Abstract Synthetic diamond and cubic boron nitride and composite materials made of these two materials are collectively referred to as superhard materials. Various tools and functional parts made of them are collectively referred to as superhard materials. Superhard materials and products are high-efficiency, high-precision, energy-saving, green and environmentally friendly products...
table of Contents
Foreword 1 Major achievements in the superhard materials industry during the “Twelfth Five-Year Plan†period
1.1 Innovative development of a number of new super-hard materials to fill the domestic gap and the world's advanced level. Synthetic diamonds have entered the field of jewelry decoration. 1.2 Breaking through many key technologies, and pushing some enterprises to achieve the world's leading level of sawing and drilling tool technology. 1.2.1 Diamond saw Significant breakthroughs in production technology and equipment for sheet and thin wall drills 1.2.2 Rapid development of diamond wire saw technology, making stone mining into a new era of energy saving and green development 1.2.3 Diamond wire saw development success and scale Chemical production, strongly support and promote the development of China's photovoltaic, electronic information and LED and other emerging high-tech industries 1.2.4 Geological drilling and oil and natural gas mining diamond bit technology to achieve new breakthroughs 1.3 grinding products technology has made great progress, development A number of products with international advanced level have achieved the substitution of imported high-end products in many application fields. 1.4 Tool products have developed world-leading products. 2 Development situation and environment
2.1 Global product competition pattern 2.2 Opportunities and challenges for industry product development 2.2.1 Opportunities 2.2.2 Challenges 3 Guiding ideology and goals
3.1 Development Ideas 3.2 Principles 3.3 Objective 4 Main Tasks
4.1 Strengthening Market Segmentation 4.2 Promoting Intelligent Manufacturing 4.3 Accelerating the Application of “Internet Plus†4.4 Strengthening the Construction of Industry Foundation and Applied Scientific Research Platform 4.5 Development Research Direction 5 Key Development Applications
5.1 Aerospace field 5.2 Defence military sector 5.3 Electronic information field 5.4 Clean energy field 5.5 Automotive manufacturing field 5.6 Household appliance manufacturing field 5.7 Functional applications such as bioengineering 5.8 Advanced tool manufacturing field 5.9 Oil and gas field and mineral exploration and mining field 5.10 Building materials field 6 Industry policy advice
6.1 It is recommended that the state explicitly include superhard materials and products in the national “13th Five-Year Planâ€. 6.2 Implement tax incentives for domestically produced innovative applications and replace imported high-grade super-hard materials. 6.3 Encourage the use of domestic high-end superhard materials 6.3 Improve superhard materials The export tax rebate level of the product 6.4 Increase the support for the construction of the innovation system of the super-hard materials industry Superhard materials industry development plan (finished)
Superhard Materials Industry Development Plan (2016-2020)
Synthetic diamond and cubic boron nitride and composite materials made of these two materials are collectively referred to as superhard materials, and various tools and functional parts made of them are collectively referred to as superhard material products. Superhard materials and products are high-efficiency, high-precision, energy-saving, and environmentally-friendly products. They are not only the hardest materials found by humans, but also have excellent mechanical, thermal, optical, acoustic, electrical and chemical properties. Wang is praised and is an extremely versatile material. Utilizing its unparalleled mechanical properties, it can process all the known materials in the world; with its unparalleled thermo-acoustic electrical properties, it can be used for astronauts to prevent cosmic rays, stealth and anti-corrosion of cutting-edge weapons and improve missile strike accuracy, high-power lasers. It is an irreplaceable and sophisticated field of detection, large-scale integrated circuits and LED new light source heat sinks.
Under the care and support of leaders at all levels in the country, China has been insisting on the development of unique “six-faced†equipment and processes for synthesizing superhard materials with independent intellectual property rights for more than 50 years, which is fundamentally different from the technical methods of developed countries. At present, China's unique equipment and processes have reached the international advanced level. The most powerful and advanced companies in developed countries all purchase Chinese equipment in the same way, and learn from China's unique methods to produce super-hard materials, which is extremely rare in China's entire manufacturing industry and even all industries.
After years of unremitting efforts by scientists and engineers and over 50 years of development, China has already formed a relatively complete and huge industrial system of super-hard materials and products, which has long enjoyed a good reputation in the world. In 2000, China's synthetic diamond production exceeded 1 billion carats (200 tons, diamond measurement unit is carat, 1 carat = 0.2 grams), and became the world's superhard material country. In 2015, China's total output of synthetic diamonds was 15.1 billion carats (equivalent to More than 3,000 tons), accounting for more than 90% of global production, cubic boron nitride production reached 540 million carats (equivalent to 108 tons), accounting for 70% of global production, has become the world's largest production and consumption of superhard materials And exporting countries. The quality of single crystals of super-hard materials is also reaching the world's advanced level, and has the right to speak in the international market. The largest super-hard material products in the market have also reached the world's advanced level, with the highest market share, and are competing with individual developed countries for the right to speak.
Superhard materials and products have been widely used in national defense, aerospace, machinery, electronics, automotive, machine tool, precision manufacturing, medical, clean energy, high-speed railway, highway, stone, building materials, airport, oil and gas drilling, geological exploration , coal and mineral mining, disaster relief, home renovation and other areas of national economy and people's livelihood. It can be said that the cutting-edge technology and the field of national defense, down to the processing industry and people's daily life are inseparable from super-hard materials and products. Leaving them, many high-tech fields are difficult to develop and develop! They have already and will continue to play the role of “four or two†in the entire national economy, and have continued to achieve great social and economic benefits, winning and will continue to win the praise of “big industry in small industriesâ€.
During the “Twelfth Five-Year Plan†period, with the support of national industrial policies, the super-hard materials industry has developed rapidly, the original advantages have been fully promoted, and the international market share has been higher; the innovation capability has been effectively improved, and research and development have been carried out. A large number of high-tech products; most of the scientific research achievements have entered or entered industrial production, filling some domestic gaps, effectively supporting the development of high-tech fields such as national defense, aerospace, electronic information, high-end equipment manufacturing, and clean energy. In these areas, the industry structure and product structure of the industry have been initially improved, shortening the gap between the cutting-edge application of super-hard materials and developed countries. The goal of the “Twelfth Five-Year Plan†was achieved, and the “Twelfth Five-Year Plan†in 2015 achieved a perfect ending.
With the continuous advancement of science and technology, the unique properties of super-hard materials have been continuously developed and applied. Super-hard materials are continuously enriched and upgraded. New tools and functional components made of super-hard materials are emerging one after another, and the application fields are expanding and extending. It has promoted revolutionary changes in related application fields and promoted the development of related application fields. From satellites, missiles, rockets, aircraft, large warships and civilian ships, to large-scale integrated circuits, nuclear power plants, nuclear power reactors, automobiles, and daily building materials, ultra-hard tools can process all the known materials in the world. Improve the processing efficiency and processing quality of various new difficult-to-machine materials, especially as an important part of advanced manufacturing technologies such as high-speed ultra-high speed, precision ultra-precision, numerical control, micro-machining, etc. High-efficiency precision super-hard material tools have become modern industrial green The development of one of the irreplaceable high-end tools has more than one hundred times more leverage for the development of the national economy. For this reason, Western developed countries have even used super-hard materials and products as a strategic reserve material, and their production technology has long imposed an “embargo†on other countries in an attempt to achieve the goal of monopoly.
During the "Twelfth Five-Year Plan" period, although China's super-hard materials industry has made remarkable achievements, some areas have reached the world's advanced level, but there are also common foundations and cutting-edge technology research, and innovation ability is not strong; product segmentation The degree is not enough, the specificity is not strong; some products are still mainly imported products from developed countries, and some high-precision products are difficult to meet the increasing demand of national defense military and many high-tech industries. In order to strive for the country to continue the "Twelfth Five-Year Plan" period and even increase policy support for the industry, continue to maintain and even strengthen the original advantages of the industry, fill the shortcomings of the industry development, and fully catch up with the world's advanced level, so as to achieve super hard as soon as possible The great goal of a material power. Therefore, we must conscientiously do a good job in the development plan of the industry during the "13th Five-Year Plan" period to guide the future development of the industry.
1 Major achievements in the superhard materials industry during the “Twelfth Five-Year Plan†period
The main achievements in the construction of soft power during the “Twelfth Five-Year Plan†period were: with the support of the state and local governments, a number of state-level, provincial-level super-hard materials public service platforms and key laboratories were established, and high-efficiency was established. National and local strategic alliances such as precision abrasive industry technology innovation have improved the ability of technology development, engineering experiment and collaborative innovation; revised and promulgated 31 national and industry technical standards in the field of superhard materials, compared with the "Eleventh Five-Year Plan" It has increased by 121% and played a pivotal role in promoting technological progress, improving product quality, improving social and economic benefits, and developing foreign relations. The super-hard materials industry has obtained 1,398 invention patents granted by China, the United States, European Union countries and Japan. Compared with the “Eleventh Five-Year Planâ€, it has increased by 218%, which has greatly enhanced the visibility of the industry and its competitiveness in the international arena. The international operation of industry enterprises has taken substantial steps. The establishment of international marketing networks, the establishment of factories to set up factories, the establishment of R&D centers in developed countries, and the recruitment of highly skilled individuals from developed countries as development consultants have achieved various forms of international cooperation. Unprecedented results.
During the “Twelfth Five-Year Plan†period, a large number of major achievements in research and development and industrialization with international cutting-edge technologies have been achieved. Representatively, large-scale nano-polycrystalline diamonds have been successfully developed, and gem-quality diamonds have been successfully developed and put into industrial production. The main achievements of each sub-sector of the superhard materials industry are summarized below.
1.1 Innovatively developed a number of new superhard materials that fill the domestic gap and the world's advanced level. Synthetic diamonds have entered the field of jewelry decoration.
The engineered bulk (Ф6×6 mm) diamond nanopolycrystal (NPD) has been successfully developed. Its hardness is 30% higher than that of single crystal diamond, and it is isotropic. It has been put into application test. The initial test shows that its large area application It will lead to revolutionary progress in the field of diamond tools, greatly improve the processing accuracy, efficiency and service life of diamond tools, and solve the problem of processing difficult and difficult materials in the fields of aerospace, defense and military. This kind of product to fill the domestic gap can only be seen in the large-scale engineering report in Japan. In other developed countries, it is a laboratory result of 1-2 mm, which has not reached the engineering application level; the gem-quality diamond large single crystal of 5 mm particle size The industrialization has been realized, and the industrialization of yellow and colorless transparent gem-quality diamond single crystals has been completed and successfully entered the field of jewelry diamonds, making China one of the world's largest producers and sellers of synthetic diamonds, breaking the individual developed countries. The monopoly of the technology has opened up the international market and exported a large amount abroad. This kind of technology that fills the domestic blank can synthesize diamonds with the same chemical composition, color and clarity of natural diamonds, and has spawned the field of professional production and sales of synthetic diamond rings, necklaces and other jewelry products. The terminal sales price of the finished jewelry products is about 50% to 70% of the same level of natural diamonds. The current synthetic colorless diamonds are mostly small drills of 20 points (0.2 carats/piece), and yellow diamonds weigh less than 50 points (0.5 carats/piece). Larger-grained diamonds are being developed in the laboratory, and the laboratory has been able to synthesize samples of carat-class or even larger diamonds. It is advancing toward the field of large-grain diamonds, such as larger jewelry diamonds, defense and other cutting-edge industries.
The chip-shaped diamond single crystal tool material used in strategic emerging industries such as modern communication has broken through the key technologies and realized industrialization. The market product specifications are 3×3×1mm～8×8×(1～2)mm, which has broken the developed countries. The monopoly on the world market including China for more than 20 years has been sold to domestic and foreign markets, which not only strongly supports the application of high-tech fields such as national defense military and electronic information, but also breaks the technological monopoly of products in developed countries and the high-end applications of products to China. Restrictions, and greatly reduce the application cost of other high-tech fields; the above innovations are completed on the domestic six-sided top press with completely independent intellectual property rights, using unique technology independently developed, low cost and high efficiency High quality, filled the domestic gap, reached the international advanced level, improved the product structure of the industry, and opened up a bright new application prospect for diamond.
Micron-sized diamond polycrystalline products are represented by a large number of oil and gas drilling and tool PDC. The drilling PDC has developed deep-drilling and offshore hard-drilling drilling products of 4000 meters and above, and has obtained domestic and foreign customers. The recognition has reached the world's advanced level. At present, the main tasks during the “Thirteenth Five-Year Plan†period are brand promotion, market development, industrial production, promotion and application, and deep development of higher-end products. PCD and PCBN for tools have been recognized in the domestic market for rough machining. PCD and PCBN for finishing have achieved zero breakthrough, that is, success in individual material finishing. At present, the main task during the “Thirteenth Five-Year Plan†period is to strengthen research and development and solve the problem of different materials finishing problems one by one; on the other hand, it is necessary to strengthen brand promotion, market development, industrial production, promotion and application.
During the “Twelfth Five-Year Plan†period, CVD diamonds have achieved relatively rapid development, and basic research and scientific and technological achievements have made great progress. CVD diamond single crystals have achieved a small-scale, large-scale preparation, and nearly 5,000-scale large-size CVD diamond single crystals have achieved technical results. The quality and output of CVD diamond polycrystalline film have also been greatly improved, and the cost advantage is obvious. Some imported products have been replaced in precision cutting tools, dressing tools, wire drawing dies, heat sinks and other applications, and have entered the international market and maintained good. Sustainable development momentum. The level of localization of high-power microwave plasma CVD equipment has been greatly improved, and several companies have begun to provide equipment for domestic users. It can be said that the process of realizing rapid development of China's CVD diamond products and industrialization began in the "Twelfth Five-Year Plan". Although it has developed rapidly in all aspects and has formed an industrial scale, it is lagging behind the international developed level in the types of CVD diamond products and high-end products. It is necessary to continue efforts during the 13th Five-Year Plan period to upgrade China's CVD diamond materials. International status in the field of products.
The six-face press machine produces diamond single crystals to realize networked intelligent group control. One worker controls the press from 6 presses at the end of the “Eleventh Five-Year Plan†to more than 20 sets at the end of the “Twelfth Five-Year Planâ€, especially the gemstones. 40 or more of the single-crystal production, almost to the extent that only the inspection and upper and lower composite blocks are required. The level of automated production has been greatly improved.
1.2 Breaking through many key technologies and promoting the cutting-edge drilling tool technology of some enterprises to reach the world's leading level 1.2.1 Diamond saw blade and thin-walled diamond production process technology and equipment made a major breakthrough
During the “Twelfth Five-Year Plan†period, China’s diamond saw blades and thin-walled drilling technology have made major breakthroughs. R&D, production and market development have achieved extraordinary achievements. All forms of molding, sintering, brazing and laser welding technologies have been broken, especially with independence. Intellectual property, high-tech diamond orderly saw blades and thin-walled drills have been put into mass production, and the production process of saw blades and thin-wall drill bits has been revolutionized. Through a series of technological innovations, most products are discontinuous. The hot pressing sintering is transformed into a tunnel kiln without pressure continuous sintering, which not only eliminates the graphite mold with high pollution and high energy consumption, but also achieves clean and pollution-free production in the workshop, and the production efficiency is increased by 75% to 80%, and the energy consumption is reduced by 80% to 86%. For the future, from the powder to the finished tool head automation, intelligent production, to meet the needs of personalized customized products laid a solid foundation. The domestically produced new laser Welding Machine for saw blades and thin-walled drills has been successfully developed and put into use. Its power has been reduced from 50 kW to 15 kW, energy consumption has been reduced by 70%, and welding speed has also been significantly improved. It can be said that China and the major competitors have no principle differences in technology and products, and have reached the world's advanced level. Some enterprises' technologies and products have reached the world's leading level. In the high-end engineering profession in Europe and America, it has been steadily advanced, not only competing with the world's top products, but also eroding the product market in developed countries. Forcing the developed countries to gradually abandon this type of market and open up new markets. In the world's low-end saw blade market, Chinese companies have further reduced their costs through technological advancement, further consolidating the irreplaceable dominant position of China's products.
1.2.2 The rapid development of diamond wire saw technology has enabled stone mining to enter a new era of energy-saving and material-saving development.
In recent years, domestic wire saw technology has achieved rapid development. The performance of wire saws for domestic stone mining and factory stone cutting is close to the world advanced level. The cost performance is far higher than the world advanced level, and the domestic mining has entered the new energy-saving and material-saving development. At the same time, it has opened up a new situation of strong competition in the international market. In the world where there are Chinese factories selling stone cutting wire saws, stone cutting wire saws from other countries will gradually withdraw from the good situation of the place; domestic steel concrete ropes Saw has reached the threshold of most of the world's requirements, and the price/performance ratio has been accepted. The pattern of Chinese wire saw products and the world famous wire saw products has been formed, and the market share of Chinese wire saw products is gradually expanding. In the field of wire saw group saws, Chinese products are in the trial stage, and the cost performance is similar to that of foreign products. There is still a big gap between absolute performance and foreign products. For special products such as shipwreck salvage, Chinese wire saw products are basically blank.
In order to solve the problem that the diamond wire saw saws the sheet when the sawing is large, the stone yield is low, the resource waste is serious, the sawing process consumes a large amount of energy, the noise is large, the waste residue is discharged, and the environmental pollution is serious, people have been working on reducing Small wire saw diameter. During the "Twelfth Five-Year Plan" period, the diameter of the wire saw was reduced from Ф11.5 mm, Ф11 mm, ... to Ф6 mm, and even a new structure with a completely self-owned intellectual property with a diameter of only 3 mm and 2.0 mm diamond wire saw was used. Cutting of shaped stone and silicon ingot. The results of the ultra-fine diamond wire saw sawing marble test with a diameter of 2.0 mm show that the sawing speed is faster than the diamond wire saw with a diameter of 8.8 mm, and the cutting power consumption is small, the waste residue is less, and the stone cutting yield is increased by 40%. This technology should be the first in the world and has not seen this product abroad.
1.2.3 Diamond wire saws have been successfully developed and put into large-scale production, breaking foreign monopoly and effectively supporting and promoting the development of China's strategic emerging industries.
During the “Twelfth Five-Year Plan†period, China’s diamond wire saws were successfully developed and put into large-scale production, which greatly improved the efficiency of production of silicon wafers and sapphire wafers, improved their quality, saved valuable materials, reduced pollution, and broke the developed countries. The monopoly and blockade of this technology has effectively supported and promoted the development of China's emerging high-tech industries such as photovoltaics, electronic information and LEDs.
Diamond wire saw is the latest product developed internationally in recent years. It is a composite tool made of nickel-diamond composite plating or resin-diamond curing on high carbon steel wire. It is mainly used for silicon materials, sapphire, precision ceramics and glass. High-efficiency, material-saving and environmentally-friendly cutting production of hard and brittle materials such as magnetic materials. When it is used to cut silicon wafers, the silicon consumption is reduced by 10% to 15% compared with conventional steel wire and silicon carbide mortar, and the filming rate is increased by 5% to 7%; the cutting speed is increased from the conventional 500 to 700 m/min. 900~1200 m/min, even on special high-speed cutting machine can reach 1800 m/min, the higher the cutting speed, the better the surface quality of the silicon wafer; the chemical oxygen demand (COD) in the waste liquid produced by traditional mortar cutting is as high as tens Million, and the diamond wire saw cutting waste liquid has only a few thousand COD, and the pollution degree is reduced by 99%, which greatly reduces the subsequent cleaning work of the silicon wafer.
The specifications and uses of the main wire saws that have been successfully developed and put into production during the “Twelfth Five-Year Plan†period are shown in the table below.
1.2.4 Geological Drilling and Diamond Drilling Technology for Oil and Gas Mining Make New Breakthroughs
Geological drilling and diamond drill bits for oil and gas extraction, with the development of drilling engineering to deep, hard rock and complex formations, the requirements for drilling quality and drilling efficiency are higher, and the demand for various high-performance drill bits has also increased significantly. During the “Twelfth Five-Year Plan†period, China has made new breakthroughs in structural design such as bit cutting teeth, crown shape teeth and drill working layer waterways. The cost performance of drill bits has reached the international advanced level and fully meets domestic geological drilling. Requirements, but 4,000-meter deep wells and directional well horizontal wells, offshore hard-to-drill formation oil and gas field mining drill bits still need imported products. Domestically, the diamond geologic drill bit with brazed arrangement has been developed. After drilling into the granite test, the time of the drill is 85.7% higher than that of the ordinary hot-pressed drill bit, and the service life is increased by 11.1%. However, there is a big gap between the material and its process design and computer simulation in developed countries. The design improvement of the carcass material and the establishment of the drilling database are important development routes for the design and manufacture of diamond bits for geological exploration and oil and gas extraction in the future.
1.3 Grinding products technology has made great progress, developed a number of products with international advanced level, and realized the substitution of imported high-end products in many application fields.
As an irreplaceable tool in the field of mechanical precision machining, superhard material abrasive tools have covered high-tech fields such as aerospace, defense and military, and important industries of the national economy such as automobiles, electronic information, household appliances, as well as ships and energy equipment. In important fields such as rail transit, machinery, machine tools, tools, building materials and medical equipment, domestic products basically meet the needs of the national economy and national defense construction and play an increasingly important role. Domestic abrasive tools have made great progress in high-speed ultra-high speed, high efficiency, precision ultra-precision, green processing, etc. For example, the grinding wheel with a grinding speed of 160 m/s has entered the practical application, and the grinding wheel of 200 m/s is also under development. The sapphire substrate LED epitaxial wafer back-thinning and tempered cermet composite bond diamond grinding wheel was successfully developed and put into the market. The service life and processing efficiency index reached or exceeded the level of similar foreign products, filling the domestic gap and breaking the gap. Foreign product technology blockade, replacing imports. The CNC tool opens the main groove grinding wheel with resin/metal composite bonding agent, the cutting depth is 3~4 mm, and the feed speed can reach 100 mm/min. CBN various grinding wheels, grinding discs and other tools have been widely promoted and applied, which not only improves the processing. Efficiency and service life, and reduce the dust pollution in the workshop by several tens of times, greatly improving the processing environment; the successful development of crystal and zircon grinding diamond discs not only greatly reduces the heavy metal pollution caused by the original cerium oxide resin grinding disc, but also The service life has been extended from the previous few days to several months; the high-efficiency cutting of the QuadFlat No-lead Package (Quad Flat No-lead Package), using a 58 mm diameter integral resin ultra-thin cutting wheel, cut into The speed can reach 60~80 mm/min; the 1A1R base type ultra-thin cutting wheel has a symmetry of 0.02 mm, and the thickness of 0.05 mm overall type ultra-thin cutting wheel can also be mass-produced; the engine casing deburring uses electroplated super hard grinding wheel instead of ordinary Resin grinding wheel not only achieves efficient processing, but also eliminates residual dust and dust, greatly improving the processing environment, and so on. In many areas of the domestic market, the substitution of imported high-end products has been realized, and the gap between domestic products and the world's advanced level is gradually narrowing.
1.4 Tool products develop world-leading products
During the “Twelfth Five-Year Plan†period, domestic PCD and PCBN tools broke through the technical bottlenecks of micro-precision machining and welding, which not only reduced the tool cost, but also improved the wear resistance, impact resistance and thermal stability of the tool, and greatly enriched the product. species. Has been widely used in aerospace, automotive, electronic information, metallurgy, mining, engineering machinery and other industries, some products have reached or even surpassed the world's advanced level, and achieved a large batch of exports. LCD glass substrate / panel cut diamond cutter wheel outer diameter 2.0 ~ 4.0 mm, inner diameter 0.8 mm, thickness 0.65 mm, angle 105 ° ~ 145 °, the number of teeth 110 ~ 280, tooth depth 7.0 ~ 15 μm, the product is the highest level in the world , has been industrialized production, not only filled the domestic gap, replaced the import, occupied the domestic market, and opened the international market, bulk export to developed countries; aluminum alloy high-speed, high-light, high stability processing PCD spiral end mill development Successfully, the knife adopts a spiral back angle cutting edge, the cutting is stable, the vibration is not easy to occur, and the surface roughness of the workpiece is good. The application of Foxconn proves that the cutting speed is increased by 5 times, the tool life is increased by 10 times, and the surface quality of the machine is obviously improved.
Superhard Materials Industry Development Plan (II): Development Situation and Environment ( click to read )
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