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Material Development

US Synthetic Mining makes the longest lasting and most technically advanced roof-bolting products on the market. US Synthetic Mining offers a proven track record of performance—delivering unmatched durability and toughness from the easiest to the most difficult roof-bolting conditions. US Synthetic Mining manufactures its own polycrystalline diamond (PCD) material and finishes each part to exact specifications to give customers the confidence that their high-performance product will hold up under the most demanding conditions.

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Technology


Advanced Technology


Our ongoing research and development efforts ensure that US Synthetic Mining roof-bolting products are better able to handle the demanding environments found in underground mining operations. From ceramic (diamond) powders to the finishing phase, every possible aspect of roof bolt development is monitored, measured and improved. Because of our commitment to quality, US Synthetic Mining roof-bolting products are simply the best technology available.

Whether you're mining 300 tons or 30,000 tons of coal, your business is likely looking for roof-bolting tools that provide faster penetration, increased production, reduced dust and noise, lower drilling costs, or reduced equipment downtime. And there's no place where these things matter more than the extreme conditions our customers and their equipment work in.

That's why US Synthetic Mining has leveraged more than three decades of experience and know-how in working with the hardest substance known to man-diamond. The unparalleled strength and performance of our ceramic (diamond) roof bolting tools are delivering significant returns to our customers, allowing them to drill faster, increase tonnage, and work longer with parts that keep running, no matter what.

Today, US Synthetic Mining is a leader in developing and producing reliable, performance-ready roof-bolting tools that use polycrystalline diamond that meet the highest standards and match the requirements of the most demanding coal mining operations.

This absolute, no compromises commitment to superior quality and constant innovation sets US Synthetic Mining apart from the competition and makes our roof-bolting tools your best choice for all kinds of diamond solutions.

So, what's our technology advantage? Our products are engineered diamond tough.


Diamond Sintering

The extreme hardness, wear resistance, and thermal conductivity of diamond make it an ideal engineering material. Individual diamond crystals cleave quite easily when struck parallel to certain planes (the process used to facet diamond gemstones takes advantage of these relatively weak planes). As a result, individual diamond crystals do not make good engineering material-unless they are meticulously oriented.

Diamond sintering overcomes the problem of weak planes in diamond gemstones by bonding a mass of small diamond particles onto a larger, coherent structure. Sintered diamond provides greater toughness and durability than single crystals because the individual crystals in a sintered body are randomly oriented. This prevents cracks from propagating along the weak planes where traditional diamond crystals cleave most easily. Sintered diamonds also provide more uniform wear than a single crystal, while maintaining similar thermal conductivity and hardness properties. All of these factors combine to make sintered diamond the preferred material for bearings--especially those that run in abrasive conditions.

At US Synthetic Mining, the sintering process begins with premium saw-grade diamond crystals. These crystals are sintered together at temperatures of approximately 1400°C and pressures of around 60 kbar in the presence of a liquid metal catalyst. Typically, the diamond is bonded to a tungsten carbide substrate during the same high-temperature, high-pressure process. This sintered diamond and tungsten carbide composite is known as a polycrystalline diamond insert. All US Synthetic Mining roof-bolt bits use PCD inserts.

To find out more about US Synthetic Mining products, contact us today.