Wire saw diamond micron powder for sapphire, LCD, magnetic materials and semiconductor materials

Our wire saw diamond micron powder uses premium grade MBD diamond grits as raw materials, it features with high strength, sharp and blocky crystal shape, highly concentrated particle size distribution & effective particles, we have a strict control of rod-like, flaky shape and over size particles, low impurity, high cutting efficiency of good sharpness, prominent dispersity and wear resistance.

(1). Diamond Powder with various size and grade quality.

(2). Consistent quality and narrow PSD.

(3). Fast delivery, we have most sizes diamond micron for Wire Saw in stocks.

(4). Narrow PSD, if you demand for D50=6um, then we can get our D50=5.9um, 6.1um, 7um and 8um, etc.

Main usage of our diamond wire is for dicing & slicing monocrystalline silicon, polycrystalline silicon, sapphire, LCD, magnetic materials, semiconductor materials, also used for other premium diamond grinding & polishing tools.

Other Usages of diamond wire saw:

Stone: Mining and quarrying industries commonly use a wire saw to cut hard stone into large blocks that can then be shipped to processing plants to be further refined (in the case of ore dressing) or shipped to distributors (in the case of granite or marble for building). These wire saws are large machines that use diamond-impregnated beads on a cable. The saws allow the bottom of a quarry slab to be cut free (after the cable is passed through access drill holes); with the bottom cut, back and side charges (explosives) can cleanly cleave the slab. Quarry saws on this principle date back centuries; before the era of steel cables with diamond cutters, there were fiber ropes that drew sand through the kerf. The sand (flushed with water) cut the stone (albeit more slowly than diamond does today).

Foam: Foam manufacturers commonly use an abrasive wire saw, either manual or automatic, to cut foam to certain sizes or certain profiles (shapes). Foam saws are used in many industries, include housing (insulation, pipe insulation), furniture (couches, couch cushions, chair cushions), and entertainment (foam fingers, foam accessories). Abrasive-wire cutting is often done with a computer numerical control device that automatically cuts the pattern (or patterns) that are specified in a two-dimensional (2D) CAD/CAM drawing. The materials to be cut can range from polystyrene, polyethylene, and polyurethane, to high-density or rigid types of foam, such as cellular glass (e.g., Foamless®). Oscillating saws are used to cut foam rubber.

Semiconductors: In the semiconductor industry, multi-wire saws are used to cut cylindrical ingots of silicon boules into thin wafers. Thin wire is used to minimize the loss of material. For example, the Peter Wolters DW 291 has a minimum wire diameter of 40µm and can cut an 860mm work piece into 100µm wafers.

Advantages and disadvantages:

Diamond wire cutting (DWC) is the process of using wire of various diameters and lengths, impregnated with diamond dust of various sizes to cut through materials. Because of the hardness of diamonds, this cutting technique can cut through almost any material that is softer than the diamond abrasive. DWC is also practical and less expensive than some other cutting techniques, for example, thin diamond wire cost around 10-20 cents per foot ($0.7/m) in 2005 for 140 to 500 micrometer diameter wire, to manufacture and sells around $1.25 a foot ($4.10/m) or more, compared to solid diamond impregnated blade cutters costing thousands of dollars. Thus a 1,000-foot (300 m) spool of diamond wire costs around $200 to manufacture and sells for around $1,250. Selling cost may vary because of wire grade and demand. Other diamond wire cutting can use shaped diamond rings threaded through cables. These larger cables are used to cut concrete and other large projects.

Advantages:

DWC produces less kerf and wasted materials compared to solid blades (slurry wire may be similar). On very expensive materials, this could save hundreds or thousands of dollars of waste. Unlike slurry saws that use bare wire and contain the cutting material in the cutting fluid, DWC uses only water or some fluid to lubricate, cool the cut, and remove debris. On some materials DWC may not need water or cutting fluid, thus leaving a clean dry cut.

Disadvantages:

Using diamond wire for cutting does have the problem of being less robust (snapping when fatigued, bent, jammed or tangling) than solid cutting blades and possibly more dangerous because when the wire breaks it can whip. Because of the unique nature of DWC, most saws are expensive and are tailor-made to handle diamond wire. Commercial saws that utilize solid blades can be augmented with diamond dust blades and thus may be more economical to operate in some areas. Another problem is when the diamond wire breaks in say, the middle of a 3,000 ft (910 m) reel leaving two 1,500 ft (460 m) reels of wire, thus requiring up to twice the saw direction change cycles to do the same cut and wearing out the wire saw and remaining diamond wire quicker. If the diamond wire breaks more towards an end, these shorter pieces (500 ft (150 m) or less) of wire are practically unusable and are commonly disposed of due to the hundreds of feet required to thread the saw, leaving little wire to use for process cutting. Because the diamond abrasive is mechanically attached to the wire, the wire loses cutting effectiveness after a few cuts because most of the abrasive is worn off the wire. This means that the last cut may take much longer than the first cut making production timing less predictable. Diamond wire lasts around six cuts then either breaks in several places or is functionally worn out. The longevity greatly depends on the material cut and the number of slices per cut. Quality control of smaller diameter diamond wire also greatly affects wire life and getting a bad batch is not unknown.