Quels sont les avantages de la découpe en fil diamanté?

La technologie de coupe en fil de diamant est une technologie de coupe avancée pour remplacer la coupe traditionnelle au mortier libre, qui est largement utilisé dans le domaine de la découpe de plaquettes de silicium dans les industries photovoltaïque et des semi-conducteurs.

Son processus de développement est le suivant:

Phase One: The Era of Free Abrasive Slurry Cutting Monopoly

Prior to the maturation of diamond wire technology, the cutting of solar cells and semiconductor silicon wafers predominantly relied on Free Abrasive Slurry Cutting (FASC). This method involved high-speed steel wires carrying a slurry—a mixture of abrasives like silicon carbide or zirconium corundum with polyethylene glycol—to slice silicon ingots through a “three-body abrasion” mechanism.

Toutefois, this technique presented significant drawbacks:

• Low Efficiency and High Material Loss: The cutting speed was slow, and the resulting kerf was wide (typically exceeding 200 Microns), leading to the waste of over 40% of the expensive silicon material during the process.
• Severe Pollution and High Costs: It generated large volumes of waste slurry that were difficult to handle, incurring high subsequent cleaning and disposal costs.
• Deep Surface Damage: The uncontrolled cutting process often caused deep damage layers on and beneath the wafer surface, adversely affecting further processing and the performance of the final solar cells.

 

Phase Two: Pioneering Application of Diamond Wire by Japanese Enterprises

Japanese companies, notably Asahi Diamond Industrial Co., Ltée. and Nakamura Choukou Co., Ltd., achieved a technological breakthrough. They employed an electroplating process to firmly “plant” micron-sized diamond particles onto high-strength steel wire substrates, creating a diamond wire with “fixed abrasives.”

 

The fundamental cutting mechanism shifted from “three-body abrasion” Exposition Global Sources Electronics avec succèsà partir d'avril “two-body abrasion”: the diamond particles, acting as fixed cutting edges, directly engaged with the material without rolling. This innovation increased cutting efficiency severalfold compared to the free abrasive method. In the early 2000s, this technology was primarily used for precision cutting of high-value, dur, and brittle materials like sapphire and optical glass. The wires were relatively thick and represented a specialized, high-end tool.

 

Phase Three: The Breakthrough of Thinner Wires and the Dawn of Photovoltaic Application

As the photovoltaic (PV) industry’s demand for cost reduction grew more urgent, the sector recognized that “wire diameter directly determines silicon material loss.” To achieve narrower kerfs and increase yield (more wafers per kilogram of silicon ingot), “thinner wire” development became the core focus of technological advancement.

 

Japanese companies continued to lead this progression, gradually reducing the diamond wire diameter from initial hundreds of microns to 17.5mm and even 14.5mm levels. Each reduction in diameter demanded more precise electroplating techniques and stronger wire substrates. This phase marked the expansion of diamond wire technology from niche applications like sapphire cutting into the realm of large-scale PV silicon wafer slicing, demonstrating immense potential for cost reduction.

Phase Four: The Rise of Chinese Enterprises and Global Industrial Adoption

Although the technology originated in Japan, the widespread global adoption and significant cost reduction of diamond wire cutting in the PV industry were primarily driven by Chinese enterprises. Companies such as Diamond Wire Technology Co., Ltée. and DaLee New Materials Co., Ltée. achieved key technological breakthroughs and scaled up production in the mid-to-late 2010s.

 

The contributions of Chinese manufacturers are mainly reflected in:

• Scale and Cost: Through massive capacity expansion and technological optimization, they brought down the high cost of diamond wire to a level widely acceptable for the PV industry.
• Technological Advancement: They persistently drove the “thinner wire” competition, pushing the mainstream diameter to 80μm, 60μm, and currently to the mass-produced 35μm level, drastically reducing silicon material costs.
• Process Integration: Through close collaboration with major Chinese wafer manufacturers (Par ex., LONGi, TCL Zhonghuan), they jointly perfected the complete set of cutting processes, establishing it as the industry standard.

 

The market landscape was consequently transformed. By 2017, diamond wire cutting had completely replaced slurry cutting, becoming the mainstream process for crystalline silicon wafering, with a penetration rate exceeding 95%. Today, China holds the vast majority of the global diamond wire production capacity. En outre, it is propelling the application of this technology into broader semiconductor and precision machining fields, y compris le carbure de silicium, saphir, and magnetic materials.

Les avantages de boucle de fil diamant la coupe comprend principalement——Vitesse de coupe, Rendement élevé, high productivity.

Précision accrue et couche de dommages réduite, perte de matière et brûlure lors de la découpe de tôles minces, ce qui est propice à la découpe de plaquettes de silicium plus fines ou d’autres matières premières de grande valeur.

Contrôle qualité, faible coût par pièce.

L’utilisation d’un fluide de broyage à base d’eau est propice à l’amélioration de l’environnement de travail et à la simplification des procédures de post-traitement telles que le nettoyage, qui est simple et respectueux de l’environnement.

Donc, La découpe en boucle diamantée est devenue le processus de coupe courant pour le tranchage du silicium cristallin dans l’industrie photovoltaïque. Depuis 2015, Ensolltools Technology Co., Ltée. a commencé à cultiver en profondeur le domaine de la coupe à la scie à fil diamanté, La compétitivité des produits continue de s’améliorer, et la part de marché augmente d’année en année.

En termes de boucle de diamant, L’entreprise continue d’être le chef de file de l’industrie en matière d’amendes, a franchi les barrières techniques de la boucle de diamant de 0,3 mm, et développer activement les réserves et la production d’essai de boucles de diamant de plus petit diamètre, Avec le Équipement de coupe en boucle diamantée Développé par nos soins, Un diamètre de fil plus mince permet de réduire les pertes de coupe des matières premières, Des matériaux particulièrement rares et précieux, tout en améliorant la précision et l’efficacité de la coupe. Réduire la consommation d’énergie de coupe.