Effect of Fe: Cu ratio on microstructure and mechanical properties of Fe-Co-Cu-based diamond tools

Co-based diamond tools are widely appreciated for their exceptional mechanical properties and good holding ability for diamonds. However, the reliance on cobalt (Co) poses challenges due to its high cost and scarcity as a strategic resource. A potential alternative is the Fe–Co–Cu alloy, emerging as a promising substitute for Co matrix alloys. In this work, hot-press sintering was utilized to create pure matrix and diamond tools utilizing Fe–Co–Cu pre-alloyed powders of varying compositions as raw materials without the use of any sintering additives. The investigation explores the influence of different Fe: Cu ratios on the mechanical properties of diamond tools produced from Fe–Co–Cu alloys, focusing on the diamond holding force, microstructure, and phase structure evolution. Results indicate that at a Co content of 15 wt% and Fe: Cu ratios ranging from 7.5:1 to 1:7.5, the Fe–Co–Cu alloy's phase structure primarily comprises α-Fe and a Cu-rich phase. Co predominantly exists in α-Fe as a solid solution. As the Fe: Cu ratio decreases, the alloy's phase structure gradually transitions from α-Fe to a Cu-rich phase, accompanied by a progressive decline in both bending strength and hardness, while the densities gradually increase. The matrix's holding force on the diamond exhibits an increasing and then diminishing trend, peaking at the Fe: Cu ratio of 6:1. The Fe–Co–Cu alloy sintered by hot-pressing has a nearly equiaxed grain structure with no obvious texture.