Mesh-to-Micron Process
Quality Control and Customized Processing
Advanced Abrasives utilizes state of the art equipment with our quality system to monitor and control the entire micronizing process from beginning to end. To insure consistency from lot to lot, measurement techniques capable of quantifying the products characteristics are performed on each batch and retained for traceability, statistical analysis and future reference. All critical measurement equipment is monitored and calibrated using standards and statistical process control.
Particle Size Measurement
Particle Size Distribution (PSD) is one of the most critical characteristics of our superabrasive products. The PSD affects the material removal rate, surface finish and packing density. Advanced Abrasives incorporates many different techniques and instruments to measure the distributions characteristics. This will insure consistent products from lot to lot leaving the guess work and variability out of the equation for the end user.
Advanced Abrasives incorporates the following particle size measurement equipment:
| Instrument | Measurement Technique |
|---|---|
| Horiba - LA 910 | Laser light scattering |
| Coulter - Multisizer 3 | Electric sensing zone |
| Microtrac - S3000 / X-100 | Laser light scattering |
| CPS | Centripetal force and laser |
| Image Pro - Image Analysis | Microscopy |
Shape Characterization
We incorporate a qualitative technique using a microscope and image analysis system running Image Pro Plus on every batch we micronize. When detailed imaging is required, state of the art SEM or TEM units are employed.
Conductivity
The measurement of crystal surface purity as a result of dissolved solids. To insure the highest possible bond retention, the surface of the diamond must be extremely clean. Advanced Abrasives incorporates a proprietary technique which produces an ultra clean surface regardless of size or shape.
Elemental Analysis
Elemental impurities reside in all synthetic and natural diamond. Advanced Abrasives uses Inductively Coupled Plasma (ICP) and Dc Arc testing to monitor and control these impurities allowing us to offer consistent, low impurity diamond products to its demanding customer base. The ICP analysis reveals the level of cleaning by incorporating an acid leach technique which determines the elemental residuals on the surface. Dc Arc analysis shows the unconverted elemental catalysts which remain trapped inside the crystal by converting the diamond to ash.
Ion Analysis
Ion Chromatography is a process that allows the separation of ions and polar molecules based on the charge properties of the molecules. High levels of ions on the surface can have a negative effect on bond retention/compatibility, dispersion and/or surface finish.
Advanced Abrasives uses proprietary cleaning techniques along with extremely high purity water to eliminate high ion concentrations.
Mesh to Micron Processing
Advanced Abrasives Corporation micronize a majority of our products from the initial mesh feed all the way through to the finished product. This insures total control in every step of the process.
Many "micronizers" use enhanced feeds which they have no control over. In many cases these products enter the door, head to QC and are tested to see if they meet a certain specification. If they fail, they are forced to return the material or try and fix the problem.
The following is a brief outline of the entire process that our Mesh to Micron materials go through before becoming an Advanced Abrasives finished product. Due to the proprietary nature of the process, many details must be excluded:
- Mesh material is sourced from a supplier based on crystal type and size.
- A representative sample from a large feed batch is tested.
- Once received it is compared against the representative sample.
- The material is milled based on specific parameters of size and shape.
- It goes through a rough classification step which is designed to classify and remove undesirable shapes.
- The diamond/cBN undergoes a two stage process of high temperature cleaning.
- The feed is then analyzed for rough sizing, shape and quantity.
- It is then classified to a unique specification and monitored using various particle size distribution techniques.
- Once the desired distribution is achieved, the product goes through an oversize control process.
- The diamond/cBN is then checked once again for the proper particle size distribution.
- The product enters an ion reduction process.
- It is put into a controlled drying environment.
- Once dry, it is bottled, labeled and put through Quality Control for finished product approval by testing and certifying all attributes of the Product and Lot Certification.
Customized Processing
We understand that "One Size Fits All" doesn't work in the diamond world. That's why we offer customized products to fit your specific applications. Here is just a sampling of how we can work with your R&D or Engineering department to customize the right solution to your unique process:
Customized Attributes
- Particle size distributions (PSD)
- Shape characteristics through milling/shaping or in the synthesis phase
- Altered pack densities through compounding
- Nanometer and sub micron products in an agglomerate free solution (water or oil)
- Diamond-Diamond coatings
- Compound and slurry formulas
- Surface preparation compatible with your process
- Packaging and labeling