Piranha Electro-Cast Diamond Tools
The Electro-Casting Method of Manufacture
Levetec would like to introduce a new electrochemical casting method called electro-casting which has been
developed for Oil drilling Rigs in the North Sea, where it takes days to return a drilling head to the surface.
By using this method to manufacture the Levetec Diamond Tooling, it offers significant advantages over conventional sintering and Diamond distribution
techniques for the manufacture of the floor grinding diamond tools. Electro-casting is achieved at a very low
temperature below 50ºC
Levetec uses natural diamonds that have sharper less uniform shapes to cut rather then abrade the concrete
surface. The diamonds are electrochemically embedded into a selection of metal alloys for use on hard,
normal and soft concrete surfaces. The segments are also electro-cast directly onto the “tool holder”
thereby not degrading of the diamonds further through graphitization by welding or brazing the segments
onto the tool holder.
• No diamond degradation/graphitization due to elevated temperatures –
electro-casting process temperature is below 50ºC. More diamond volume is retained for tool work.
• High temperature brazes may be avoided, further protecting the diamond properties.
• Diamond content – range, concentration and distribution –
may be controlled to a superior degree to better meet the specific tool application requirements.
• The diamond grains are more firmly retained in the bonding alloy.
This allows more exposure of diamonds before the individual grains are “lost”.
• The higher exposure and sharp corners allow for making more aggressive tools –
tools that will work faster and more efficiently without scratching.
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Piranha segment without balling over |
Worn industry segment balled over |
Piranha Electro-Cast Diamond Tooling
Electro-casting Compared to the Sintering Method.
The
sintering method is a common manufacturing technique for suspending diamonds in
diamond tools. A major disadvantage inherent in the process is that diamonds are
partially degraded at the high sintering temperatures. Another disadvantage is
shifting of the diamonds during sintering. As the parts travel through the
furnace, the temperature cycle results in changes in composition and
microstructure. The microstructure developed during sintering determines the
properties of the part and are affected by oxidation.
Typically the furnace contains a protective atmosphere to prevent oxidation of
the parts in the hot zone, and to help reduce oxides still present. A effort is
sometimes made to keep the sintering temperature below the melting point of the
base metal so that the diamonds do not float into a band within the segment, if
so, some of the alloying additives may not melt, which would result in segments
shattering on impact with floor projections. To overcome this most manufacturers
heat above the base metal temperature which causes the diamonds to float into a
band within the segment and results in diamond-less bands within the segment
along with graphitization around the diamond grit.
A partial [near the surface of the diamond grit] graphitization of diamonds takes place at the
sintering temperatures. The ensuing degradation means a reduction in diamond
volume and a “dulling” as sharp corners and plane intersections become graphite.
The volume reduction also reduces the “lock-in” of individual diamond grains;
thus diamonds exposed with tool wear will fall out with less exposure.
In the electro-casting manufacturing process, diamonds are added to the growing
face of the electro-cast in layers with more evenness, and become fully embedded
into the cast body. The metal alloy grows around the diamond grains close enough
to form metal-carbon bonds. This strong bond allows a significant diamond
exposure before the diamonds will fall off. There are also no empty bands within
the segment and the tool stays open at all times. As the electro-casting process
is undertaken in a typical temperature range of 25-50° C, the embedded diamonds
retain their original properties fully – sharp corners and clean surfaces.
The dominating cost is of course always the cost of diamonds. The single
disadvantage with this new technology is that the process requires days rather
than hours for sintering. This results in a slightly more expensive cost for the
grinding tools based on electro-casting, then that of sintering.......Although the
technical advantages far outweigh the stated time penalty.
Levetec Electro-Cast Diamond Specs
The following shows a comparison between the Electro-Cast Tooling and an Industry Standard Diamond Tool on a 15 year old concrete floor of a Manufacturing Plant – 900 m2 approx 9700 sq ft
Even though 1 extra mm of wear is experienced by the Parana Electro-Cast Tooling, there is no comparison in the time taken to complete the job and the amount of material removed.
Also note that more surface area was completed in less time, this translates into getting the job done and getting home sooner.
A comparison of the nominal tool life on the bottom of the chart shows that even tool life does not factor in, because at the end of the day you get very similar wear over the life of the tools, but with much faster grinding times and higher square footage.
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For pricing or more information on how Levetec can help your floors come to a better finish please call us at
1-866-538-3832 Email us
