孕镶金刚石钻头在钢筋混凝土抽芯质量检测中被广泛应用，其中胎体对其加工性能起决定性的作用。Co基胎体是理想的金属胎体材料，但Co稀有且昂贵，因此迫切需要开发低Co乃至无Co胎体材料。Fe-Cu系预合金粉末因价格低廉而得到了广泛的应用，但其存在烧结温度高、烧结胎体的力学性能差等问题，从而限制了其应用。为此，本文采用水雾化法，以Fe-Cu为研究对象，添加Co、Sn和Ni，研究其对Fe-Cu预合金粉末性能的影响，以期使孕镶金刚石钻头具有更高的钻进效率和更长的使用寿命。

添加质量分数为20%、40%和60%的Cu，研究Cu含量对Fe-Cu预合金粉末性能的影响。研究结果表明，在760℃~920℃的烧结温度下，随着烧结温度的升高，3种Fe-Cu预合金粉末烧结胎体的相对致密度、抗弯强度和硬度均呈先增加后减小的趋势；在相同的烧结温度下，随着Cu含量的增加，其相对致密度、抗弯强度和硬度逐渐减小；Fe80Cu20的耐磨性及对金刚石的包镶能力最强，其磨损量为0.621g，抗弯强度损失率为20.98%，烧结胎体断口以穿晶断裂为主。

在Fe80Cu20的基础上，添加质量分数为10%、20%和30%的Co，研究Co含量对Fe-Cu-Co预合金粉末性能的影响。研究结果表明，3种Fe-Cu-Co预合金粉末烧结胎体的相对致密度、抗弯强度和硬度均在880℃时达到最大值；在相同的烧结温度下，随着Co含量的增加，其相对致密度、抗弯强度和硬度逐渐增大；Fe50Cu20Co30的相对致密度、抗弯强度和硬度在880℃时的最大值分别为97.61%、1704 MPa和104 HRB，抗弯强度损失率η达到最小值为17.24%，其对金刚石的包镶能力最强；在920℃时，Fe50Cu20Co30的磨损量达到最小值为0.489g，其耐磨性最强，Fe50Cu20Co30断口为沿晶脆性断裂和穿晶断裂的混合型特征。

在Fe80Cu20的基础上，添加质量分数为2%、4%和6%的Sn，研究Sn含量对Fe-Cu-Sn预合金粉末性能的影响。研究结果表明，Fe80Cu20预合金粉末烧结胎体的抗弯强度和硬度在880℃时分别达到最大值为1425 MPa和88 HRB，其烧结胎体断口组织存在较多孔隙，烧结相对致密度仅为96%；Fe76Cu20Sn4的综合性能较好，在760℃~840℃烧结时，其相对致密度为98%，抗弯强度为1534~1745 MPa，较Fe80Cu20提高15%以上，硬度可达94~99 HRB，其烧结胎体断口组织孔隙明显减少且更趋均匀化。在Fe76Cu20Sn4的基础上，添加质量分数为2%、4%和6%的Ni，结果表明，Fe72Cu20Sn4Ni4的综合性能最优，在760℃~840℃烧结时，其相对致密度为99%，抗弯强度为1758~1983 MPa，较Fe80Cu20提高30%以上，较Fe76Cu20Sn4和纯Co粉提高了10%以上，硬度可达110~115 HRB，其烧结胎体断口组织更为均匀且几乎不存在孔隙。

采用激光焊接法分别制备了纯Co粉和Fe72Cu20Sn4Ni4预合金粉末胎体孕镶金刚石钻头，并进行现场钻进试验，试验结果表明，Fe72Cu20Sn4Ni4胎体孕镶金刚石钻头平均每孔的钻进速率为4.03cm/min，平均每孔的消耗为1.31mm，其使用效果与纯Co粉胎体基本相当，但其生产成本较纯Co粉胎体可降低50%以上。

Impregnated diamond bits are widely used in the core-pulling quality inspection of reinforced concrete, in which the matrix plays a decisive role in its machining performance. Co-based matrix is an ideal metal matrix material, but Co is rare and expensive, so there is an urgent need to develop low Co or even no Co matrix materials. Fe-Cu pre-alloy powder has been widely used because of its low price, but it has some problems such as high sintering temperature and poor mechanical properties of sintered matrix, which limit its application. Therefore, this paper adopts water atomization method, takes Fe-Cu as the research object, adds Co, Sn and Ni, and studies its influence on the properties of Fe-Cu pre-alloy powder, in order to make impregnated diamond bit have higher drilling efficiency and longer service life.

The effect of Cu content on the properties of Fe-Cu prealloy powder was studied by adding 20%, 40% and 60% Cu. The results show that the relative density, bending strength and hardness of the sintered matrix of the three Fe-Cu prealloy powders increase first and then decrease with the increase of sintering temperature at 760℃~920℃. At the same sintering temperature, the relative density, bending strength and hardness of Cu decrease with the increase of Cu content. Fe80Cu20 has the strongest wear resistance and diamond embedding ability, its wear amount is 0.621g, the bending strength loss rate is 20.98%, and the sintered matrix fracture is mainly transgranular fracture.

On the basis of Fe80Cu20, 10%, 20% and 30% Co were added to investigate the effect of Co content on the properties of Fe-Cu-Co prealloy powder. The results show that the relative density, bending strength and hardness of the sintered matrix of the three Fe-Cu-Co prealloy powders reach the maximum value at 880℃. At the same sintering temperature, with the increase of Co content, the relative density, bending strength and hardness increase gradually. The maximum values of relative density, bending strength and hardness of Fe50Cu20Co30 at 880℃ are 97.61%, 1704 MPa and 104 HRB, respectively, and the minimum loss rate of η is 17.24%, which indicates that Fe50Cu20Co30 has the strongest diamond embedding ability. At 920℃, Fe50Cu20Co30 has the highest wear resistance and the minimum wear value is 0.489g. The fracture of Fe50Cu20Co30 is a mixture of intergranular brittle fracture and transgranular fracture.

On the basis of Fe80Cu20, 2%, 4% and 6% Sn were added to investigate the effect of Sn content on the properties of Fe-Cu-Sn prealloy powder. The results show that the bending strength and hardness of Fe80Cu20 prealloying powder sintered matrix reach the maximum values of 1425 MPa and 88 HRB respectively at 880℃. There are more pores in the fracture structure of the sintered matrix, and the relative density of sintering is only 96%. The comprehensive properties of Fe76Cu20Sn4 are better. When sintered at 760℃~840℃, the relative density of Fe76Cu20SN4 is 98%, the bending strength is 1534~1745 MPa, which is more than 15% higher than that of Fe80Cu20, and the hardness can reach 94~99 HRB. The porosity of the sintered matrix is significantly reduced and more homogeneous. On the basis of Fe76Cu20Sn4, Ni with mass fraction of 2%, 4% and 6% is added. The results show that Fe72Cu20Sn4Ni4 has the best comprehensive performance. The relative density of Fe72Cu20Sn4Ni4 is 99% and the bending strength is 1758~1983 MPa when sintering at 760℃~840℃. It is more than 30% higher than Fe80Cu20, more than 10% higher than Fe76Cu20Sn4 and pure Co powder, and the hardness can reach 110~115 HRB, and the fracture structure of the sintered matrix is more uniform and almost no pores exist.

Pure Co powder and Fe72Cu20Sn4Ni4 pre-alloy powder impregnated diamond bit were prepared by laser welding method, and the field drilling test was carried out. The test results showed that the average drilling rate per hole of Fe72Cu20Sn4Ni4 impregnated diamond bit was 4.03cm/min. The average consumption per hole is 1.31mm, and its use effect is basically the same as that of pure Co powder matrix, but its production cost can be reduced by more than 50% compared with pure Co powder matrix.

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