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At present, superhard materials are mainly classified into single crystal superhard materials and polycrystalline superhard materials (also called "composite superhard materials"). The single crystal superhard material is mainly a single crystal diamond/cubic boron nitride micropowder; the polycrystalline superhard material mainly refers to a composite material prepared by sintering a diamond or cubic boron nitride and a related binder.
The main difference between the two types of materials is: single crystal diamond / cubic boron nitride material is characterized by higher hardness, better heat resistance, but smaller size, mostly used in the manufacture of cutting tools such as saw blades; polycrystalline diamond / cubic nitrogen The characteristic of boron is that the hardness and heat resistance are slightly inferior to that of single crystal materials. However, since the polycrystalline superhard material is a diamond dense body with a tight internal structure, the cutting area of ​​the tool can be increased, and the single crystal superhard material is overcome due to sticking. The disadvantage of easy to fall off the surface of the saw blade caused by the small junction area has higher wear resistance.
In general, composite superhard materials have strong alternatives to traditional alloy materials and have greater market potential. They are widely used in traditional fields such as machinery, metallurgy, geology, petroleum, coal, stone, construction, etc., electronic information, aerospace. High-tech fields such as defense and military industries, as well as emerging industries such as automobiles and home appliances.
1.2 Main product uses of composite super-hard materials At present, the products of composite super-hard materials are mainly divided into four categories: polycrystalline diamond composite sheets for oil and gas drill bits, polycrystalline diamond composite sheets for coalfield mining, and high-grade diamond-shaped drawing blanks for polycrystalline diamond. Polycrystalline diamond/polycrystalline cubic boron nitride composite sheets for tools and tools.
(1) Polycrystalline diamond composite sheet for oil and natural gas drill bit The oil and natural gas polycrystalline diamond composite sheet is a combination of a cutting layer composed of numerous tiny diamond particles and a binder and a cemented carbide substrate layer sintered under high temperature and high pressure. High strength, hardness, wear resistance, impact resistance and good self-sharpness make these properties suitable for rock drilling. This product is mainly used as the cutting tooth of oil and gas drill bit, and it is the core component of cutting and excavation on the drill bit.
(2) Polycrystalline diamond composite sheets for coal mine drill bits have the characteristics of high hardness, strong wear resistance and good impact toughness. In addition to being used for making oil and gas drills, composite superhard materials can also be used to make coal mine drill bits. The use of PCD composite sheets is not limited to the drilling and cutting tools used in coal fields and mining operations. It can also be widely used in the manufacture of drilling tools in many fields such as construction, hydropower construction, rock drilling and road repair. .
(3) Polycrystalline diamond high-grade drawing die blank Drawing die is a very important consumable mold for drawing wire rods of various metal wire manufacturers (such as wire and cable factory, steel wire factory, welding wire welding factory, etc.). The wire drawing die has a wide range of applications, and is mainly used for drawing straight, difficult-to-machine objects such as bars, wires, wires, pipes, etc., and is suitable for drawing and processing of metal and alloy materials such as steel, copper, tungsten, and molybdenum. Composite superhard materials are the ideal material for making high quality wire drawing dies.
(4) Multi-tools for tools The tools made with PCD/PCBN tool composites can replace almost all traditional carbide tools and are used in a wide range of applications, including manufacturing automotive parts, processing wood, mining stone, and CNC machine heads. Due to the large scale of its downstream industry, the demand for composite sheets for tools is also huge.
1.3 Analysis of the current status of composite superhard materials industry The core of the production of composite superhard materials lies in the formulation of raw materials for single crystal superhard materials and binders. The core technology lies in the high temperature and high pressure of single crystal superhard materials and corresponding binders. The process of sintering. The quality of products on the market is excellent, and manufacturers with obvious competitive advantages all have unique formulas and advanced production processes. The above two points constitute the core competitiveness of the composite superhard materials industry. In the early stage of China's industry development, China's composite super-hard material products have a certain gap in terms of wear resistance, hardness, composite sheet uniformity and composite sheet size compared with international advanced products. However, with the continuous research of Chinese enterprises and scientific research personnel, the performance advantages of the six-face top press have been fully utilized and the disadvantages have been overcome. The technical level of China's composite super-hard industry has formed its own characteristics and is close to or achieved in the overall technical indicators. The international advanced level.
Foreign manufacturers mainly rely on two-sided top presses (such as E6, DI, Sumitomo, Nisshin for two sides, US Synthetic, Mega Diamond, Novatek, etc. for six-sided top), China's production of composite superhard material presses six The top pressing machine is mainly used (such as Sifangda, Xinya, Haimingrun for six-sided top and Jiangming for two sides). The two kinds of equipment have their own characteristics. The pressure of each set of pressure cylinder and top hammer of the two-side top press is relatively high, and the size of the high-pressure chamber is relatively large, which is suitable for the production of products with larger size. The cost of each set of top hammers of the six-sided top press is higher. Low, easy to operate, high-pressure chamber size is relatively small, suitable for the production of smaller products. However, with the enlargement of the six-face press in recent years, the size of the products that can be produced is also getting larger and larger, and the difference between the two sides is getting smaller and smaller. The Sifangda company in China has been able to produce PCD composite sheets with a diameter of 46 mm. It is expected that in the near future, a 2-inch diameter composite sheet can also be produced on a six-sided top press.
2 Industry market analysis of composite superhard materials
2.1 Market size of composite superhard materials industry According to market research and analysis of downstream market demand and sales data of overseas mainstream composite superhard material manufacturers, the market capacity of major composite superhard materials in 2009 is estimated according to major product categories as follows: PDC's global market capacity is about 9.7 billion yuan, of which the domestic market capacity is about 600 million yuan; coal mining PDC composite sheet is extremely broad due to the downstream industry mining tool market, its global market capacity exceeds 20 billion yuan; PCD high grade The current global market capacity of wire drawing blanks is about 500 million yuan, but with the price-performance advantage gradually recognized by downstream customers, the market capacity will increase to more than 1 billion yuan in the next few years; the market capacity of PCD composite sheets for cutting tools is also It has reached more than 10 billion yuan. It can be seen that the market capacity of composite superhard materials is huge, and the industry prospects are extremely broad.
2.2 Analysis of the competitive landscape of the composite super-hard materials industry In general, the old-fashioned composite super-hard material manufacturers from the United States, Japan, Ireland and other countries maintain a certain degree of leading edge in scientific research accumulation, industry experience, technical process and product quality. The international market has occupied a large market; at the same time, a group of emerging composite super-hard material manufacturing enterprises from South Korea, China and other countries have developed more unique production processes after more than ten years of technical research and development and production processes. Advantageous products, in addition to occupying a part of the market with a certain price advantage, its product range, business field and market share are constantly expanding, becoming a competitive force that cannot be ignored in the composite super-hard materials market. 2.3 Analysis of downstream industries in composite super-hard materials industry According to the investigation of downstream manufacturers of composite super-hard materials, composite super-hard materials account for 30%-60% of the downstream product costs, due to the difference in the use of composite super-hard materials. Large, the proportion of composite superhard materials in various products is also different, but in general, composite superhard materials occupy the main part of the cost of downstream products.
In 2009, the global oil drill bit market capacity is expected to reach 40 billion yuan, the mining drill bit market capacity is close to 100 billion yuan, and the market capacity of composite super-hard material tools is about 50 billion yuan. The stable demand and optimistic development of the downstream market. The prospect is an effective guarantee for the development of the composite superhard materials industry.
3 Development prospects of composite superhard materials industry
3.1 The downstream demand is stable and the potential is huge. It can be foreseen that oil exploitation and mineral resource development will be the basic guarantee for human survival and development in the next few decades or even hundreds of years, and as human demand for resources continues to grow in the above-mentioned fields. The investment will continue to expand, and this development trend has given the development of the drill bit polycrystalline diamond compact. In addition, the huge demand for wire processing, automotive/aerospace components, and wood/stone processing has resulted in a stable and growing downstream market for PCD drawn die blanks and tool PCD/PCBN composite sheets. In addition, the powerful replacement function of composite superhard materials compared with traditional cemented carbide materials brings a very bright development prospect and huge potential market capacity to composite superhard materials.
3.2 Industry gross margin will remain high As the composite superhard materials industry has high industry barriers and strong market demand, the industry has maintained a high industry gross margin in recent years. According to a survey of major players in the market, the average gross profit margin of the industry in the past three years was 31.6%, 30.4% and 35.3% respectively. The pricing of composite superhard materials is mainly based on the performance of its products. Compared with traditional alloy superhard materials and existing products, the composite superhard materials with more advanced performance and more stable quality can maintain high market sales price. The production cost of composite superhard materials is mainly concentrated on raw materials and technology research and development expenditures. Under the premise that the above production costs are well controlled, the industry profitability of composite superhard materials will be maintained at a high level. (Zhengzhou Abrasives Grinding Research Institute, Yiyunlei)
Analysis of the market of composite superhard materials industry in 2009
1 Introduction of composite superhard materials 1.1 Basic situation of composite superhard materials Materials such as diamond and cubic boron nitride are collectively referred to as superhard materials due to their extremely high hardness. They have high hardness, good wear resistance and thermal conductivity, and low thermal expansion coefficient. performance.