Vertical tube brazing furnaces help Chinese superhard diamond material companies braze PCD/PCBN tools.

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Vertical tube brazing furnaces help Chinese superhard diamond material companies braze PCD/PCBN tools.

1. Client Introduction

Client Name: China XX Superhard Diamond Material Enterprise (A leading domestic manufacturer of superhard materials and products)

Industry: Superhard Material Tool Manufacturing (Diamond Saw Blades, Grinding Wheels, PCD/PCBN Tools)

Core Needs: To achieve high-strength, high-stability brazing of PCD (polycrystalline diamond) and PCBN (polycrystalline cubic boron nitride) inserts, ensuring an oxidation-free weld interface, low residual stress, and meeting the requirements of high-speed cutting and precision machining.

This client has long focused on the R&D and production of superhard diamond materials, with products widely used in aerospace, automotive manufacturing, 3C electronics, and stone processing. PCD and PCBN composite sheets require a strong bond to a cemented carbide substrate through brazing. Traditional flame brazing or induction brazing suffers from uneven temperature fields, easy oxidation, and large variations in weld strength. The client urgently needs a professional brazing equipment that can provide a uniform temperature field, a controllable heating atmosphere (or vacuum), and is easy to operate to improve product consistency and service life.

2. Equipment Introduction

Equipment Name: Vertical Tube Brazing Furnace

Model Series: PT-MZ1100-S350LX3

Working Temperature: ≤1000℃ (Common Brazing Temperature: 650～950℃)

Heating Zone Structure: Lifting heating zone—the furnace body can be lifted up and down, separating the furnace chamber from the workpiece, making material feeding and unloading extremely convenient, especially suitable for loading and unloading long rod-shaped or irregularly shaped workpieces.

Furnace Tube Material: High-purity quartz tube/corundum tube (optional), sealing flange system supports vacuum or protective atmosphere.

Heating Element: High-quality resistance wire (or molybdenum-containing resistance wire), evenly wound around the outside of the furnace tube.

Temperature Field Characteristics: Multi-segment temperature control + compensation algorithm to achieve temperature field balance, ±1℃ temperature control accuracy.

Insulation Design: Lightweight ceramic fiber or alumina polycrystalline fiber furnace chamber, low surface temperature, significant energy saving effect.

Control System: PID+SCR thyristor power regulation, 30-segment programmable program, real-time recording of temperature curves.

Optional Configuration: Vacuum pump set (vacuum degree up to 10⁻³) Pa), mass flow meter (for Ar, N₂, H₂/N₂ mixtures, etc.).

This equipment is specifically designed for vacuum/atmosphere brazing, high-temperature sintering, and annealing of diamond tools, cemented carbide, and ceramic materials. Its unique lifting heating zone eliminates the need to move the furnace tubes after workpiece loading, significantly reducing operational complexity and making it particularly suitable for batch production scenarios requiring rapid loading and unloading.

3. Equipment Application

Specific Process: Brazing of PCD/PCBN tool diamond materials

Processed Objects:

PCD cutting tools (polycrystalline diamond composite sheets);

PCBN cutting tools (polycrystalline cubic boron nitride composite sheets);

Diamond grinding wheels;

Diamond saw blade teeth;

Brazing Materials: Silver-based, copper-based, or nickel-based active brazing filler metals (e.g., Ag-Cu-Ti, Cu-Sn-Ti, etc.);

Brazing Environment: High-purity argon protection or vacuum (vacuum degree ≤1×10⁻² Pa, to avoid diamond graphitization).

Key Advantages of the Equipment in Customer Processes:

Lifting Heating Zone: Operators do not need to put their hands into the high-temperature furnace tube; the workpiece is placed directly on the fixed platform, and the heating zone lowers to fit it in, significantly improving production efficiency.

Even Temperature Field: The temperature difference throughout the brazing zone is ≤3℃, ensuring uniform weld seams over a large area of the cutting tools, without localized incomplete fusion or overheating.

Oxidation-free welding: With the aid of a vacuum/protective atmosphere, the diamond surface remains free of oxidation or graphitization, resulting in excellent brazing filler metal spread.

Weld strength: Shear strength tests show a value of 180–220 MPa, significantly higher than traditional flame brazing (approximately 120 MPa).

4. Customer Feedback

*“We have been using this vertical tube brazing furnace for 8 months, mainly for vacuum brazing PCD and PCBN cutting tools. What we are most satisfied with is the lifting heating zone design—previously, with horizontal tube furnaces, we had to remove the flange and push the furnace tube each time we loaded samples, which was cumbersome and easily damaged the sealing rings. Now, we only need to fix the cutting tool on the special fixture, and the heating zone automatically lowers to cover the furnace tube. It's a one-button start-up, safe and efficient. The furnace temperature uniformity is excellent. When 20 PCD cutting tools are brazed simultaneously, the weld appearance is consistent, and the shear strength fluctuation during sampling is minimal. In addition, the furnace surface temperature is very low, so workers don't have to worry about getting burned when they get close. Compared with the previous outsourced brazing, our scrap rate has been significantly reduced, and the cost per batch has decreased by about 35%. This equipment has become the standard configuration for our superhard cutting tool brazing process.”*

— Production Manager, XX Superhard Diamond Materials Company, China

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