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Development of cobalt free wire saw beads and role of liquid phase sintering additives on its properties

  • : Narendra Dhokey1, Praveen Nimbalkar2
  • : 1Department of Metallurgy and Materials Science, 2College of Engineering
  • : PDF Download
  • : 2015


A simulated wear test rig was fabricated in order to provide rotational motion (30 rpm) to wire saw bead (WSB) and tangential motion (1500 rpm) to granite disc where in bead was allowed to slide on the counterface disc of granite material and thus wear performance of wire saw bead was investigated at an applied load of 0.5 kg. The WSBs were fabricated using electrolytic iron powder besides addition of nickel, copper, tungsten, aluminum and tin. These powder mixes were blended in a mixer with a ball to powder ratio of 10:1 (by wt.) for 2 h, then this blended powder was mixed manually with synthetic diamonds and 2% kenolube. The cobalt free WSBs were fabricated by using hot press sintering furnace at 820ºC. The effect of liquid phase sintering additives such as Sn and Cu-Sn alloy on sintered density, hardness and wear rates were analyzed and compared with commercially available wire saw beads containing 22% cobalt (reference WSB). Fabricated wire saw beads showed equivalent performance without appreciably affecting wear rate, hardness and sintered density in comparison to reference WSB. The resultant improved performance of fabricated wire saw bead was analyzed in light of the prevailing wear mechanism.


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