The manufacturing processes of diamond cut-off wheels mainly fall into three categories: sintering, welding and electroplating. Each process features a unique technical flow and scope of application.
Sintering process
Sintering is divided into cold pressing sintering and hot pressing sintering. Diamond grains are firmly bonded with the metal matrix through compression and sintering.
Cold pressing sintering
Process flow: Diamond grains are evenly blended with metal powders, cold-pressed into shape, and then sintered at high temperature to achieve tight bonding between diamond grains and the metal matrix.
Features: The cold pressing sintering process is simple with low production costs. However, insufficient pressure during sintering may cause uneven distribution of diamond grains, which impairs cutting performance.
Application: Suitable for scenarios with low requirements on cutting precision, such as rough machining and cutting of non-metallic materials.
Hot pressing sintering
Process flow: Compression and sintering are completed under elevated temperature and pressure to realize higher bonding strength and more uniform distribution of diamond grains.
Features: Hot pressing sintering involves complex procedures and higher costs. It enables firmer combination between diamond grains and the metal matrix, delivering superior cutting performance.
Application: Ideal for applications requiring high cutting precision and efficiency, including the cutting of hard and brittle materials such as cemented carbide and ceramics.

Welding process
Welding processes primarily include high-frequency welding and laser welding. Segments and wheel substrates are joined together by melting filler media at high temperatures.
High-frequency welding
Process flow: High-frequency induction heating melts the contact edges between segments and substrates to form metallurgical bonding.
Features: This process is simple and cost-effective. Yet, welding strength may be affected by high-frequency current, resulting in unstable welding quality.
Application: Applied to working conditions with low welding strength requirements, such as light-load cutting operations.
Laser welding
Process flow: A high-temperature laser beam melts the connecting edges of segments and substrates to form metallurgical bonding.
Features: Laser welding offers high welding strength, smooth and clean weld seams, and prevents structural changes of segment molecules caused by excessive heat. It effectively enhances the sharpness and wear resistance of cut-off wheels.
Application: Designed for operations demanding high welding strength and cutting performance, such as high-precision and high-efficiency cutting tasks.

Electroplating process
The electroplating process attaches diamond grains to the substrate via electroplating to form a thin diamond cutting layer.
Process flow:
Raw material preparation: Prepare diamond grains, metal powders (nickel, cobalt, etc.) and other auxiliary materials.
Electroplating treatment: Mix diamond grains and metal powders uniformly, place the mixture into electroplating solution, and attach diamond grains to the substrate through electroplating.
Post-treatment: Conduct heating, grinding, mechanical processing, alkali etching, edge sharpening and other treatments on electroplated wheels to improve cutting performance and service life.
Features:
Advantages: Low cost and high production efficiency, suitable for manufacturing ultra-thin cut-off wheels.
Disadvantages: The bonding strength of the electroplated layer is restricted by process parameters and material selection, which may lead to grain shedding and excessive wear during service.
Application:
Suitable for occasions requiring thin wheel thickness and moderate cutting precision, such as slicing and cutting of jade, crystal, ceramics and other materials.