Synthetic Diamonds for use in Stone and Concrete Processing

Synthetic Diamonds for use in Stone and Concrete Processing

Element Six solutions enable improved performance of the end-user tool, and a lower manufacturing cost of the tool itself.

Element Six offers a comprehensive range of supermaterial solutions for the cutting and polishing of stone and concrete. The use of synthetic diamond in these applications has increased dramatically in the last ten years as a result of its overwhelming material advantages.
Element Six synthetic diamond is typically used in the form of abrasive grains embedded in a matrix material, which is then mounted on a wire or steel frame to create a cutting tool. Polycrystalline diamond (PCD) segments can also be used for larger cutting surfaces, or where a geometrically defined cutting edge is required.

Element Six maintains innovation leadership in the market with patented and proven technologies. We build on over 50 years of experience to offer both improved performance of the finished tool and lower manufacturing cost of the tools themselves.

Element Six synthetic diamond offers improved performance of the finished tool through:
•   Engineering synthetic diamond according to particle size and strength, so as to optimise cutting rates with the available power
•   Coating synthetic diamond to improve retention in the tool and higher thermal stability during cutting
•   Encapsulating synthetic diamond to offer even higher retention and spatially uniform distribution of abrasive grains throughout the tool segments.

Element Six offers lower manufacturing cost of the tool itself through:
•   Coating the synthetic diamond to enable brazing in air and sintering at higher temperatures
•   Encapsulating synthetic diamond to simplify grain placement technologies and streamline material handling and tool production processes.

Cutting of stone
The stone extraction industry uses a combination of single-wire, multi-wire, circular blade and gang sawing techniques to extract stone from quarries and to then process it into finished slabs and tiles. The use of synthetic diamond for cutting (typically in combination with water for cooling and waste extraction) has proved highly effective. Element Six has successfully developed synthetic diamond grits to optimise the cutting rate relative to available power in operations around the world. Element Six has its own testing facilities at its Market Support Centre to assist customers in selecting the most appropriate synthetic diamond characteristics for the specific application.

Cutting of concrete
The construction industry uses a combination of circular blades and core drills (machine mounted or hand held) to refurbish or dismantle existing concrete structures. Element Six has successfully developed synthetic diamond grits with higher retention to deal with variable hardness in the aggregate as well as high thermal stability to handle reinforced steel within the concrete. In addition, Element Six polycrystalline diamond segments have been developed for applications needing faster penetration in the drilling of steel reinforced concrete.

Polishing of stone and concrete
The stone industry polishes slabs that have been cut to size to meet the aesthetic expectations of consumers. In addition, the trend to polish concrete floors is increasing as an inexpensive, but cosmetically attractive, solution particularly in industrial environments. Element Six has successfully developed synthetic diamond grit with an optimal shape for smoothing, rather than cutting.