Brazing diamond segments onto a circular saw blade creates a new diamond saw blade, thereby enabling the capability to cut through hard materials. However, due to specific operational procedures and technical nuances involved in the brazing process, the bond strength of many blades often proves unsatisfactory. Consequently, shortly after being put into use, these blades may suffer from segment detachment; in even worse cases, uneven segment wear can occur, leading to scratches on the stone slabs being cut. Therefore, a skilled mastery of the techniques for brazing diamond segments is of immense benefit to both the service life and cutting performance of diamond saw blades.<\/p>\n\n\n\n
So, what specific points require attention during the saw blade brazing process? Below, we have listed seven common brazing techniques designed to help you improve your brazing process and enhance the bond strength of the segments.<\/p>\n\n\n\n
1: Regarding the selection of brazing materials: If you are working with segments intended for cutting marble, it is highly recommended to choose silver brazing sheets or silver-copper alloy sheets whenever possible. If copper brazing sheets are chosen instead, the difficulty of brazing increases significantly, and there is a risk that the segments may fail to bond properly. Conversely, for segments designed to cut granite, copper brazing sheets are a suitable choice.<\/p>\n\n\n\n
2: The selection of silver brazing sheets should be determined by the hardness of the stone material being cut. For softer stones, a silver content of 18% to 35% in the brazing sheet is sufficient. However, if you intend to cut harder stones, it is best to select silver brazing sheets with a silver content exceeding 35%. This is particularly important for customers utilizing cobalt-based segments, as a brazing sheet with a 35% silver content ensures a more secure bond and significantly boosts the overall brazing strength.<\/p>\n\n\n\n
3: During the brazing process, a high-frequency induction brazing machine offers distinct advantages over simpler flame-brazing methods, primarily due to its ability to heat up rapidly and maintain a constant brazing temperature. These advantages extend beyond merely providing precise control over brazing temperature and duration; more importantly, this method avoids causing significant adverse effects on the quality of the diamond segments themselves. In contrast, flame brazing\u2014due to the prolonged heating times involved\u2014often leads to fluctuations in the internal material stability of the segments. Therefore, if resources permit, it is highly recommended to utilize a high-frequency induction brazing machine to execute the segment brazing process. 4: Removal of Worn-out Tips Prior to Welding: Currently, the most common method involves rapidly heating the tip to melt the solder, then quickly stripping away the old tip. While this stripping method is simple and fast, it often presents a specific issue: if the temperature is too low, the solder will not melt completely and will remain adhered to the surface of the saw blade’s base teeth, negatively impacting subsequent welding operations. Conversely, if the temperature is too high, the tip may detach too rapidly, creating a safety hazard and increasing the risk of injury to the operator. Therefore, the optimal approach is to set the temperature to an appropriate level and allow the worn-out tips to fall directly into a designated collection container; this significantly enhances safety.<\/p>\n\n\n\n
5: Welding Process: “Skip-Tooth” Welding is Preferred. During the saw blade welding process, the “skip-tooth” method is the most widely adopted technique. The primary advantage of this method lies in its high tolerance for error; even if a tip is welded slightly off-center, the spacing provided by the skipped teeth allows for subsequent adjustments to realign the saw blade. The specific procedure involves welding one tip, skipping the adjacent tooth, and then welding the next one. Once this sequence is complete, the saw blade is flipped over to finish welding the remaining tips.<\/p>\n\n\n\n
6: Solder Run-off During Welding: The occurrence of solder “run-off” (where molten solder flows excessively) is typically caused by the solder having an excessively low melting point. In such instances, the welding temperature should be adjusted quickly to effectively prevent this issue. If significant solder run-off persists across a large area, the problem can also be mitigated by increasing the welding speed and reducing the overall welding duration.<\/p>\n\n\n\n
7: Post-Welding Inspection: Upon completion of the welding process, it is imperative to verify the welding strength of the saw blade. Using a pair of pliers, apply lateral pressure (rocking left and right) to each tip to quickly identify any that have not been securely bonded. Any loose tips should be immediately stripped off and re-welded.<\/p>\n\n\n\n
In summary, the process of welding saw blade tips involves numerous specific nuances and technical considerations. In fact, there is a wealth of information to be shared regarding the operational aspects of the various welding machines themselves\u2014particularly concerning the distinct techniques required for different equipment types, such as flame welding setups, high-frequency automatic welding machines, and semi-automatic welders. These specific details will be covered in future discussions; therefore, this article will not delve into them further at this time.<\/p>\n","protected":false},"excerpt":{"rendered":"
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