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We propose an original route to process diamond wires, denominated In Situ Technology, whose fabrication involves mechanical conformation processes, such as rotary forging, copper tubes restacking, and thermal treatments, such as sintering and recrystallisation of a bronze 4 wt.% diamond composite. Tensile tests were performed, reaching an ultimate tensile strength (UTS) of 230 MPa for the diameter of Æ = 1.84 mm. Scanning electron microscopy showed the diamond crystals distribution along the composite rope during its manufacture, as well as the diamond adhesion to the bronze matrix. Cutting tests were carried out with the processed wire, showing a probable performance 4 times higher than the diamond sawing discs, however its probable performance was about 5 to 8 times less than the conventional diamond wires (pearl system) due to the low abrasion resistance of the bronze matrix, and low adhesion between the pair bronze-diamond due to the use of not metallised diamond single crystals.

This paper aims at showing a new route to process diamond wires, called “in situ” technology, whose fabrication involves mechanical fabrication processes such as rotary forging and wire drawing, copper tube restacking, and thermal treatments, i.e. sintering and annealing. Copper–15 vol.% Nb composite wires was used as the high tensile strength cable, covered with an external cutting rope, made of bronze 4 wt.% diamond composite, along the overall wire surface. Thus, this work shows the manufacturing route of the bronze 4 wt.% diamond composite. Tensile tests were performed, reaching an ultimate tensile strength (UTS) of 230 MPa for the rope diameter of φ=1.84 mm. Scanning electron microscopy showed the diamond crystals distribution and integrity along the composite rope during its manufacturing, as well as the diamond adhesion to the matrix. Cutting tests were carried out with the external cutting rope, presenting probable performance four times superior to diamond saws. However, the probable performance showed to be five to eight times inferior to conventional diamond wires. [Copyright &y& Elsevier]