-high pressure and ultra-high temperature sintering, and advanced systemic theory on diamond fluid activated strengthen sintering under ultra-high pressure and temperature, namely, the plastic flowing, the Recrystallization and regrowth of diamond, the medi-bonding.
3. Cobalt acts as the binder. The paper has studied s interfacial microstructure, interfacial reaction, the diffusing rule and action mechanism of cobalt and the interface influence on performances of PDC.
It shows that:
(1) The bonding interface between WC-Co matrix and diamond layer was not clear, and occurs in the form of WC-Co-D bonding, that is to say, there is a thin cobalt-enriched area. The cobalt content in the interface is higher by the process of mixture sintering of diamond and cobalt than by the process of Sweep Through Catalyzed Recrystallization sintering(STCR).
(2) Cobalt distributes equably between diamond grains by sintering of Sweep Through Catalyzed Recrystallization, the intergranular has formed firm bonding of D-D; but the intergranular has formed firm bonding of D-Co-D by mixture sintering of diamond and cobalt, and cobalt is basically distributed as laminated gangue along grain boundary.
(3) The contents of WC, Co2C, Co3C, 77-Co3W3C in grain boundary are higher by sintering of Sweep Through Catalyzed Recrystallization than by mixture sintering of diamond and cobalt, with sintering temperature increasing, the eutectic mixture of cobalt and graphite CoxC is reduced gradually.
(4) The grain boundary is simply the surface at which the regrowth fronts expanding from the original grains met during manufacture of the compact. The grain boundary is quite irregular, and there is no simple orientation relationship, exists in a high-angle grain boundary. The small-angle grain boundary can be observed in a high-angle grain boundary, and it is made up of dislocations. There are a lot of crystal defects in grain boundary, this defects are dislocations and twins. At the same time, there is a trivial cobalt inclusions and graphite inclusions.
(5) The heat stress and the heat resistance of PDC depend on the binder and the structure of reactants which were formed by reaction of the binders to diamond in grain boundary.
4. This paper deals with two types of compounding between WC-Co and PCD, and compounding between diamond and diamond. It shows that:
(1) The bonding strength betwe
引文
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