Quartz has long ceased to be just a piece of jewelry. This mineral forms the backbone of most modern electronic devices. Its unique properties make it possible to create ultra-precise resonators used in smartphones, medical equipment, and even space technology. The production of microchips and other components vital to the digital world would be impossible without quartz.
However, working with quartz has always been a real challenge for engineers. The material combines high hardness with brittleness, which often leads to cracks and chips during drilling. Even a minor error can destroy the part, driving up production costs and reducing product quality.
To address this problem, specialists from Perm Polytechnic University conducted a series of experiments with various types of diamond drills. They compared three methods of securing diamond grains: vacuum sintering, hot pressing, and the electroplating method. All tools were tested under identical conditions—using the same equipment, at a constant rotation speed, and until the cutting layer was completely worn out.
The results showed that drills produced using vacuum sintering technology, although durable, are not suitable for working with brittle materials. Their rigid structure does not absorb impact loads, which leads to the formation of microcracks and rapid tool failure. Hot pressing did not solve the problem either: after the top diamond layer wears off, the tool loses its cutting ability and stops performing effectively.
The most effective method proved to be electroplating. In this process, diamond grains are fixed in a thin layer of nickel, which is applied to a metal base using electrolysis. This design ensures gentle interaction with quartz: the tool does not damage the material but carefully removes its microparticles. As it wears, new sharp edges of the diamonds are exposed, enabling consistently high performance throughout the drill’s lifespan.
Experimental samples created using the electroplating method delivered the best results in terms of drilling depth, hole precision, and minimal defects. Tool operating time increased, while defect rates were almost halved compared to traditional methods. This opens up new opportunities for electronics manufacturers and other industries where high-precision quartz processing is required.
The research was conducted in collaboration with industrial enterprises that have already begun implementing the new technology in their production processes. Experts note that switching to galvanic drills not only improves product quality but also reduces dependence on imported tools. In the long term, this could lower production costs and expand the use of quartz across various industries.
The work of Russian scientists is one of the first comprehensive studies dedicated to optimizing the processing of brittle materials for high-tech industries. The data obtained is already being used to establish new standards and guidelines for choosing tools for drilling quartz. Further development of this technology is expected to increase production efficiency and reliability even more.
