In industries that demand precision, durability, and efficiency, the way superhard materials like PCD, PCBN, and CVD diamond are bonded plays a critical role in the performance and longevity of cutting, drilling, and grinding tools. However, brazing superhard materials is one of the most complex processes in manufacturing—one that can determine the success or failure of a tool’s performance.
At Euro Superabrasives, we are committed to providing our customers with the best brazing technology and expertise, supporting manufacturers with cutting-edge vacuum brazing solutions from PIN POWER CO.,LTD and superior material knowledge from Element Six(E6).
This article explores how vacuum brazing technology combined with Element Six’s best practices in brazing superhard materials is revolutionising tool production, ensuring stronger joints, enhanced tool longevity, and superior performance.
1. The Challenge: Brazing Superhard Materials with Precision & Reliability
Superhard materials like PCD (polycrystalline diamond), PCBN (polycrystalline cubic boron nitride), tungsten carbide, and CVD diamond provide exceptional wear resistance and cutting performance. However, achieving a secure, long-lasting bond between these materials and tool bodies presents unique challenges:
- High-temperature sensitivity – Excessive heat can cause material degradation, weakening the tool.
- Difficult wetting properties – Many superhard materials do not bond well with conventional brazing alloys.
- Residual stress issues – Uneven heating and cooling cause cracks, delamination, or premature tool failure.
- Impurities from flux – Traditional brazing methods introduce contaminants that weaken the joint.
These challenges highlight why standard brazing techniques fall short when working with superhard materials.
2. Why Vacuum Brazing is the Solution
Vacuum brazing is emerging as the gold standard for bonding superhard materials. Unlike traditional induction or flame brazing, vacuum brazing provides better joint integrity, improved cleanliness, and reduced stress formation.
Advantages of Vacuum Brazing Over Traditional Methods
- Stronger Braze Joints – Vacuum-brazed joints are 20-30% stronger than silver solder joints, reducing the risk of tip loss during use.
- Flux-Free & Clean Process – Unlike traditional methods, vacuum brazing requires no flux, eliminating contamination risks.
- Even Heat Distribution – The entire workpiece is uniformly heated, preventing thermal stress and material distortion.
- Faster Production Cycles – The PINPOWER PP Series completes a full brazing cycle in just 30 minutes, drastically reducing downtime.
- Multiple Components in One Cycle – Vacuum brazing allows for batch processing, increasing manufacturing efficiency.
PIN POWER’s PP Series: Next-Generation Vacuum Brazing Machines
Euro Superabrasives proudly supplies PIN POWER’s PP Series high-speed vacuum brazing machines, designed to meet the demands of modern tool manufacturers.
- Advanced Automation – Fully automated brazing for high repeatabilitywithout the need for skilled labor.
- Real-Time Monitoring – Temperature discrepancy alerts, cooling system monitoring, and remote diagnostics for optimal control.
- Energy Management System – Tracks energy consumption for sustainable and cost-efficient operations.
- User-Friendly Operation – One-touch operation for fast and simple brazing—even for operators with no prior brazing experience.
With vacuum brazing, manufacturers achieve superior bonding between superhard materials, extending tool lifespan and performance while reducing defects and production waste.
3. Element Six’s Best Practices in Brazing Superhard Materials
As a global leader in synthetic diamond and superhard materials, Element Six (E6) provides industry-leading guidance on how to optimise brazing techniques to achieve strong, defect-free joints.
Key Recommendations from the Element Six Case Study
Proper Joint Design & Preparation
- Ensure correct pocket size and segment relief to avoid cracking.
- Use copper shims or controlled gap spacing to absorb contraction stresses.
Surface Cleaning & Flux Application
- Clean all parts using alcohol in an ultrasonic bath to remove contaminants.
- Use the right flux to prevent oxidation and ensure proper alloy flow.
Controlled Heating & Cooling Cycles
- Maintain the lowest possible brazing temperature to prevent PCD graphitisation.
- Avoid quenching or forced cooling—allow components to air cool or use sand submersion.
Visual Inspection & Quality Control
- Check for delamination, voids, and uniform braze flow.
- Avoid graphitisation of PCD or cracking of PCBN, which weaken tool performance.
By implementing Element Six’s expert brazing techniques and using PINPOWER’s vacuum brazing machines, manufacturers can achieve flawless, high-strength brazed joints that improve tool reliability and cutting efficiency.
Contact our team today to explore how PINPOWER’s vacuum brazing machines and our Element Six’s material expertise can enhance your manufacturing efficiency.