How Are Diamond Saw Blades Made?

Diamond Saw Blade

Diamond saw blades are made by bonding diamond grits to the steel body of the blade to create a tougher, more resilient blade that's suited to cutting even the hardest of materials.

Steel Core (The Support Part)

The steel core is typically a flat metal disc that's purpose is to support the outer segments. The steel core is usually attached to the segment, the cutting part where the diamond is located, using one of the

following methods. The type of blade being produced will influence the choice of method.  

ㆍVacuum Brazed or Sintered Attachment

This process is often used for lower cost and higher quantity diamond saw blades. It is better suited to create diamond blades intended to use dry cutting softer materials and low horsepower equipment. This is because the method is best for creating smaller, sharper blades.  

ㆍLaser Welded Attachment

Laser welding creates a stronger attachment to the blade core, making it ideal for diamond blades used for wet cutting harder materials to a higher depth and higher horsepower equipment. Steel blade cores used with this method are thicker, precision ground, heat-treated and tensioned. This means they are less susceptible to bending and flexing stress from the heavier machinery and usage.  

Segment (The Cutting Part)

The segment, the cutting part of the blade, is made up of two parts. The first is the diamond crystals, and the second is the bonding system that holds them in place and creates the correct wear rate for the intended use.  

ㆍDiamond Crystals

In diamond saw blades, synthetic or manufactured diamonds are preferred to natural. This is because there is more control over the size, shape and strength of synthetic diamonds, meaning they provide better control during the manufacturing process. This control means a more accurate prediction of the cutting speed and precision of the resulting diamond blade. It also helps consistent recreation of these qualities.

ㆍAmount of Diamond

The intended use of the blade will dictate the quantity of diamond used. The more diamond used in a blade, the higher the amount of horsepower needed for the blade to effectively cut. For example, a blade intended for use cutting materials like concrete will feature more diamonds than one intended for use cutting ceramics. Since the harder materials often require more tools with more horsepower, more diamonds are necessary for an effective diamond blade.

ㆍQuality of Diamond

The quality of the diamond used in diamond blades will determine the diamonds ability to resist heat and maintain sharpness. Superior diamonds will have better longevity, maintaining sharpness at a higher temperature.

ㆍSize of Diamond

Diamond sizes are specified in mesh ranges, such as 25-35 or 50-60. A higher number in mesh size indicates a finer individual diamond particle. Whilst coarser diamond particles will be better for cutting asphalt and red brick, finer diamond particles will serve well for cutting very hard materials like quartz.  

Diamond Saw Blade

ㆍBonding Systems

The bond that holds the diamond particles in place within the blade is created from a mixture of metal powders. Different metal powders are combined in particular ratios to achieve specific wear rates. The right wear rate will ensure that the diamond particles are held in place for just long enough to achieve maximum wear. They will then release them to expose the next layer of diamond particles beneath. Soft bonds, that wear quickly, would be made up of soft metal powders such as bronze. These are best for cutting materials like ceramics and porcelain, which are very hard but less abrasive. Hard bonds, that wear slowly, would be made up of hard metals like tungsten carbide. These are best for cutting materials like asphalt, which are generally soft but very abrasive. Remember that opposites attract; for hard but less abrasive materials, a softer bond is best. Vice versa, for materials that are soft but more abrasive, a harder bond is best.  

How do diamond blades work?

The key thing to remember about how diamond saw blades work: they don't cut, they grind. The diamonds do all the work in a diamond blade. They grind through the material whilst the metal bond holds them in place. The rotation of the blade allows the diamonds to grind through the material, turning the material it grinds into a fine powder. After extended use, around several thousand rounds of the blade, the diamonds will begin to fracture and the bond holding them in place will begin to wear away. This will then lead to this layer of diamond particles breaking away and mixing with the fine dust produced in the grinding process. The erosion of the diamond particles and bond will expose a new layer of sharp diamond particles. This new layer will then begin the cycle again. The cycle continues until all layers of diamond particles have been exhausted.  

Are blades for different materials made differently?

The method of production for each diamond saw blade will depend on its intended use. The process used to make a diamond blade for cutting ceramics will differ from that intended to cut concrete. A diamond blade for cutting ceramics, for example, will require fewer and finer diamond particles than a diamond blade for concrete. The process of production is also more likely to use vacuum brazed or sintered attachment, whereas a diamond blade for concrete will likely use the laser-welded attachment. The combination of techniques and materials does depend on what material the blade will be used to saw.

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