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CN110799306A - Abrasive article and method of forming the same - Google Patents

Abrasive article and method of forming the same Download PDF

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Publication number
CN110799306A
CN110799306A CN201880022620.1A CN201880022620A CN110799306A CN 110799306 A CN110799306 A CN 110799306A CN 201880022620 A CN201880022620 A CN 201880022620A CN 110799306 A CN110799306 A CN 110799306A
Authority
CN
China
Prior art keywords
microns
bond material
abrasive particles
abrasive
abrasive article
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201880022620.1A
Other languages
Chinese (zh)
Inventor
J·李
K·麦克尼尔
S·拉马纳斯
C·O·梅琴
J·王
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
Original Assignee
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint Gobain Abrasifs SA, Saint Gobain Abrasives Inc filed Critical Saint Gobain Abrasifs SA
Publication of CN110799306A publication Critical patent/CN110799306A/en
Pending legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/06Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • B24D3/10Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for porous or cellular structure, e.g. for use with diamonds as abrasives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/06Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental
    • B24D5/063Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental with segments embedded in a matrix which is rubbed away during the grinding process
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0009Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0072Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/14Zonally-graded wheels; Composite wheels comprising different abrasives
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00Materials not provided for elsewhere
    • C09K3/14Anti-slip materials; Abrasives
    • C09K3/1409Abrasive particles per se
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00Materials not provided for elsewhere
    • C09K3/14Anti-slip materials; Abrasives
    • C09K3/1436Composite particles, e.g. coated particles

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

The present disclosure relates to an abrasive article comprising a body having a bond material comprising a metal and a microporosity within the bond material, wherein the average pore size (D50) is not greater than 10 microns and the standard deviation of pore size is at least 0.2 microns, and wherein the body further comprises abrasive particles contained within the bond material, the abrasive particles having an ovality of not greater than 1.18 and an average toughness of at least 11257 cycles.

Description

Abrasive article and method of forming the same
Technical Field
The present disclosure relates to abrasive articles, particularly bonded abrasive articles including abrasive particles contained in a bond material comprising a metal or metal alloy.
Background
Abrasives used in machining applications typically include bonded abrasive articles and coated abrasive articles. Coated abrasive articles are typically layered articles having a backing and a binder coating for securing the abrasive particles to the backing, with the most common example being sandpaper. Bonded abrasives are comprised of rigid, generally unitary, three-dimensional, abrasive composites in the shape of wheels, discs, segments, mounting points, honing and other tools that may be mounted on a processing device such as a grinding or polishing device.
Bonded abrasives typically have at least two phases including abrasive particles and bond material. Certain bonded abrasive articles may have an additional phase present in the form of porosity. Bonded abrasive tools may be made in various "grades" and "structures" as defined in practice in the art by the relative hardness and density of the abrasive composites (grades), and by the volume percent of abrasive grains, binder, and porosity within the composites (structures).
Some bonded abrasive tools may be particularly useful in abrading and shaping certain types of workpieces, including, for example, metals, ceramics, and crystalline materials used in the electronics and optics industries. In other examples, certain bonded abrasive tools may be used in the formation of superabrasive materials for industrial applications. In the case of abrading and shaping certain workpieces with metal bonded abrasive articles, this process typically requires a significant amount of time and labor to maintain the bonded abrasive article. That is, metal bond abrasive articles typically require periodic dressing and finishing operations to maintain the abrasive capabilities of the abrasive article.
The industry continues to demand improved methods and articles capable of being ground.
Brief description of the drawings
The embodiments are shown by way of example and are not limited by the accompanying figures.
FIG. 1A includes a cross-sectional view of an abrasive article according to an embodiment.
Fig. 1B includes a cross-sectional view of an abrasive particle according to an embodiment.
Fig. 2 includes a Scanning Electron Microscope (SEM) image of a portion of a conventional abrasive article.
Fig. 3 includes an SEM image of a portion of an abrasive article according to an example.
FIG. 4 includes a plot of current versus number of workpieces for the samples described herein.
FIG. 5 includes a plot of current versus number of workpieces for samples described herein.
Fig. 6 includes an SEM image of a portion of sample S5 according to an embodiment.
Fig. 7 includes a run length plot for the samples described herein.
Fig. 8 includes a plot of coolant flow rate versus trim frequency for the samples described herein.
Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.
Detailed Description
The following discussion will focus on specific implementations and examples of the present teachings. This detailed description is provided to aid in the description of certain embodiments and should not be construed to limit the scope or applicability of the disclosure or teachings. It is to be understood that other embodiments may be used based on the present disclosure and teachings.
The terms "consisting of …," "including," "containing," "having," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features but may include other features not expressly listed or inherent to such method, article, or apparatus. In addition, "or" refers to an inclusive "or" rather than an exclusive "or" unless explicitly stated otherwise. For example, any of the following conditions a or B may be satisfied: a is true (or present) and B is false (or not present), a is false (or not present) and B is true (or present), and both a and B are true (or present).
Also, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to provide a general understanding of the scope of the invention. Unless clearly indicated otherwise, such description should be understood to include one, at least one, or the singular also includes the plural, or vice versa. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for more than one item.
The abrasive article may be formed according to the following method. A mixture including abrasive particles is formed in the precursor bond material. The precursor bond material may include a raw material powder comprising a metal, metal alloy, or metal forming material or compound. In one embodiment, the precursor bond material may be a powder material, and may have an average particle size (D50) of no greater than 25 microns, or no greater than 10 microns, or no greater than 1 micron, or no greater than 0.75 microns, or no greater than 0.5 microns, or no greater than 0.25 microns, or no greater than 0.1 microns. However, in one embodiment, the precursor bonding material may have an average particle size of at least 0.001 microns, such as at least 0.01 microns or at least 0.1 microns or even at least 0.5 microns. It will be appreciated that the average particle size of the precursor bond material can be within a range between any minimum and maximum value noted above.
According to one embodiment, the mixture may include a precursor bond material that may be formed from one or more powder metal materials. For example, in one embodiment, the precursor bond material of the bond material forming the body of the abrasive article may comprise cobalt, tin, tungsten, copper, or any combination thereof. In a more specific embodiment, the precursor bonding material may include cobalt, tin, and tungsten.
According to particular embodiments, the precursor bond material may have particular levels of cobalt and tin, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include cobalt (CCo) and tin (CSn) in a ratio [ CCo/CSn ] of no greater than 0.2, where CCo is the weight percent of cobalt based on the entire weight of the precursor bond material and CSn is the weight percent of tin based on the entire weight of the precursor bond material. In other examples, the ratio [ CCo/CSn ] may be no greater than 0.19, such as no greater than 0.18, or no greater than 0.17, or no greater than 0.16, or no greater than 0.15, or no greater than 0.14, or no greater than 0.13, or no greater than 0.12, or no greater than 0.11, or no greater than 0.10, or no greater than 0.09, or no greater than 0.08, or no greater than 0.07, or no greater than 0.06, or no greater than 0.05, or no greater than 0.04, or no greater than 0.03, or no greater than 0.02, or no greater than 0.01. In one non-limiting embodiment, the ratio [ CSn/CCo ] can be at least 0.001, or at least 0.002, or at least 0.003, or at least 0.004, or at least 0.005, or at least 0.006, or at least 0.007, or at least 0.008, or at least 0.009, or at least 0.01, or at least 0.015, or at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1. It will be appreciated that the ratio [ CSn/CCo ] can range between any of the minimum and maximum values recited above.
According to particular embodiments, the precursor bond material may have particular levels of cobalt and tungsten, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include cobalt (CCo) and tungsten (CW) in a ratio [ CW/CCo ] of no greater than 0.9, where CCo is the weight percent of cobalt based on the entire weight of the precursor bond material and CW is the weight percent of tin based on the entire weight of the precursor bond material. In another embodiment, the ratio [ CW/CCo ] may be no greater than 0.8, such as no greater than 0.7, or no greater than 0.6, or no greater than 0.5, or no greater than 0.4, or no greater than 0.3, or no greater than 0.2, or no greater than 0.10, or no greater than 0.09, or no greater than 0.08, or no greater than 0.07, or no greater than 0.06, or no greater than 0.05, or no greater than 0.04, or no greater than 0.03, or no greater than 0.02, or no greater than 0.01. In another embodiment, the ratio [ CW/CCo ] may be at least about 0.001, such as at least 0.002, or at least 0.003, or at least 0.004, or at least 0.005, or at least 0.006, or at least 0.007, or at least 0.008, or at least 0.009, or at least 0.01, or at least 0.015, or at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7. It will be appreciated that the ratio [ CW/CCo ] can range between any of the minimum and maximum values recited above.
According to particular embodiments, the precursor bond material may have particular contents of tungsten and tin, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include tin (CSn) and tungsten (CW) in a ratio [ CSn/CW ] of no greater than 1, where CW is the weight percent of tungsten based on the entire weight of the precursor bond material and CSn is the weight percent of tin based on the entire weight of the precursor bond material. In another embodiment, the ratio [ CSn/CW ] may be not greater than 0.9, such as not greater than 0.8, or not greater than 0.7, or not greater than 0.6, or not greater than 0.5, or not greater than 0.4, or not greater than 0.3, or not greater than 0.2, or not greater than 0.1. In one non-limiting embodiment, the ratio [ CSn/CW ] may be at least 0.01, such as at least 0.02, or at least 0.05, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9. It will be appreciated that the ratio [ CSn/CW ] can range between any of the minimum and maximum values noted above.
The precursor bond material can have a particular content of cobalt, which can help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material may comprise at least 40 wt% cobalt of the total precursor bond material weight, such as at least 50 wt%, or at least 51 wt%, or at least 52 wt%, or at least 53 wt%, or at least 54 wt%, or at least 55 wt%, or at least 56 wt%, or at least 57 wt%, or at least 58 wt%, or at least 59 wt%, or at least 60 wt%, or at least 61 wt%, or at least 62 wt%, or at least 63 wt%, or at least 64 wt%, or at least 65 wt%, or at least 66 wt%, or at least 67 wt%, or at least 68 wt%, or at least 69 wt%, or at least 70 wt%, or at least 71 wt%, or at least 72 wt%, or at least 73 wt%, or at least 74 wt%, or at least 75 wt%, or at least 76 wt%, or at least 77 wt%, or at least 78 wt%, or at least 79 wt%, or at least 70 wt%, or at least 71 wt%, or at least 72 wt%, or at least 73 wt%, or at, Or at least 80 wt%, or at least 81 wt%, or at least 82 wt%, or at least 83 wt%, or at least 84 wt%, or at least 85 wt%, or at least 86 wt%, or at least 87 wt%, or at least 88 wt%, or at least 89 wt%, or at least 90 wt%, or at least 91 wt%, or at least 92 wt%, or at least 93 wt%, or at least 94 wt%, or at least 95 wt% cobalt. In one non-limiting embodiment, the precursor bond material can include no greater than 99wt cobalt of the total precursor bond material weight, such as no greater than 98 wt%, or no greater than 97 wt%, or no greater than 96 wt%, or no greater than 95 wt%, or no greater than 94 wt%, or no greater than 93 wt%, or no greater than 92 wt%, or no greater than 91 wt%, or no greater than 90 wt%, or no greater than 89 wt%, or no greater than 88 wt%, or no greater than 87 wt%, or no greater than 86 wt%, or no greater than 85 wt%, or no greater than 84 wt%, or no greater than 83 wt%, or no greater than 82 wt%, or no greater than 81 wt%, or no greater than 80 wt%, or no greater than 79 wt%, or no greater than 78 wt%, or no greater than 77 wt%, or no greater than 76 wt%, or no greater than 75 wt%, or no greater than 74 wt%, of the total precursor bond material weight, Or not greater than 73 wt%, or not greater than 72 wt%, or not greater than 71 wt%, or not greater than 70 wt%, or not greater than 69 wt%, or not greater than 68 wt%, or not greater than 67 wt%, or not greater than 66 wt%, or not greater than 65 wt% cobalt. It will be appreciated that the amount of cobalt in the precursor bond material can be within a range including any of the minimum and maximum values noted above.
The precursor bond material can have a particular content of tin, which can help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material may include at least 0.1 wt% tin of the total precursor bond material weight, such as at least 0.2 wt%, or at least 0.3 wt%, or at least 0.4 wt%, or at least 0.5 wt%, or at least 0.6 wt%, or at least 0.7 wt%, or at least 0.8 wt%, or at least 0.9 wt%, or at least 1 wt%, or at least 1.1 wt%, or at least 1.2 wt%, or at least 1.3 wt%, or at least 1.4 wt%, or at least 1.5 wt%, or at least 1.6 wt%, or at least 1.7 wt%, or at least 1.8 wt%, or at least 1.9 wt%, or at least 2 wt%, or at least 2.1 wt%, or at least 2.2 wt%, or at least 2.3 wt%, or at least 2.4 wt%, or at least 2.5 wt%, or at least 2.6 wt%, or at least 2.7 wt%, or at least 2.8 wt%, or at least 2.9 wt%, or at least 3 wt%, or at least 3.3 wt%, or at least 1.6 wt% of the total precursor bond material weight, Or at least 3.2 wt%, or at least 3.3 wt%, or at least 3.4 wt%, or at least 3.5 wt%, or at least 3.6 wt%, or at least 3.7 wt%, or at least 3.8 wt%, or at least 3.9 wt%, or at least 4 wt%, or at least 4.1 wt%, or at least 4.2 wt%, or at least 4.3 wt%, or at least 4.4 wt%, or at least 4.5 wt%, or at least 5 wt% tin. In one non-limiting embodiment, the precursor bond material can include not greater than 15 wt% tin for the total precursor bond material weight, such as not greater than 12 wt%, or not greater than 10 wt%, or not greater than 9 wt%, or not greater than 8.5 wt%, or not greater than 8 wt%, or not greater than 7.5 wt%, or not greater than 7 wt%, or not greater than 6.5 wt%, or not greater than 6 wt%, or not greater than 5.5 wt%, or not greater than 5 wt%, or not greater than 4.5 wt%, or not greater than 4 wt%, or not greater than 3.5 wt%, or not greater than 3 wt%, or not greater than 2.5 wt%, or not greater than 2 wt%, or not greater than 1.5 wt%, or not greater than 0.5 wt% tin for the total precursor bond material weight. It will be appreciated that the tin content of the precursor bond material can be within a range including any of the minimum and maximum values noted above.
The precursor bond material can have a particular content of tungsten, which can help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material may comprise at least 1 wt% tungsten of the total precursor bond material weight, such as at least 0.1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 3.4 wt% or at least 4 wt% or at least 3.4 wt% or at least 4 wt% or at least 3.4 wt% or at least 4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 4 wt% 5 wt% less or at least 5.1 wt% or at least 5.2 wt% or at least 5.3 wt% or at least 5.4 wt% or at least 5.5 wt% or at least 5.6 wt% or at least 5.7 wt% or at least 5.8 wt% or at least 5.9 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% less tungsten. However, in at least one non-limiting embodiment, the precursor bond material can include not greater than 20 wt% tungsten for the total precursor bond material weight, such as not greater than 18 wt% or not greater than 16 wt% or not greater than 14 wt% or not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% or not greater than 5 wt% or not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt% tungsten for the total precursor bond material weight. It will be appreciated that the tungsten content of the precursor bond material can be within a range including any of the minimum and maximum values noted above. In at least one embodiment, the precursor bond material is substantially free of tungsten.
The mixture may include a particular content of iron, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material may include at least 0.05 wt% iron for the total weight of the precursor bond material, such as at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 wt% or at least 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% iron for the total weight of the precursor bond material. In another non-limiting embodiment, the precursor bond material can include no greater than 5wt iron, such as no greater than 4wt or no greater than 3wt or no greater than 2wt or no greater than 1.5wt or no greater than 1wt or no greater than 0.9wt or no greater than 0.8wt or no greater than 0.7wt or no greater than 0.6wt or no greater than 0.5wt or no greater than 0.4wt or no greater than 0.3wt, of the total weight of the precursor bond material. It will be appreciated that the iron content of the precursor bond material can be within a range including any of the minimum and maximum values noted above. However, in at least one embodiment, the precursor bond material is substantially free of iron.
The mixture may include a particular content of aluminum, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include not greater than 1 wt% aluminum, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%, of the total weight of the precursor bond material. However, in another non-limiting embodiment, the precursor bond material can include at least 0.001 wt% or at least 0.01 wt% aluminum for the total weight of the precursor bond material. It will be appreciated that the aluminum content of the precursor bond material can be within a range including any of the minimum and maximum values noted above. However, in one embodiment, the precursor bond material is substantially free of aluminum.
The mixture may include a particular amount of copper, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include not greater than 20 wt% copper, such as not greater than 15 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt% of the total weight of the precursor bond material. However, in another non-limiting embodiment, the precursor bond material can include at least 0.001 wt% or at least 0.01 wt% copper for the total weight of the precursor bond material. It will be appreciated that the copper content of the precursor bond material can be within a range including any of the minimum and maximum values noted above. However, in one embodiment, the precursor bond material is substantially free of copper.
The mixture may include a particular content of manganese, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include not greater than 1 wt% manganese, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt% of the total weight of the precursor bond material. However, in another non-limiting embodiment, the precursor bond material can include at least 0.001 wt% or at least 0.01 wt% manganese for the total weight of the precursor bond material. It will be appreciated that the manganese content of the precursor bond material can be within a range including any of the minimum and maximum values noted above. However, in one embodiment, the precursor bond material is substantially free of manganese.
The mixture may include a particular content of titanium, which may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include not greater than 1 wt% titanium for the total weight of the precursor bond material, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt%. However, in another non-limiting embodiment, the precursor bond material can include at least 0.001 wt% or at least 0.01 wt% titanium for the total weight of the precursor bond material. It will be appreciated that the titanium content of the precursor bond material can be within a range including any of the minimum and maximum values noted above. However, in one embodiment, the precursor bond material is substantially free of titanium.
In another embodiment, the precursor bond material may have a particular content of certain metals that may help to improve the formation and/or performance of the abrasive article. For example, the precursor bond material can include not greater than 20 wt% aluminum, copper, manganese, lead, silicon, and titanium (i.e., the total weight percent of the listed elements) for the total weight of the precursor bond material, such as not greater than 15 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt%. However, in one non-limiting embodiment, the precursor bond material can include at least 0.001 wt% or at least 0.01 wt% of aluminum, copper, manganese, lead, silicon, and titanium, based on the total weight of the precursor bond material. It will be appreciated that the aluminum, copper, manganese, lead, silicon, and titanium content of the precursor bond material can be within a range including any of the minimum and maximum values noted above.
In at least one embodiment, the precursor bond material is substantially free of aluminum, copper, manganese, lead, silicon, and/or titanium. As used herein, the term substantially free is intended to include a minimum amount of material limited to impurity levels, including but not necessarily limited to levels no greater than 0.01 wt%. Accordingly, if a component is described as consisting of components X, Y and Z or consisting essentially of components X, Y and Z, the component should be construed as including components X, Y and Z and including only the impurity qualities of the other components or minimal amounts of the other components, that is, the other components do not affect the properties or performance of the component. These statements apply to the description of any embodiment herein.
In another embodiment, the precursor bond material may be formed to include at least 95 wt% cobalt, tin, and tungsten for a total weight of the precursor bond material. Further, in this embodiment, no greater than 5 wt% of the precursor bond material may include a second element selected from the group consisting of aluminum, copper, manganese, lead, silicon, and titanium. In yet another embodiment, the precursor bond material can be formed to include at least 95 wt% cobalt and tin, such as at least 96 wt%, or at least 97 wt%, or at least 98 wt%, or even at least 99 wt% cobalt and tin, for the total weight of the precursor bond material.
The mixture may include one or more other additives, for example, including fillers that may be present in the final abrasive article and aid in improved operation of the abrasive article. Suitable fillers may include fillers known in the art, including, for example, pore formers and the like. Some additives may be included in the mixture and may be consumed or removed during processing. Such additives may be added to the mixture to improve processing of the abrasive article. Some exemplary additives may include compounding agents (e.g., dispersants, surfactants, etc.).
According to one embodiment, the abrasive particles may comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, or any combination thereof. For example, the abrasive particles may comprise a superabrasive material, such as diamond. In one particular example, the abrasive particles may consist essentially of diamond. It is also understood that the abrasive particles may comprise a mixture of abrasive particles that differ from each other based on at least one characteristic selected from the group consisting of: average particle size, average toughness, hardness, ellipticity, composition, or any combination thereof. For example, in one particular embodiment, the abrasive particles may comprise a mixture of two different types of diamond particles including a first type of diamond particles and a second type of diamond-like particles, wherein the first type of diamond particles differs from the second type of diamond particles based on an average particle size, an average toughness, a hardness, ovality, or any combination thereof.
In another aspect, the abrasive particles can have a coating overlying the outer surface. The coating can help improve the formation and performance of the abrasive article. In some cases, the coating may include a material that reduces chemical changes to the abrasive particles (e.g., oxidation of the abrasive particles) during formation. In other cases, the coating may limit the chemical interaction between the abrasive particles and the bond material during formation. The coating may comprise a metal or metal alloy. Some suitable metallic materials may include one or more transition metal elements. In particular embodiments, the coating may include titanium, and may consist essentially of titanium.
The weight and/or thickness of the coating may be varied to facilitate proper processing and/or performance of the abrasive article. Further, the coating may be formed to cover a majority of the outer surface of the abrasive particle, for example at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95% of the outer surface of the abrasive particle.
The abrasive particles may have a particular particle size distribution that helps to improve the performance of the abrasive article. For example, the abrasive particles can have a median particle size (D50) (which may also be referred to herein as an average particle size) of: at least 65 microns, such as at least 75 microns, or at least 90 microns, or at least 95 microns, or at least 97 microns, or at least 100 microns, or at least 105 microns, or at least 110 microns, or at least 120 microns. However, in another non-limiting embodiment, the abrasive particles can have a median particle size (D50) of not greater than 150 microns, or not greater than 140 microns, or not greater than 130 microns, or not greater than 120 microns, or not greater than 110 microns, or not greater than 105 microns, or not greater than 100 microns. It will be appreciated that the abrasive particles can have a median particle size within a range between any minimum and maximum values noted above.
The abrasive particles may also have a particular D10, the D10 may define the maximum particle size of the particles in the lowest 10% of the distribution (i.e., the size of the abrasive particles in 10% of the distribution). For example, the abrasive particles can have a D10 of at least 57 microns, such as at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 77 microns, or at least 80 microns, or at least 83 microns, or at least 85 microns, or at least 87 microns, or at least 90 microns, or at least 93 microns, or at least 95 microns. In one non-limiting embodiment, the abrasive particles have a D10 of no greater than 127 microns, or no greater than 120 microns, or no greater than 110 microns, or no greater than 100 microns, or no greater than 95 microns, or no greater than 93 microns, or no greater than 90 microns, or no greater than 87 microns, greater than 85 microns, or no greater than 83 microns, or no greater than 80 microns. It will be appreciated that the abrasive particles can have a D10 within a range between any of the minimum and maximum values noted above.
The abrasive particles may also have a particular D90, the D90 may define the smallest particle size of the particles in the highest 10% of the distribution (i.e., the particle size of the abrasive particles in 90% of the distribution). For example, the abrasive particles may have a D90 of at least 97 microns, such as at least 100 microns, or at least 103 microns, or at least 105 microns, or at least 108 microns, or at least 110 microns, or at least 113 microns, or at least 115 microns, or at least 118 microns, or at least 120 microns, or at least 123 microns, or at least 125 microns, or at least 128 microns, or at least 130 microns, or at least 133 microns, or at least 135 microns, or at least 138 microns. In another non-limiting embodiment, the abrasive particles can have a D90 of not greater than 165 microns, such as not greater than 160 microns, or not greater than 155 microns, or not greater than 150 microns, or not greater than 145 microns, or not greater than 140 microns, or not greater than 135 microns, or not greater than 133 microns, or not greater than 130 microns, or not greater than 128 microns, or not greater than 125 microns, or not greater than 123 microns, or not greater than 120 microns, or not greater than 118 microns, or not greater than 115 microns, or not greater than 113 microns, or not greater than 110 microns, or not greater than 108 microns, or not greater than 105 microns. It will be appreciated that the substrate 20 can have a thickness within a range between any of the minimum and maximum values noted above.
The abrasive particles may also define a particle size distribution of greater than 120 microns with special limitations. For example, in one example, the abrasive particles define a particle size distribution in which abrasive particles having a particle size of greater than 120 microns make up no greater than 10col of the total volume of the abrasive particles, e.g., in which abrasive particles having a particle size of greater than 120 microns make up no greater than 9 vol%, or no greater than 8 vol%, or no greater than 7 vol%, or no greater than 6 vol%, or no greater than 5 vol%, or no greater than 4 vol%, or no greater than 3 vol%, or no greater than 2 vol%, or no greater than 1.8 vol%, or no greater than 1.5 vol% of the total volume of the abrasive particles. However, in at least one example, the abrasive particles having a particle size greater than 120 microns in the particle size distribution are present in an amount of at least 0.1 vol% or at least 0.5 vol% or even at least 0.8 vol% of the total volume of abrasive particles. It is to be understood that the content of abrasive particles having a particle size greater than 120 microns in the particle size distribution can be within a range including any of the minimum and maximum percentages noted above with respect to the total volume of abrasive particles.
The abrasive particles may have a particular vickers hardness, which may help to improve the performance of the abrasive article. For example, the abrasive particles have a Vickers hardness of at least 2000kg/mm2Or at least 3000kg/mm2Or at least 4000kg/mm2Or at least 5000kg/mm2. In another non-limiting embodiment, the abrasive particles have a Vickers hardness of no greater than 12,000kg/mm2. It will be appreciated that the vickers hardness of the abrasive particles can be within a range including any of the minimum and maximum values noted above.
According to another aspect, the abrasive particles can have a particular average toughness that contributes to improved performance of the abrasive article. The toughness of abrasive particles obtained from commercial suppliers was measured under ambient conditions according to ANSIB74.23 without machining or treatment, such as heating, of the abrasive particles prior to measurement. As used herein, average toughness is understood to be an average calculated based on toughness test data that varies by less than or equal to 5%. For example, the abrasive particles may have an average toughness of 11257 cycles, which may include variations up to ± 563. In another embodiment, the average toughness may be at least 11850 cycles or at least 11900 cycles or at least 12000 cycles or at least 12100 cycles or at least 12200 cycles or at least 12300 cycles or at least 12400 cycles or at least 12500 cycles or at least 12600 cycles or at least 12700 cycles or at least 12800 cycles or at least 12900 cycles or at least 13000 cycles or at least 13100 cycles or at least 13200 cycles. In another non-limiting embodiment, the abrasive particles have an average toughness of no greater than 16000 cycles or no greater than 15000 cycles or no greater than 14500 cycles or no greater than 14000 cycles or no greater than 13900 cycles or no greater than 13800 cycles or no greater than 13700 cycles or no greater than 13600 cycles or no greater than 13500 cycles or no greater than 13400 cycles or no greater than 13300 cycles. It will be appreciated that the average toughness of the abrasive particles can be within a range including any of the minimum and maximum values noted above.
In another aspect, the abrasive particles can have a particular shape, as measured by ellipticity, which can help to improve the performance of the abrasive particles. For example, the ovality of the abrasive particles is not greater than 1.18, such as not greater than 1.17 or not greater than 1.16 or not greater than 1.15 or not greater than 1.14 or not greater than 1.13 or not greater than 1.12 or not greater than 1.11 or not greater than 1.10. However, in one non-limiting embodiment, the abrasive particles can have an ellipticity of at least 1.01 or at least 1.02 or at least 1.03 or at least 1.04 or at least 1.05 or at least 1.06 or at least 1.07 or at least 1.08 or at least 1.09 or at least 1.10 or at least 1.11 or at least 1.12 or at least 1.13 or at least 1.14 or at least 1.15 or at least 1.16. It will be appreciated that the ovality of the abrasive particles can be within a range including any of the minimum and maximum values noted above.
Ellipticity is measured by image analysis of an appropriate number of randomly sampled particles. A random sample of at least 2000 discrete abrasive particles was obtained and placed on the bonding side of the tape. Care should be taken to distribute the particles evenly over the tape to avoid agglomeration of the particles. The tape may be attached to a glass slide or other surface that facilitates imaging of particles contained on the tape. The diamonds were scanned on glass slide tape using a Pro scanner 7200 commercially available from Reflecta, GmbH. Multiple scans may be required until the scanner generates a sharp image of each of the particles. Images were analyzed using the diascape software. Care should be taken to ensure that the number of particles identified by the software is the same as the number of particles originally sampled. The biashape software calculates the ellipticity of each particle and then calculates the average ellipticity of the particle samples.
The mixture can be formed to include a particular content of the abrasive particles, which can facilitate the formation and performance of the abrasive article. For example, in one example, the mixture can include at least 2 wt% abrasive particles for the total weight of the mixture, or at least 2.5 wt% or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt% abrasive particles for the total weight of the mixture. In one non-limiting embodiment, the mixture can include not greater than 10 wt% abrasive particles for the total weight of the mixture, for example not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 wt% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater than 5.5 wt% or not greater than 5 wt% or not greater than 4.5 wt% or not greater than 4 wt% or not greater than 3.5 wt% or not greater than 3 wt% or not greater than 2.5 wt% or not greater than 1.5 wt% or not greater than 1 wt% abrasive particles for the total weight of the mixture. It will be appreciated that the mixture can include an amount of abrasive particles within a range including any of the minimum and maximum values noted above.
The mixture can be formed to include a particular content of the bond material or precursor bond material that can facilitate the formation and performance of the abrasive article. For example, in one example, the mixture may include at least 20 wt% of the total mass of the mixture of the binder material or precursor binder material, such as at least 25 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt% or at least 95 wt% of the total mass of the mixture of the binder material or precursor binder material. In one non-limiting embodiment, the mixture can include no greater than 99 wt% of the total mass of the mixture of the binder material or precursor binder material, for example no greater than 95 wt% or no greater than 90 wt% or no greater than 80 wt% or no greater than 70 wt% or no greater than 60 wt% or no greater than 50 wt% or no greater than 40 wt% or no greater than 30 wt% or no greater than 25 wt% of the total mass of the mixture of the binder material or precursor binder material. It will be appreciated that the mixture can include a binder material or precursor binder material in an amount within a range including any of the minimum and maximum values noted above. It is also understood that the binder material or precursor binder material may be the total content of raw material powder particles to be used for the binder material.
After the mixture is created to combine the desired components, the mixture may be molded into a green body. Some suitable processes for forming the green body from the mixture may include shaping, pressing, casting, punching, cutting, printing, spraying, depositing, or any combination thereof.
During or after forming the green body, the body may be processed to form the final formed abrasive article. Some suitable treatments may include drying, curing, heating, sintering, or any combination thereof. In at least one embodiment, the mixture is placed in a mold and an appropriate pressure and temperature are applied to facilitate formation of the finally-formed abrasive article.
According to one embodiment, the process of forming the abrasive article may include heating the mixture to form the body of the finally-formed abrasive article. Heating may be performed at a specific temperature to ensure proper formation of microstructures that contribute to improved performance. For example, the temperature at which the mixture is heated may be at least 700 ℃ or at least 725 ℃ or at least 750 ℃ or at least 775 ℃ or at least 800 ℃ or at least 825 ℃ or at least 850 ℃ or at least 875 ℃ or at least 900 ℃ or at least 925 ℃ or at least 950 ℃ or at least 975 ℃ or at least 1000 ℃. However, in one non-limiting embodiment, the heating of the mixture can be conducted at a temperature of no greater than 1100 ℃, or no greater than 1050 ℃, or no greater than 1000 ℃, or no greater than 975 ℃, or no greater than 950 ℃, or no greater than 925 ℃, or no greater than 900 ℃. It will be appreciated that the heating can be accomplished at a temperature within a range including any of the minimum and maximum values noted above. The heating temperature may be the maximum temperature at which the mixture is sintered to facilitate formation of the abrasive article. The heating temperature may also be a maximum temperature consistent with a maximum pressure applied to the mixture, in which case a combination of heat and pressure is applied to the mixture to facilitate formation of the abrasive article.
According to one embodiment, the process for forming the body of the finally-formed abrasive article may include hot pressing the mixture, wherein a combination of pressure and temperature is applied to the mixture to facilitate the forming. In one embodiment, the hot pressing operation may be performed at a temperature within any of the temperature ranges described above. In one embodiment, the process for forming the body may include hot pressing the mixture at a pressure of at least 1000psi, such as at least 1500psi or at least 2000psi or at least 2200 psi. In another non-limiting embodiment, the hot pressing can be performed at a pressure of no greater than 5000psi, such as no greater than 4000psi, or no greater than 3000psi, or no greater than 2750 psi. It will be appreciated that the pressure can range between any of the minimum and maximum values recited above. The pressure may be the maximum pressure exerted on the mixture during forming. The pressure may also be a maximum pressure corresponding to the highest temperature applied to the mixture during forming. The hot pressing may be unidirectional or isostatic pressing.
The resulting abrasive article may be a bonded abrasive body comprising a three-dimensional bond of a bonding material defining a matrix of material as a continuous phase and including abrasive particles therein. In some cases, the body of the abrasive article may include some phase or porosity.
According to one embodiment, the body may have a particular porosity content that helps to improve the performance of the abrasive particles. For example, the body can include a porosity content of at least 0.5 vol% of the total volume of the body, such as at least 1 vol% or at least 1.5 vol% or at least 2 vol% or at least 2.5 vol% or at least 3 vol% or at least 3.5 vol% or at least 4 vol% or at least 4.5 vol% or at least 5 vol% or at least 5.5 vol% or at least 6 vol% or at least 7 vol% or at least 8 vol% or at least 9 vol% or at least 10 vol%. In one non-limiting embodiment, the porosity content in the body is not greater than 50 vol% or not greater than 30 vol% or not greater than 20 vol% or not greater than 15 wt% or not greater than 12 wt% or not greater than 10 vol% or not greater than 9 vol% or not greater than 8 vol% or not greater than 7 vol% or not greater than 6 vol% or not greater than 5 vol% or not greater than 4 vol% or not greater than 3 vol% or not greater than 2 vol% or not greater than 1 vol% for the total volume of the body. It will be appreciated that the porosity content of the body may be within a range including any of the minimum and maximum values mentioned above.
The body of the abrasive article may be formed to include a particular content of the abrasive particles, which may facilitate an improvement in the performance of the abrasive article. For example, in one example, the body comprises at least 2 wt% abrasive particles, or at least 2.5 wt% or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt% of the total mass of the body. In one non-limiting embodiment, the body can include not greater than 10wt abrasive particles for the total weight of the body, for example not greater than 9wt, or not greater than 8.5wt, or not greater than 8wt, or not greater than 7.5wt, or not greater than 7wt, or not greater than 6.5wt, or not greater than 6wt, or not greater than 5.5wt, or not greater than 5wt, or not greater than 4.5wt, or not greater than 3.5wt, or not greater than 3wt, or not greater than 2.5wt, or not greater than 1.5wt, or not greater than 1wt for the total mass of the body. It will be appreciated that the abrasive particle content of the body can be within a range including any of the minimum and maximum values noted above.
The body may be formed with a specific content of the bond material, which may help to improve the performance of the abrasive article. For example, in one example, the body may comprise at least 20 wt% of the bonding material or materials for the total weight of the body, such as at least 25 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt% or at least 95 wt% of the total weight of the body. In one non-limiting embodiment, the body can include no greater than 99 wt% of the bond material for the total weight of the body, such as no greater than 95 wt% or no greater than 90 wt% or no greater than 80 wt% or no greater than 70 wt% or no greater than 60 wt% or no greater than 50 wt% or no greater than 40 wt% or no greater than 30 wt% or no greater than 25 wt% for the total weight of the body. It should be understood that the body can include a bonding material content within a range including any of the minimum and maximum values noted above.
The abrasive particles contained in the body can have any of the characteristics described in the examples herein with respect to the abrasive particles contained in the mixture used to form the abrasive article. Notably, the abrasive particles of the finally-formed abrasive article can have the same characteristics as the compositions, coatings, coating compositions, coating levels, particle size distributions (i.e., D10, D50, D90, and volume percentages greater than 120 microns), vickers hardness, average toughness, and/or ellipticity described herein.
The bond material contained in the body may have any of the characteristics described in the examples herein with respect to the bond material or precursor bond material contained in the mixture used to form the abrasive article. According to particular embodiments, the bond material may have particular levels of cobalt and tin, which may help to improve the performance of the abrasive article. For example, the precursor bond material may include cobalt (CCo) and tin (CSn) in a ratio [ CCo/CSn ] of no greater than 0.2, where CCo is the weight percent of cobalt in the entire weight of the precursor bond material and CSn is the weight percent of tin in the entire weight of the precursor bond material. In other examples, the ratio [ CCo/CSn ] may be no greater than 0.19, such as no greater than 0.18, or no greater than 0.17, or no greater than 0.16, or no greater than 0.15, or no greater than 0.14, or no greater than 0.13, or no greater than 0.12, or no greater than 0.11, or no greater than 0.10, or no greater than 0.09, or no greater than 0.08, or no greater than 0.07, or no greater than 0.06, or no greater than 0.05, or no greater than 0.04, or no greater than 0.03, or no greater than 0.02, or no greater than 0.01. In one non-limiting embodiment, the ratio [ CSn/CCo ] can be at least 0.001, or at least 0.002, or at least 0.003, or at least 0.004, or at least 0.005, or at least 0.006, or at least 0.007, or at least 0.008, or at least 0.009, or at least 0.01, or at least 0.015, or at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1. It will be appreciated that the ratio [ CSn/CCo ] can range between any of the minimum and maximum values recited above.
According to particular embodiments, the bond material may have particular levels of cobalt and tungsten, which may help to improve the formation and/or performance of the abrasive article. For example, the bond material may include cobalt (CCo) and tungsten (CW), with a ratio [ CW/CCo ] of no greater than 0.9, where CCo is the weight percent of cobalt in the entire weight of the bond material and CW is the weight percent of tungsten in the entire weight of the bond material. In another embodiment, the ratio [ CW/CCo ] may be no greater than 0.8, such as no greater than 0.7, or no greater than 0.6, or no greater than 0.5, or no greater than 0.4, or no greater than 0.3, or no greater than 0.2, or no greater than 0.10, or no greater than 0.09, or no greater than 0.08, or no greater than 0.07, or no greater than 0.06, or no greater than 0.05, or no greater than 0.04, or no greater than 0.03, or no greater than 0.02, or no greater than 0.01. In another embodiment, the ratio [ CW/CCo ] may be at least about 0.001, such as at least 0.002, or at least 0.003, or at least 0.004, or at least 0.005, or at least 0.006, or at least 0.007, or at least 0.008, or at least 0.009, or at least 0.01, or at least 0.015, or at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7. It will be appreciated that the ratio [ CW/CCo ] can range between any of the minimum and maximum values recited above.
According to particular embodiments, the bond material may have particular contents of tungsten and tin, which may help to improve the formation and/or performance of the abrasive article. For example, the bond material can include tin (CSn) and tungsten (CW) in a ratio [ CSn/CW ] of no greater than 1, where CW is the weight percent of tungsten in the entire weight of the bond material and CSn is the weight percent of tin in the entire weight of the bond material. In one embodiment, the average pore size may be no greater than 0.9 microns, such as no greater than 0.8 microns, no greater than 0.7 microns, no greater than 0.6 microns, no greater than 0.5 microns, no greater than 0.4 microns, no greater than 0.3 microns, no greater than 0.2 microns, or no greater than 0.1 microns. In one non-limiting embodiment, the ratio [ CSn/CW ] may be at least 0.01, such as at least 0.02, or at least 0.05, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9. It will be appreciated that the ratio [ CSn/CW ] can range between any of the minimum and maximum values noted above.
The bond material may have a particular content of cobalt, which may help to improve the performance of the abrasive article. For example, the binder material may comprise at least 40 wt% cobalt of the total weight of the binder material, such as at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least 54 wt% or at least 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt% or at least 72 wt% or at least 73 wt% or at least 74 wt% or at least 75 wt% or at least 76 wt% or at least 77 wt% or at least 78 wt% or at least 79 wt% or at least 80 wt% or at least 81 wt% or at least 82 wt% or at least 83 wt% or at least 84 wt% or at least 85 wt% or at least 86 wt% or at least 87 wt% or at least 88 wt% or at least 90 wt% to at least 90 wt% of the total weight of the 91 wt% less or at least 92 wt% or at least 93 wt% or at least 94 wt% or at least 95 wt% less cobalt. In one non-limiting embodiment, the bond material can include no greater than 99wt cobalt for the total weight of the bond material, such as no greater than 98wt or no greater than 97wt or no greater than 96wt or no greater than 95wt or no greater than 94wt or no greater than 93wt or no greater than 92wt or no greater than 91wt or no greater than 90wt or no greater than 89wt or no greater than 88wt or no greater than 87wt or no greater than 86wt or no greater than 85wt or no greater than 84wt or no greater than 83wt or no greater than 82wt or no greater than 81wt or no greater than 80wt or no greater than 79wt or no greater than 78wt or no greater than 77wt or no greater than 76wt or no greater than 75wt or no greater than 74wt or no greater than 73wt or no greater than 72wt or no greater than 71wt or no greater than 70wt or no greater than 69wt or no greater than 68wt or no greater than 67wt or no greater than 66wt or no greater than 65wt for the total weight of the bond material Of (3) cobalt. It will be appreciated that the cobalt content of the bond material can be within a range including any of the minimum and maximum values noted above.
The bond material of the finally-formed abrasive article has a particular content of tin, which can help to improve the performance of the abrasive article. For example, the bonding material may comprise at least 0.1 wt% tin for the total weight of the bonding material, such as at least 0.2 wt% or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 2.3 wt% or at least 3 wt% or at least 3.3 wt% or at least 3 wt% or at least 3.4 wt% or at least 3 wt% or at least 3.3 wt% or at least 3 wt% or at least 3.7 wt% or at least 3 wt% Less than 4.3 wt% or at least 4.4 wt% or at least 4.5 wt% or at least 5 wt% tin. In one non-limiting embodiment, the bond material can include not greater than 15 wt% tin for the total weight of the bond material, such as not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 wt% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater than 5.5 wt% or not greater than 5 wt% or not greater than 4.5 wt% or not greater than 4 wt% or not greater than 3.5 wt% or not greater than 3 wt% or not greater than 2.5 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 0.5 wt% tin for the total weight of the bond material. It will be appreciated that the tin content of the bond material can be within a range including any of the minimum and maximum values noted above.
The bond material of the finally-formed abrasive article has a particular content of tungsten, which can help to improve the performance of the abrasive article. For example, the binder material may comprise at least 1 wt% of tungsten for the total weight of the binder material, such as at least 0.1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 3.1 wt% or at least 3.4 wt% or at least 4 wt% or at least 4.5 wt% or at least 3.6 wt% or 4 wt% or at least 4 wt% or 4.7 wt% or 4 wt% or at least 5.1 wt% less or at least 5.2 wt% or at least 5.3 wt% or at least 5.4 wt% or at least 5.5 wt% or at least 5.6 wt% or at least 5.7 wt% or at least 5.8 wt% or at least 5.9 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8.5 wt% or at least 9 wt% less tungsten. However, in at least one non-limiting embodiment, the bond material can include not greater than 20wt tungsten for the total weight of the bond material, such as not greater than 18wt, or not greater than 16wt, or not greater than 14wt, or not greater than 12wt, or not greater than 10wt, or not greater than 9wt, or not greater than 8wt, or not greater than 7wt, or not greater than 6wt, or not greater than 5wt, or not greater than 4wt, or not greater than 3wt, or not greater than 2wt, or not greater than 1.5wt tungsten for the total weight of the bond material. It will be appreciated that the tungsten content of the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material is substantially free of tungsten.
The bond material of the finally-formed abrasive article has a particular content of iron, which can help to improve the performance of the abrasive article. For example, the binder material may comprise at least 0.05 wt% iron for the total weight of the binder material, such as at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 wt% or at least 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% iron for the total weight of the binder material. In another non-limiting embodiment, the bond material can include no greater than 5wt iron, such as no greater than 4wt or no greater than 3wt or no greater than 2wt or no greater than 1.5wt or no greater than 1wt or no greater than 0.9wt or no greater than 0.8wt or no greater than 0.7wt or no greater than 0.6wt or no greater than 0.5wt or no greater than 0.4wt or no greater than 0.3wt, of the total weight of the bond material. It will be appreciated that the iron content of the bond material can be within a range including any of the minimum and maximum values noted above.
The bond material of the finally-formed abrasive article has a particular content of aluminum, which can help to improve the performance of the abrasive article. For example, the bond material can include not greater than 1 wt% aluminum, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%, of the total weight of the bond material. However, in another non-limiting embodiment, the bond material can include at least 0.001 wt% or at least 0.01 wt% aluminum for the total weight of the bond material. It will be appreciated that the aluminum content of the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material is substantially free of aluminum.
The bond material of the finally-formed abrasive has a specific content of copper, which can help to improve the performance of the abrasive article. For example, the bond material can include no greater than 20 wt% copper, such as no greater than 15 wt% or no greater than 10 wt% or no greater than 5 wt% or no greater than 2 wt% or no greater than 1 wt% or no greater than 0.9 wt% or no greater than 0.8 wt% or no greater than 0.7 wt% or no greater than 0.6 wt% or no greater than 0.5 wt% or no greater than 0.4 wt% or no greater than 0.3 wt% or no greater than 0.2 wt% or no greater than 0.1 wt% or no greater than 0.09 wt% or no greater than 0.05 wt% or no greater than 0.01 wt% of the total weight of the bond material. However, in another non-limiting embodiment, the bond material can include at least 0.001 wt% or at least 0.01 wt% copper for the total weight of the bond material. It will be appreciated that the copper content of the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material is substantially free of copper.
The bond material of the finally-formed abrasive has a particular content of manganese, which can help to improve the performance of the abrasive article. For example, the bond material can include not greater than 1 wt% manganese, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt% of the total weight of the bond material. However, in another non-limiting embodiment, the bond material can include at least 0.001 wt% or at least 0.01 wt% manganese for the total weight of the bond material. It will be appreciated that the manganese content of the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material is substantially free of manganese.
The bond material of the finally-formed abrasive has a certain content of titanium, which can help to improve the performance of the abrasive article. For example, the bond material can include no greater than 1wt titanium, such as no greater than 0.9wt or no greater than 0.8wt or no greater than 0.7wt or no greater than 0.6wt or no greater than 0.5wt or no greater than 0.4wt or no greater than 0.3wt or no greater than 0.2wt or no greater than 0.1wt or no greater than 0.09wt, based on the total weight of the bond material. However, in another non-limiting embodiment, the bond material can include at least 0.001 wt% or at least 0.01 wt% titanium for the total weight of the bond material. It will be appreciated that the titanium content of the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material is substantially free of titanium.
In another embodiment, the bond material of the finally-formed abrasive has a particular content of certain metals, which can help to improve the performance of the abrasive article. For example, the bond material can include not greater than 20 wt% aluminum, copper, manganese, lead, silicon, and titanium (i.e., the total weight percent of the listed elements) for the total weight of the bond material, such as not greater than 15 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt%. However, in one non-limiting embodiment, the bond material can include at least 0.001 wt% or at least 0.01 wt% aluminum, copper, manganese, lead, silicon, and titanium, based on the total weight of the bond material. It will be appreciated that the aluminum, copper, manganese, lead, silicon, and titanium content of the bond material can be within a range including any of the minimum and maximum values noted above. In at least one embodiment, the bond material is substantially free of aluminum, copper, manganese, lead, silicon, and/or titanium.
According to another aspect, the bond material of the finally-formed abrasive can be formed to include at least 95 wt% cobalt, tin, and tungsten. Further, in this embodiment, no greater than 5 wt% of the bond material may include a second element selected from the group consisting of aluminum, copper, manganese, lead, silicon, and titanium. In yet another embodiment, the bond material may be formed to include at least 95wt cobalt and tin for a total weight of the bond material, such as at least 96wt or at least 97wt or at least 98wt or even at least 99wt cobalt and tin.
The resulting abrasive article body may have a particular microstructure that contributes to improved performance. For example, the body can have a microporosity that includes discrete porosities in the form of isolated porosities contained in the bond material. The microporosity consists essentially of discontinuous porosity. The entire body can include microporosity, and in some cases, the body can include only microporosity having the features described herein. That is, in one embodiment, all of the porosity of the body is microporosity having the characteristics described herein.
In at least one aspect, the microporosity can have a particular pore size distribution that can help improve the performance of the abrasive article. For example, the microporosity can have an average pore size (D50) of at least 0.01 microns or at least 0.05 microns or at least 0.1 microns or at least 0.2 microns or at least 0.25 microns or at least 0.3 microns or at least 0.35 microns or at least 0.4 microns or at least 0.45 microns or at least 0.5 microns. However, in one non-limiting embodiment, the average pore size (D50) of the microporosity is not greater than 9 microns or not greater than 8 microns or not greater than 7 microns or not greater than 6 microns or not greater than 5 microns or not greater than 4 microns or not greater than 3 microns or not greater than 2 microns or not greater than 1 micron or not greater than 0.9 microns or not greater than 0.8 microns or not greater than 0.7 microns or not greater than 0.6 microns or not greater than 0.5 microns. It will be appreciated that the average pore size of microporosity within the bulk (D50) can be within a range between any of the minimum and maximum values noted above.
The microporosity can also have a specific standard deviation, a first standard deviation of the porosity distribution in the body calculated from the porosity distribution measured from an image obtained from a sample of the finally-formed abrasive article. A final shaped sample of the abrasive article was obtained and four cubic samples 0.3 inches in size per side were removed from the abrasive article. These samples were taken from random locations on the abrasive article. The cube samples were mounted in epoxy and polished to reveal the surface of the abrasive for image analysis. For each cubic sample, using a scanning electron microscope in backscatter mode (10kV), a portion of the sample having an area of at least 50x40 micrometers was identified, the portion not including abrasive particles. Multiple images representing the region are obtained and then further analyzed using suitable imaging processing software (e.g., ImageJ) to create a binary image representing the region. The imaging software is used for identifying the amount and the size of the porosity and drawing a porosity size distribution map. The mean pore size and the standard deviation of pore size were calculated from the pore size distribution map.
In one embodiment, the microporosity can have a pore size standard deviation of at least 0.2 microns, such as at least 0.22 microns or at least 0.24 microns or at least 0.26 microns or at least 0.28 microns or at least 0.3 microns or at least 0.32 microns or at least 0.34 microns or at least 0.36 microns or at least 0.38 microns or at least 0.4 microns or at least 0.42 microns or at least 0.44 microns. In one non-limiting embodiment, the pore size standard deviation of the microporosity is no greater than 2 microns, such as no greater than 1.8 microns or no greater than 1.6 microns or no greater than 1.4 microns or no greater than 1.2 microns or no greater than 1 micron or no greater than 0.8 microns or no greater than 0.6 microns or no greater than 0.5 microns. It will be appreciated that the standard deviation of pore size for the microporosity can be within a range between any of the minimum and maximum values noted above.
The abrasive particles may have a particular particle size distribution that helps to improve the performance of the abrasive article. For example, the abrasive particles can have a median particle size (D50) (which may also be referred to herein as an average particle size) of: at least 65 microns, such as at least 75 microns or at least 90 microns or at least 95 microns or at least 97 microns or at least 100 microns or at least 105 microns or at least 110 microns or at least 120 microns. However, in another non-limiting embodiment, the abrasive particles can have a median particle size (D50) of not greater than 150 microns, or not greater than 140 microns, or not greater than 130 microns, or not greater than 120 microns, or not greater than 110 microns, or not greater than 105 microns, or not greater than 100 microns. It will be appreciated that the abrasive particles can have a median particle size within a range between any minimum and maximum values noted above.
As described in other embodiments herein, the abrasive particles of the abrasive article may also have a particular D10 corresponding to any D10 value of the abrasive particles in the mixture used to form the abrasive article. Further, the abrasive particles in the abrasive body can have a D90 corresponding to any D90 value for the abrasive particles included in the mixture used to form the abrasive article.
FIG. 1A includes a cross-sectional view of an abrasive article according to an embodiment. The abrasive article 100 formed by the above-described method includes a core 101 and abrasive bodies 103 disposed on a peripheral surface of the core 101. In one particular example, as shown in FIG. 1A: the abrasive body 103 may be disposed within an internal recess of the outer peripheral surface of the core 101. Core 101 may also include an opening 107, which may be configured to engage a mandrel and facilitate rotation of abrasive article 100.
As shown in the embodiment of fig. 1A. The abrasive body 103 can include a contoured surface 105, which can have a particular shape suitable for abrading the edge of a workpiece. While the contoured surface 105 of fig. 1A generally has either a U-shaped contour or a concave contour, other shapes may be used, including but not limited to a planar contour, a V-shaped contour, and the like.
The core 101 may comprise a variety of materials including, but not limited to, inorganic materials (e.g., metals, metal alloys, ceramics, etc.), organic materials, or combinations thereof. In one embodiment, the core 101 may include an organic material that may help improve the performance of the bonded abrasive body including, but not limited to, strength, wear resistance, vibration damping, and manufacturability.
In one embodiment, the core 101 may comprise a polymeric material selected from the group consisting of Polyamide (PA), polybutylene terephthalate (PBT), polyphenylene sulfide ((PPS), ethylene tetrafluoroethylene ETFE), Polyetherketone (PEEK), polyester ((PE), polyethyleneimine PEI), Polyethersulfone (PESU), polyethylene terephthalate (PET), polyphthalamide (PPA), polyphenylene sulfide, Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), PC-ABS, or any combination thereof. In one aspect, the polymer material may be nylon, PBT, PPS, or PC-ABS. The nylon may be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46. In particular embodiments, the polymer material of the core may consist essentially of PPS. In another particular embodiment, the polymer material of the core may consist essentially of PC-ABS. In another embodiment, the polymeric material of the core is substantially free of nylon.
In another embodiment, the core 101 may also include reinforcing fibers and/or powder distributed within the polymeric material. The reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof. Suitable powders may be, for example, calcium carbonate, glass powder, mineral powder or talc.
Fig. 1B includes a cross-sectional illustration of a portion of an abrasive article according to an embodiment. As with the abrasive article shown in fig. 1A. The abrasive article portion of fig. 1B includes a core 101 and an abrasive body 103 disposed on an outer peripheral surface of the core 101. The abrasive body 103 can include a contoured surface 105, and the contoured surface 105 can have a particular shape suitable for abrading an edge of a workpiece.
As shown in fig. 1B, the abrasive body 103 includes a first region 151, a second region 161, and a third region 171. It should be understood that the embodiment of fig. 1B includes three regions, but other abrasive bodies may be formed with fewer or greater numbers of regions. According to one aspect, the rank and/or structure of the regions may be different from one another. For example, the regions may have different abrasive particle contents, different abrasive particle sizes (e.g., D10, D50, and/or D90), different abrasive particle compositions, different binder material contents, different binder material compositions, different porosities, different microstructural characteristics, or any combination thereof. It is believed that such controlled differences between regions may contribute to improved operation of the abrasive article. Any of the regions may have one or more features of any of the embodiments herein.
According to one embodiment, the first region 151 may have a first content of abrasive particles 153 contained in the bonding material 152, the second region 161 may have a second content of abrasive particles 163 contained in the bonding material 162, and further, the first content and the second content may be different from each other. In a particular example, the second amount can be greater than the first amount. The content of abrasive particles can be measured as the volume percent or weight percent of abrasive particles in a given region. If the distinction between the regions is not significant, at least three random material samples can be selected from the body portion suspected of being part of different regions, and the content of abrasive particles can be measured and averaged. The average content may represent the content of a given region. The volume percent or weight percent may be based on the weight or volume sampled from the region.
In a particular embodiment, the abrasive body 103 having the first and second regions 151 and 161 can define a ratio of not greater than 0.97) (C1/C2), wherein C1 represents a first content (vol% or wt%) of abrasive particles in the first region and C2 represents a second content (vol% or wt%) of abrasive particles in the second region. According to an embodiment, the ratio (C1/C2) may be not greater than 0.95, such as not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.43 or not greater than 0.40. However, in another non-limiting embodiment, the ratio (C1/C2) may be at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It will be appreciated that the ratio (C1/C2) can range between any minimum and maximum value noted above.
In some cases, the abrasive particles 153 of the first region 151 can be the same type of abrasive particles 163 contained in the second region 161. Reference herein to abrasive particle types may be with reference to at least one characteristic selected from median particle size (D50), D10, D90, vickers hardness, ellipticity, average toughness, composition, or any combination thereof. For example, abrasive particles 153 and abrasive particles 163 can have the same composition as each other. However, it should be understood that in other embodiments, the composition of abrasive particles 153 may be different than the composition of abrasive particles 163. In another aspect, the abrasive particles 153 of the first region 151 can be the same size as the abrasive particles 163 contained in the second region 161 (e.g., D10, D50, and/or D90). For example, abrasive particles 153 and abrasive particles 163 can have an average particle size relative to each other (i.e., D50). However, it should be understood that in other embodiments, the composition of abrasive particles 153 may have a different average particle size (i.e., D50) than abrasive particles 163.
In certain examples, as shown in fig. 1B, the first region 151 can be in the form of a layer that extends radially between the inner wall 112 of the cavity and the molding surface 105. Additionally, the second region 161 may be in the form of a layer, such as a layer extending radially between the inner wall 112 and the molding surface 105. The second region 161 may be in direct contact with the first region 151 such that there is no intervening layer or object positioned between the first region 151 and the second region 161.
In another aspect, the first region 151 can have a first content of the first bonding material 152 and the second region 161 can have a second content of the second bonding material 162. For certain abrasive articles of the embodiments described herein, the second content of the second bond material 162 may be different than the first content of the first bond material 152. Further, in an alternative design, the second content of the second bonding material 162 may be the same as the first content of the first bonding material 152.
For certain embodiments, the first bonding material 152 of the first region 151 and the second bonding material 162 of the second region 161 may have the same composition. The first bonding material 152 and the second bonding material 162 may have any composition of bonding materials as described in the embodiments described herein. In one particular example, the first and second bonding materials 152, 162 may be inorganic materials, such as metals, metal alloys, amorphous materials, glasses, ceramics, or any combination thereof. Further, it should be understood that in certain examples, the first bonding material 152 and the second bonding material 162 may have different compositions from each other. Two compositions may be considered different when at least one component (e.g., element, compound, or complex) differs by at least 5% between the two compositions.
As shown in fig. 1B, certain abrasive bodies can include third regions 171 having a third content of abrasive particles 173. In addition, as shown in fig. 1B, the second region 161 may be disposed between the first region 151 and the third region 171. In at least one embodiment, the third content of abrasive particles 173, measured in terms of volume percent or weight percent, may be different than the second content of abrasive particles 163 contained within the second region 161. Further, in other examples, the first content of abrasive particles 153 and the third content of abrasive particles 173 may be the same as each other.
For one particular embodiment, the second content of abrasive particles 163 in the second regions 161 may be greater than the third content of abrasive particles 173 in the third regions 171. This may be advantageous because the second region 161 may perform a majority of the material removal operation compared to the third region 171. Further, the second content of abrasive particles 163 in the second region 161 may be greater than the first content of abrasive particles 153 in the first region 151.
The abrasive body 103 may include a ratio (C3/C2) of not greater than 0.97, where C3 represents a third content of abrasive particles 173 in the third region 171, and C2 represents a second content of abrasive particles 163 in the second region 161. In one embodiment, the ratio (C3/C2) may be no greater than 0.95, such as no greater than 0.93, or no greater than 0.90, or no greater than 0.87, or no greater than 0.85, or no greater than 0.83, or no greater than 0.80, or no greater than 0.77, or no greater than 0.75, or no greater than 0.73, or no greater than 0.70, or no greater than 0.67, or no greater than 0.65, or no greater than 0.63, or no greater than 0.60, or no greater than 0.57, or no greater than 0.55, or no greater than 0.53, or no greater than 0.50, or no greater than 0.47, or no greater than 0.45, or no greater than 0.43, or no greater than 0.40. Further, in another non-limiting embodiment, the ratio (C3/C2) may be at least 0.1, such as at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.93, or at least 0.95. It will be appreciated that the ratio (C3/C2) can be within the range of any minimum and maximum value noted above.
According to another aspect, the abrasive particles 173 of the third region 171 can be of the same type as the abrasive particles 163 contained in the second region 161. Reference to "type" in the context of abrasive particles refers to at least one feature selected from the group consisting of: median particle size (D50), D10, D90, vickers hardness, ellipticity, average toughness, composition, or any combination thereof. For example, abrasive particles 173 and abrasive particles 163 can have the same composition as each other. However, it should be understood that in other embodiments, the abrasive particles 163 and 173 may be of different types from each other. For example, in one embodiment, the composition of abrasive particles 173 may be different than the composition of abrasive particles 163. In another aspect, the abrasive particles 173 of the third region 171 can have the same grit size as the abrasive particles 163 contained in the second region 161 (e.g., D10, D50, and/or D90). For example, abrasive particles 173 and 163 can have an average particle size relative to each other (i.e., D50). However, it should be understood that in other embodiments, the composition of the abrasive particles 173 may have a different average particle size (i.e., D50) than the abrasive particles 163.
Similar to the first region 151 in some embodiments, the third region 171 can be in the form of a layer that extends radially between the inner wall 112 and the molding surface 105. In addition, the second region 161 may be in the form of a layer. The second region 161 may be in direct contact with the third region 171 such that there is no intervening layer or object positioned between the third region 171 and the second region 161.
In another aspect, the third region 171 can have a third content of the third bonding material 172 and the second region 161 can have a second content of the second bonding material 162. For certain abrasive articles of the embodiments described herein, the second content of the second bond material 162 may be different than the third content of the third bond material 172. Further, in an alternative design, the second content of the second bonding material 162 may be the same as the third content of the third bonding material 172. Additionally, the first content of the first bonding material 152 may be the same as the third content of the third bonding material 172. Further, in one non-limiting embodiment, the second content of the second bonding material 162 may be the same as the third content of the third bonding material 172.
For certain embodiments, the third bonding material 172 of the third region 171 and the second bonding material 162 of the second region 161 may have the same composition. The second bonding material 162 and the third bonding material 172 may have any composition of bonding materials as described in the embodiments described herein. In one particular example, the second bonding material 162 and the third bonding material 172 may be inorganic materials, such as metals, metal alloys, amorphous materials, glasses, ceramics, or any combination thereof. Further, it should be understood that in certain examples, the second bonding material 162 and the third bonding material 172 may have different compositions from one another. Two compositions may be considered different when at least one component (e.g., element, compound, or complex) differs by at least 5% between the two compositions.
According to a particular embodiment, the first region 151 includes particles having a first median particle size (D50)1) And the second region 161 may comprise particles having a second median particle size (D50)2) Of abrasive particles of the second type. In certain examples, a first median particle size (D50)1) May be different from the second median particle size (D50)2). In a particular embodiment, the second type of abrasive particles has a median particle size (D50)2) Greater than the median particle size of the first type of abrasive particles (D50)1). In one aspect, the abrasive body can have a ratio (D50 78) of not greater than 0.97, such as not greater than 0.95, or not greater than 0.93, or not greater than 0.90, or not greater than 0.87, or not greater than 0.85, or not greater than 0.83, or not greater than 0.80, or not greater than 0.77, or not greater than 0.75, or not greater than 0.73, or not greater than 0.70, or not greater than 0.67, or not greater than 0.65, or not greater than 0.63, or not greater than 0.60, or not greater than 0.57, or not greater than 0.55, or not greater than 0.53, or not greater than 0.50, or not greater than 0.47, or not greater than 0.45, or not greater than 0.43, or not greater than 01/D502). Further, in one non-limiting embodiment, the ratio (D50)1/D502) May be at least 0.1, such as at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.93. Or at least 0.95. It should be understood that the ratio (D50)1/D502) Can be within the range of any minimum and maximum values noted above.
As described in embodiments herein, the third region 171 can include a third type of abrasive particles 173. In at least one example, the third type of abrasive particles 173 can be different than the second type of abrasive particles 163 in the second regions 161. In particular examples, the abrasive body 103 can have a ratio (D50) of not greater than 0.973/D502) Wherein D503Represents the median particle size of the third type of abrasive particles 173, and D502Representing the median particle size of the second type of abrasive particles 163. For example, the ratio (D50)3/D502) May be no greater than 0.95, such as no greater than 0.93, or no greater than 0.90, or no greater than 0.87, or no greater than 0.85, or no greater than 0.83, or no greater than 0.80, or no greater than 0.77, or no greater than 0.75, or no greater than 0.73, or no greater than 0.70, or no greater than 0.67, or no greater than 0.65, or no greater than 0.63, or no greater than 0.60, or no greater than 0.57, or no greater than 0.55, or no greater than 0.53, or no greater than 0.50, or no greater than 0.47, or no greater than 0.45, or no greater than 0.43, or no greater than 0.40. Further, in one non-limiting embodiment, the ratio (D50)3/D502) May be at least 0.1, such as at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.93, or at least 0.95. It should be understood that the ratio (D50)3/D502) Can be within the range of any minimum and maximum values noted above.
In another embodiment, the third type of abrasive particles 173 and the first type of abrasive particles 153 may be the same type of abrasive particles. Thus, the first type of abrasive particles 153 and the third type of abrasive particles 173 may have the same median particle size (D50), D10, D90, vickers hardness, ellipticity, average toughness, and composition.
Example (b):
embodiment 1. an abrasive article comprising:
a body, the body comprising:
a bond material comprising a metal and further comprising a microporosity within the bond material, the microporosity comprising an average pore size (D50) of no greater than 10 microns and a pore size standard deviation of at least 0.2 microns;
abrasive particles contained within a bond material, the abrasive particles further comprising at least one of:
an ellipticity of not greater than 1.18; or
An average toughness of at least 11257 cycles as measured in accordance with ANSIB 74.23.
Embodiment 2. the abrasive article of embodiment 1, wherein the abrasive particles comprise a material selected from the group consisting of: an oxide, a carbide, a nitride, a boride, or any combination thereof.
Embodiment 3. the abrasive article of embodiment 1, wherein the abrasive particles comprise a superabrasive material.
Embodiment 4. the abrasive article of embodiment 1, wherein the abrasive particles comprise diamond.
Embodiment 5. the abrasive article of embodiment 1, wherein the abrasive particles consist essentially of diamond.
Embodiment 6. the abrasive article of embodiment 1, wherein the abrasive particles comprise a coating.
Embodiment 7. the abrasive article of embodiment 6, wherein the coating comprises a metal or metal alloy comprising a transition metal element.
Embodiment 8. the abrasive article of embodiment 6, wherein the coating comprises titanium.
Embodiment 9. the abrasive article of embodiment 6, wherein the coating is located over a majority, or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 95%, of the outer surface of the abrasive particle.
Embodiment 10 the abrasive article of embodiment 1, wherein the abrasive particles comprise a median particle size (D50) of at least 65 microns, or at least 75 microns, or at least 90 microns, or at least 95 microns, or at least 97 microns, or at least 100 microns, or at least 105 microns, or at least 110 microns, or at least 120 microns.
Embodiment 11 the abrasive article of embodiment 1, wherein the abrasive particles comprise a median particle size (D50) of not greater than 150 microns, or not greater than 140 microns, or not greater than 130 microns, or not greater than 120 microns, or not greater than 110 microns, or not greater than 105 microns, or not greater than 100 microns.
Embodiment 12 the abrasive article of embodiment 1, wherein the abrasive particles comprise D10 of at least 57 microns, or at least 60 microns, or at least 65 microns, or at least 70 microns, or at least 75 microns, or at least 77 microns, or at least 80 microns, or at least 83 microns, or at least 85 microns, or at least 87 microns, or at least 90 microns, or at least 93 microns, or at least 95 microns.
Embodiment 13 the abrasive article of embodiment 1, wherein the abrasive particles comprise D10 of not greater than 127 microns, or not greater than 120 microns, or not greater than 110 microns, or not greater than 100 microns, or not greater than 95 microns, or not greater than 93 microns, or not greater than 90 microns, or not greater than 87 microns, or not greater than 85 microns, or not greater than 83 microns, or not greater than 80 microns.
Embodiment 14 the abrasive article of embodiment 1, wherein the abrasive particles comprise D90 of at least 97 microns, or at least 100 microns, or at least 103 microns, or at least 105 microns, or at least 108 microns, or at least 110 microns, or at least 113 microns, or at least 115 microns, or at least 118 microns, or at least 120 microns, or at least 123 microns, or at least 125 microns, or at least 128 microns, or at least 130 microns, or at least 133 microns, or at least 135 microns, or at least 138 microns.
The abrasive article of embodiment 1, wherein the abrasive particles comprise D90 of not greater than 165 microns, or not greater than 160 microns, or not greater than 155 microns, or not greater than 150 microns, or not greater than 145 microns, or not greater than 140 microns, or not greater than 135 microns, or not greater than 133 microns, or not greater than 130 microns, or not greater than 128 microns, or not greater than 125 microns, or not greater than 123, or not greater than 120 microns, or not greater than 118 microns, or not greater than 115 microns, or not greater than 113 microns, or not greater than 110 microns, or not greater than 108 microns, or not greater than 105 microns.
Embodiment 16 the abrasive article of embodiment 1, wherein the abrasive particles comprise at least 2000kg/mm2Or at least 3000kg/mm2Or at least 4000kg/mm2Or at least 5000kg/mm2Vickers hardness of (2).
Embodiment 17 the abrasive article of embodiment 16, wherein the abrasive particles comprise diamond.
Embodiment 18 the abrasive article of embodiment 1, wherein the abrasive particles have an average toughness of at least 11900 cycles, or at least 12000 cycles for at least 12100 cycles, or at least 12200 cycles, or at least 12300 cycles, or at least 12400 cycles, or at least 12500 cycles, or at least 12600 cycles, or at least 12700 cycles, or at least 12800 cycles, or at least 12900 cycles, or at least 13000 cycles, or at least 13100 cycles, or at least 13200 cycles.
Embodiment 19. the abrasive article of embodiment 18, wherein the abrasive particles have an average toughness of not greater than 16000, or not greater than 15000, or not greater than 14500, or not greater than 14000, or not greater than 13900, or not greater than 13800, or not greater than 13700, or not greater than 13600, or not greater than 13500, or not greater than 13400, or not greater than 13300.
Embodiment 20 the abrasive article of embodiment 1, wherein the abrasive particles have an ellipticity of not greater than 1.17, or not greater than 1.16, or not greater than 1.15, or not greater than 1.14, or not greater than 1.13, or not greater than 1.12, or not greater than 1.11, or not greater than 1.10.
Embodiment 21 the abrasive article of embodiment 20, wherein the abrasive particles comprise an ellipticity of at least 1.01, or at least 1.02, or at least 01.03, or at least 1.04, or at least 1.05, or at least 1.06, or at least 1.07, or at least 1.08, or at least 1.09, or at least 1.10, or at least 1.11, or at least 1.12, or at least 1.13, or at least 1.14, or at least 1.15, or at least 1.16.
Embodiment 22 the abrasive article of embodiment 1, wherein the body comprises abrasive particles in an amount of at least 2 wt%, or at least 2.5 wt%, or at least 3 wt%, or at least 3.5 wt%, or at least 4 wt%, or at least 4.5 wt%, or at least 5 wt%, or at least 5.5 wt%, or at least 6 wt%, or at least 6.5 wt%, or at least 7 wt%, or at least 7.5 wt%, or at least 8 wt%, or at least 8.5 wt%, or at least 9 wt%, or at least 9.5 wt%, or at least 10 wt%.
Embodiment 23 the abrasive article of embodiment 1, wherein the body comprises abrasive particles in an amount of not greater than 10wt, or not greater than 9wt, or not greater than 8.5wt, or not greater than 8wt, or not greater than 7.5wt, or not greater than 7wt, or not greater than 6.5wt, or not greater than 6wt, or not greater than 5.5wt, or not greater than 5wt, or not greater than 4.5wt, or not greater than 4wt, or not greater than 3.5wt, or not greater than 3wt, or not greater than 2.5wt, or not greater than 2wt, or not greater than 1.5wt, or not greater than 1 wt.
Embodiment 24. the abrasive article of embodiment 1, wherein the body comprises the bond material in an amount of at least 20 wt%, or at least 30 wt%, or at least 40 wt%, or at least 50 wt%, or at least 60 wt%, or at least 70 wt%, or at least 80 wt%, or at least 90 wt%, or at least 95 wt%.
Embodiment 25. the abrasive article of embodiment 1, wherein the body comprises the bond material in an amount not greater than 99 wt%, or not greater than 95 wt%, or not greater than 90 wt%, or not greater than 80 wt%, or not greater than 70 wt%, or not greater than 60 wt%, or not greater than 50 wt%, or not greater than 40 wt%, or not greater than 30 wt%, or not greater than 25 wt% of the total weight of the body.
Embodiment 26 the abrasive article of embodiment 1, wherein the bond material comprises at least one of cobalt, tin, tungsten, copper, or any combination thereof.
Embodiment 27. the abrasive article of embodiment 1, wherein the bond material comprises cobalt (CCo) and tin (CSn) in a ratio [ CSn/CCo ] of not greater than 0.2, or not greater than 0.19, or not greater than 0.18, or not greater than 0.17, or not greater than 0.16, or not greater than 0.15, or not greater than 0.14, or not greater than 0.13, or not greater than 0.12, or not greater than 0.11, or not greater than 0.10, or not greater than 0.09, or not greater than 0.08, or not greater than 0.07, or not greater than 0.06, or not greater than 0.05, or not greater than 0.04, or not greater than 0.03, or not greater than 0.02, or not greater than 0.01, wherein CCo is a weight percentage of cobalt to the entire weight of the body and CSn is a weight percentage of tin to the entire weight of the body.
Embodiment 28 the abrasive article of embodiment 27, wherein the bond material comprises a ratio [ CSn/CCo ] of at least 0.001, or at least 0.002, or at least 0.003, or at least 0.004, or at least 0.005, or at least 0.006, or at least 0.007, or at least 0.008, or at least 0.009, or at least 0.01, or at least 0.015, or at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1.
Embodiment 29 the abrasive article of embodiment 1, wherein the bond material comprises a ratio [ CW/CCo ] of not greater than 0.9, or not greater than 0.8, or not greater than 0.7, or not greater than 0.6, or not greater than 0.5, or not greater than 0.4, or not greater than 0.3, or not greater than 0.2, or not greater than 0.10, or not greater than 0.09, or not greater than 0.08, or not greater than 0.07, or not greater than 0.06, or not greater than 0.05, or not greater than 0.04, or not greater than 0.03, or not greater than 0.02, or not greater than 0.01, wherein CCo is the weight percent of cobalt and CW is the weight percent of tungsten based on the entire weight of the body.
Embodiment 30 the abrasive article of embodiment 1, wherein the bond material comprises a ratio [ CW/o ] of at least about 0.001, or at least 0.002, or at least 0.003, or at least 0.004, or at least 0.005, or at least 0.006, or at least 0.007, or at least 0.008, or at least 0.009, or at least 0.01, or at least 0.015, or at least 0.02, or at least 0.03, or at least 0.04, or at least 0.05, or at least 0.06, or at least 0.07, or at least 0.08, or at least 0.09, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7, wherein CCo is a weight percent of cobalt and CW is a weight percent of tungsten based on the entire weight of the body.
Embodiment 31. the abrasive article of embodiment 1, wherein the bond material comprises tungsten (CW) and tin (CSn) in a ratio [ CSn/CW ] of not greater than 1, or not greater than 0.9, or not greater than 0.8, or not greater than 0.7, or not greater than 0.6, or not greater than 0.5, or not greater than 0.4, or not greater than 0.3, or not greater than 0.2, or not greater than 0.1, wherein CW is a weight percentage of tungsten based on an entire weight of the body and CSn is a weight percentage of tin based on the entire weight of the body.
Embodiment 32. the abrasive article of embodiment 1, wherein the bond material comprises tungsten (CW) and tin (CSn) in a ratio [ CSn/CW ] of at least 0.01, or at least 0.02, or at least 0.05, or at least 0.1, or at least 0.2, or at least 0.3, or at least 0.4, or at least 0.5, or at least 0.6, or at least 0.7, or at least 0.8, or at least 0.9, wherein CW is the weight percent of tungsten over the entire weight of the body and CSn is the weight percent of tin over the entire weight of the body.
Embodiment 33 the abrasive article of embodiment 1, wherein the bond material comprises an amount of at least 40 wt%, or at least 50 wt%, or at least 51 wt%, or at least 52 wt%, or at least 53 wt%, or at least 54 wt%, or at least 55 wt%, or at least 56 wt%, or at least 57 wt%, or at least 58 wt%, or at least 59 wt%, or at least 60 wt%, or at least 61 wt%, or at least 62 wt%, or at least 63 wt%, or at least 64 wt%, or at least 65 wt%, or at least 66 wt%, or at least 67 wt%, or at least 68 wt%, or at least 69 wt%, or at least 70 wt%, or at least 71 wt%, or at least 72 wt%, or at least 73 wt%, or at least 74 wt%, or at least 75 wt%, or at least 76 wt%, or at least 77 wt%, or at least 78 wt%, or at least 79 wt%, or at least 80 wt%, based on the total weight of the body, Or at least 81 wt%, or at least 82 wt%, or at least 83 wt%, or at least 84 wt%, or at least 85 wt%, or at least 86 wt%, or at least 87 wt%, or at least 88 wt%, or at least 89 wt%, or at least 90 wt%, or at least 91 wt%, or at least 92 wt%, or at least 93 wt%, or at least 94 wt%, or at least 95 wt% cobalt.
Embodiment 34 the abrasive article of embodiment 1, wherein the bond material comprises an amount of not greater than 99 wt%, or not greater than 98 wt%, or not greater than 97 wt%, or not greater than 96 wt%, or not greater than 95 wt%, or not greater than 94 wt%, or not greater than 93 wt%, or not greater than 92 wt%, or not greater than 91 wt%, or not greater than 90 wt%, or not greater than 89 wt%, or not greater than 88 wt%, or not greater than 87 wt%, or not greater than 86 wt%, or not greater than 85 wt%, or not greater than 84 wt%, or not greater than 83 wt%, or not greater than 82 wt%, or not greater than 81 wt%, or not greater than 80 wt%, or not greater than 79 wt%, or not greater than 78 wt%, or not greater than 77 wt%, or not greater than 76 wt%, or not greater than 75 wt%, or not greater than 74 wt%, or not greater than 73 wt%, or not greater than 72 wt%, or not greater, Or not more than 70 wt%, or not more than 69 wt%, or not more than 68 wt%, or not more than 67 wt%, or not more than 66 wt%, or not more than 65 wt% cobalt.
Embodiment 35 the abrasive article of embodiment 1, wherein the bond material comprises an amount of at least 0.1 wt%, or at least 0.2 wt%, or at least 0.3 wt%, or at least 0.4 wt%, or at least 0.5 wt%, or at least 0.6 wt%, or at least 0.7 wt%, or at least 0.8 wt%, or at least 0.9 wt%, or at least 1 wt%, or at least 1.1 wt%, or at least 1.2 wt%, or at least 1.3 wt%, or at least 1.4 wt%, or at least 1.5 wt%, or at least 1.6 wt%, or at least 1.7 wt%, or at least 1.8 wt%, or at least 1.9 wt%, or at least 2 wt%, or at least 2.1 wt%, or at least 2.2 wt%, or at least 2.3 wt%, or at least 2.4 wt%, or at least 2.5 wt%, or at least 2.6 wt%, or at least 2.7 wt%, or at least 2.8 wt%, or at least 2.9 wt%, or at least 3 wt%, or at least 2.3 wt%, or at least 3 wt%, or at least 2.7 wt%, or at least 2wt, Or at least 3.3 wt%, or at least 3.4 wt%, or at least 3.5 wt%, or at least 3.6 wt%, or at least 3.7 wt%, or at least 3.8 wt%, or at least 3.9 wt%, or at least 4 wt%, or at least 4.1 wt%, or at least 4.2 wt%, or at least 4.3 wt%, or at least 4.4 wt%, or at least 4.5 wt%, or at least 5 wt% tin.
Embodiment 36 the abrasive article of embodiment 1, wherein the bond material comprises tin in an amount not greater than 15 wt%, or not greater than 12 wt%, or not greater than 10 wt%, or not greater than 9 wt%, or not greater than 8.5 wt%, or not greater than 8 wt%, or not greater than 7.5 wt%, or not greater than 7 wt%, or not greater than 6.5 wt%, or not greater than 6 wt%, or not greater than 5.5 wt%, or not greater than 5 wt%, or not greater than 4.5 wt%, or not greater than 4 wt%, or not greater than 3.5 wt%, or not greater than 3 wt%, or not greater than 2.5 wt%, or not greater than 2 wt%, or not greater than 1.5 wt%, or not greater than 1 wt%, or not greater than 0.5 wt% of the total weight of the body.
Embodiment 37 the abrasive article of embodiment 1, wherein the bond material comprises an amount of at least 1 wt%, or at least 1.1 wt%, or at least 1.2 wt%, or at least 1.3 wt%, or at least 1.4 wt%, or at least 1.5 wt%, or at least 1.6 wt%, or at least 1.7 wt%, or at least 1.8 wt%, or at least 1.9 wt%, or at least 2 wt%, or at least 2.1 wt%, or at least 2.2 wt%, or at least 2.3 wt%, or at least 2.4 wt%, or at least 2.5 wt%, or at least 2.6 wt%, or at least 2.7 wt%, or at least 2.8 wt%, or at least 2.9 wt%, or at least 3 wt%, or at least 3.1 wt%, or at least 3.2 wt%, or at least 3.3 wt%, or at least 3.4 wt%, or at least 3.5 wt%, or at least 3.6 wt%, or at least 3.7 wt%, or at least 3.8 wt%, or at least 3.9 wt%, or at least 4 wt%, or at least 1.5 wt%, or at least 1.6 wt%, or at least 2.6 wt%, or at least, Or at least 4.2 wt%, or at least 4.3 wt%, or at least 4.4 wt%, or at least 4.5 wt%, or at least 4.6 wt%, or at least 4.7 wt%, or at least 4.8 wt%, or at least 4.9 wt%, or at least 5 wt%, or at least 5.1 wt%, or at least 5.2 wt%, or at least 5.3 wt%, or at least 5.4 wt%, or at least 5.5 wt%, or at least 5.6 wt%, or at least 5.7 wt%, or at least 5.8 wt%, or at least 5.9 wt%, or at least 6 wt%, or at least 6.5 wt%, or at least 7 wt%, or at least 7.5 wt%, or at least 8 wt%, or at least 8.5 wt%, or at least 9 wt% tungsten.
Embodiment 38 the abrasive article of embodiment 1, wherein the bond material comprises tungsten in an amount not greater than 20 wt%, or not greater than 18 wt%, or not greater than 16 wt%, or not greater than 14 wt%, or not greater than 12 wt%, or not greater than 10 wt%, or not greater than 9 wt%, or not greater than 8 wt%, or not greater than 7 wt%, or not greater than 6 wt%, or not greater than 5 wt%, or not greater than 4 wt%, or not greater than 3 wt%, or not greater than 2 wt%, or not greater than 1.5 wt% of the total weight of the body.
Embodiment 39 the abrasive article of embodiment 1, wherein the bond material comprises iron in an amount of at least 0.05 wt%, or at least 0.06 wt%, or at least 0.07 wt%, or at least 0.08 wt%, or at least 0.09 wt%, or at least 0.1 wt%, or at least 0.15 wt%, or at least 0.2 wt%, or at least 0.25 wt%, or at least 0.3 wt%, or at least 0.35 wt%, or at least 0.4 wt%, or at least 0.45 wt%, or at least 0.5 wt%, or at least 0.55 wt%, or at least 0.6 wt%, or at least 0.7 wt%, or at least 0.8 wt%, or at least 0.9 wt%, or at least 1 wt% of the total weight of the body.
Embodiment 40 the abrasive article of embodiment 1, wherein the bond material comprises iron in an amount not greater than 5 wt%, or not greater than 4 wt%, or not greater than 3 wt%, or not greater than 2 wt%, or not greater than 1.5 wt%, or not greater than 1 wt%, or not greater than 0.9 wt%, or not greater than 0.8 wt%, or not greater than 0.7 wt%, or not greater than 0.6 wt%, or not greater than 0.5 wt%, or not greater than 0.4 wt%, or not greater than 0.3 wt% of the total weight of the body.
Embodiment 41 the abrasive article of embodiment 1, wherein the bond material comprises aluminum in an amount not greater than 1 wt%, or not greater than 0.9 wt%, or not greater than 0.8 wt%, or not greater than 0.7 wt%, or not greater than 0.6 wt%, or not greater than 0.5 wt%, or not greater than 0.4 wt%, or not greater than 0.3 wt%, or not greater than 0.2 wt%, or not greater than 0.1 wt%, or not greater than 0.09 wt%, or not greater than 0.05 wt%, or not greater than 0.01 wt% of the total weight of the body.
Embodiment 42 the abrasive article of embodiment 1, wherein the bond material comprises copper in an amount not greater than 20 wt%, or not greater than 15 wt%, or not greater than 10 wt%, or not greater than 5 wt%, or not greater than 2 wt%, or not greater than 1 wt%, or not greater than 0.9 wt%, or not greater than 0.8 wt%, or not greater than 0.7 wt%, or not greater than 0.6 wt%, or not greater than 0.5 wt%, or not greater than 0.4 wt%, or not greater than 0.3 wt%, or not greater than 0.2 wt%, or not greater than 0.1 wt%, or not greater than 0.09 wt%, or not greater than 0.05 wt%, or not greater than 0.01 wt% of the total weight of the body.
Embodiment 43 the abrasive article of embodiment 1, wherein the bond material comprises manganese in an amount not greater than 1 wt%, or not greater than 0.9 wt%, or not greater than 0.8 wt%, or not greater than 0.7 wt%, or not greater than 0.6 wt%, or not greater than 0.5 wt%, or not greater than 0.4 wt%, or not greater than 0.3 wt%, or not greater than 0.2 wt%, or not greater than 0.1 wt%, or not greater than 0.09 wt%, or not greater than 0.05 wt%, or not greater than 0.01 wt% of the total weight of the body.
Embodiment 44. the abrasive article of embodiment 1, wherein the bond material comprises titanium in an amount not greater than 1 wt%, or not greater than 0.9 wt%, or not greater than 0.8 wt%, or not greater than 0.7 wt%, or not greater than 0.6 wt%, or not greater than 0.5 wt%, or not greater than 0.4 wt%, or not greater than 0.3 wt%, or not greater than 0.2 wt%, or not greater than 0.1 wt%, or not greater than 0.09 wt% of the total weight of the body.
Embodiment 45 the abrasive article of embodiment 1, wherein the body comprises aluminum, copper, manganese, lead, silicon, and titanium in a total content of not greater than 20 wt%, or not greater than 15 wt%, or not greater than 10 wt%, or not greater than 5 wt%, or not greater than 2 wt%, or not greater than 1 wt%, or not greater than 0.9 wt%, or not greater than 0.8 wt%, or not greater than 0.7 wt%, or not greater than 0.6 wt%, or not greater than 0.5 wt%, or not greater than 0.4 wt%, or not greater than 0.3 wt%, or not greater than 0.2 wt%, or not greater than 0.1 wt% of the total weight of the body.
Embodiment 46. the abrasive article of embodiment 1, wherein at least 95 wt% of the bond material comprises cobalt, tin, and tungsten, and no more than 5 wt% of the bond material comprises a second element selected from the group consisting of: aluminum, copper, manganese, lead, silicon, and titanium.
Embodiment 47 the abrasive article of embodiment 1, wherein the microporosity comprises an average pore size (D50) of not greater than 9 microns, or not greater than 8 microns, or not greater than 7 microns, or not greater than 6 microns, or not greater than 5 microns, or not greater than 4 microns, or not greater than 3 microns, or not greater than 2 microns, or not greater than 1 micron, or not greater than 0.9 microns, or not greater than 0.8 microns, or not greater than 0.7 microns, or not greater than 0.6 microns, or not greater than 0.5 microns.
Embodiment 48 the abrasive article of embodiment 1, wherein the microporosity comprises a mean pore size (D50) of at least 0.01 microns, or at least 0.05 microns, or at least 0.1 microns, or at least 0.2 microns, or at least 0.25 microns, or at least 0.3 microns, or at least 0.35 microns, or at least 0.4 microns, or at least 0.45 microns, or at least 0.5 microns.
Embodiment 49 the abrasive article of embodiment 1, wherein the microporosity comprises a pore size standard deviation of at least 0.2 microns, or at least 0.22 microns, or at least 0.24 microns, or at least 0.26 microns, or at least 0.28 microns, or at least 0.3 microns, or at least 0.32 microns, or at least 0.34 microns, or at least 0.36 microns, or at least 0.38 microns, or at least 0.4 microns, or at least 0.42 microns, or at least 0.44 microns.
Embodiment 50 the abrasive article of embodiment 1, wherein the microporosity comprises a pore size standard deviation of not greater than 2 microns, or not greater than 1.8 microns, or not greater than 1.6 microns, or not greater than 1.4 microns, or not greater than 1.2 microns, or not greater than 1 micron, or not greater than 0.8 microns, or not greater than 0.6 microns, or not greater than 0.5 microns.
Embodiment 51. the abrasive article of embodiment 1, wherein the body comprises a porosity in an amount of at least 0.5vol, or at least 1vol, or at least 1.5vol, or at least 2vol, or at least 2.5vol, or at least 3vol, or at least 3.5vol, or at least 4vol, or at least 4.5vol, or at least 5vol, or at least 5.5vol, or at least 6vol, or at least 7vol, or at least 8vol, or at least 9vol, or at least 10vol, of the total volume of the body.
Embodiment 52. the abrasive article of embodiment 1, wherein the body comprises a porosity in an amount not greater than 50vol, or not greater than 30vol, or not greater than 20vol, or not greater than 15wt, or not greater than 12wt, or not greater than 10vol, or not greater than 9vol, or not greater than 8vol, or not greater than 7vol, or not greater than 6vol, or not greater than 5vol, or not greater than 4vol, or not greater than 3vol, or not greater than 2vol, or not greater than 1vol for the total volume of the body.
Embodiment 53. the abrasive article of embodiment 1, wherein the body comprises a first region and a second region, the first region comprising a first content of abrasive particles and the second region comprising a second content of abrasive particles, wherein the first content and the second content are different from each other.
Embodiment 54 the abrasive article of embodiment 53, wherein the second content is greater than the first content.
Embodiment 55 the abrasive article of embodiment 53, further comprising a ratio (C1/C2) of not greater than 0.97, wherein C1 represents the first content and C2 represents the second content, and wherein the ratio (C1/C2) is not greater than 0.95, or not greater than 0.93, or not greater than 0.90, or not greater than 0.87, or not greater than 0.85, or not greater than 0.83, or not greater than 0.80, or not greater than 0.77, or not greater than 0.75, or not greater than 0.73, or not greater than 0.70, or not greater than 0.67, or not greater than 0.65, or not greater than 0.63, or not greater than 0.60, or not greater than 0.57, or not greater than 0.55, or not greater than 0.53, or not greater than 0.50, or not greater than 0.47, or not greater than 0.45, or not greater than 0.43, or not greater than 0.40.
Embodiment 56 the abrasive article of embodiment 53, further comprising a ratio of at least 0.1 (C1/C2), wherein C1 represents the first content and C2 represents the second content, and wherein the ratio (C1/C2) is at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.93, or at least 0.95.
Embodiment 57 the abrasive article of embodiment 53, wherein the abrasive particles of the first region and the abrasive particles of the second region are the same type of abrasive particles.
Embodiment 58. the abrasive article of embodiment 53, wherein the abrasive particles of the first region and the abrasive particles of the second region are different types of abrasive particles.
Embodiment 59. the abrasive article of embodiment 53, wherein the first region is in the form of a layer.
Embodiment 60 the abrasive article of embodiment 53, wherein the second region is in the form of a layer.
Embodiment 61 the abrasive article of embodiment 53, wherein the second region directly contacts the first region.
Embodiment 62 the abrasive article of embodiment 53, wherein the first region comprises a first content of the first bond material, and wherein the second region comprises a second content of the second bond material, and wherein the second content of the second bond material is different than the first content of the first bond material.
Embodiment 63. the abrasive article of embodiment 62, wherein the first bond material and the second bond material have the same composition.
Embodiment 64. the abrasive article of embodiment 62, wherein the first bond material and the second bond material have different compositions from each other.
Embodiment 65. the abrasive article of embodiment 62, further comprising a third region comprising a third content of abrasive particles, wherein the third content is different from the second content.
Embodiment 66 the abrasive article of embodiment 65, wherein the second region is disposed between the first region and the third region.
Embodiment 67. the abrasive article of embodiment 65, wherein the first content and the third content are the same as each other.
Embodiment 68. the abrasive article of embodiment 65, wherein the second content is greater than the third content.
Embodiment 69 the abrasive article of embodiment 65, further comprising a ratio (C3/C2) of not greater than 0.97, wherein C3 represents the third content and C2 represents the second content, and wherein the ratio (C3/C2) is not greater than 0.95, or not greater than 0.93, or not greater than 0.90, or not greater than 0.87, or not greater than 0.85, or not greater than 0.83, or not greater than 0.80, or not greater than 0.77, or not greater than 0.75, or not greater than 0.73, or not greater than 0.70, or not greater than 0.67, or not greater than 0.65, or not greater than 0.63, or not greater than 0.60, or not greater than 0.57, or not greater than 0.55, or not greater than 0.53, or not greater than 0.50, or not greater than 0.47, or not greater than 0.45, or not greater than 0.43, or not greater than 0.40.
Embodiment 70 the abrasive article of embodiment 65, further comprising a ratio of at least 0.1 (C3/C2), wherein C3 represents the third content and C2 represents the second content, and wherein the ratio (C3/C2) is at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.93, or at least 0.95.
Embodiment 71. the abrasive article of embodiment 65, wherein the abrasive particles of the third region and the abrasive particles of the second region are the same type of abrasive particles.
Embodiment 72 the abrasive article of embodiment 65, wherein the abrasive particles of the third region and the abrasive particles of the second region are different types of abrasive particles.
Embodiment 73. the abrasive article of embodiment 65, wherein the abrasive particles of the third region and the abrasive particles of the first region are the same type of abrasive particles.
Embodiment 74 the abrasive article of embodiment 65, wherein the third region is in the form of a layer.
Embodiment 75. the abrasive article of embodiment 65, wherein the second region is in the form of a layer and directly contacts the third region.
Embodiment 76 the abrasive article of embodiment 65, wherein the third region comprises a third content of a third bond material and the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the third content of the third bond material.
Embodiment 77 the abrasive article of embodiment 76, wherein the third bond material and the second bond material have the same composition.
Embodiment 78 the abrasive article of embodiment 76, wherein the third bond material and the second bond material have different compositions from each other.
Embodiment 79. the abrasive article of embodiment 1, wherein the body comprises a first region and a second region, the first region comprising a first type of abrasive particles and the second region comprising a second type of abrasive particles, and the first type of abrasive particles and the second type of abrasive particles are different from each other.
Embodiment 80. the abrasive article of embodiment 79, wherein the first type and the second type are different from each other based on at least one characteristic selected from the group consisting of: median particle size (D50), D10, D90, vickers hardness, ellipticity, average toughness, composition, or any combination thereof.
Embodiment 81 the abrasive article of embodiment 79, wherein the first type and the second type differ from each other based on median particle size.
Embodiment 82. the abrasive article of embodiment 79, wherein the second type of abrasive particles has a greater median particle size than the first type of abrasive particles.
Embodiment 83 the abrasive article of embodiment 79, further comprising a ratio (D501/D502) of not greater than 0.97, wherein D501 represents the median particle size of the first type of abrasive particles, and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D501/D502) is not greater than 0.95, or not greater than 0.93, or not greater than 0.90, or not greater than 0.87, or not greater than 0.85, or not greater than 0.83, or not greater than 0.80, or not greater than 0.77, or not greater than 0.75, or not greater than 0.73, or not greater than 0.70, or not greater than 0.67, or not greater than 0.65, or not greater than 0.63, or not greater than 0.60, or not greater than 0.57, or not greater than 0.55, or not greater than 0.53, or not greater than 0.50, or not greater than 0.47, or not greater than 0.45, or not greater than 0.43, or not greater than 0.40.
Embodiment 84. the abrasive article of embodiment 79, further comprising a ratio (D501/D502) of at least 0.1, wherein D501 represents the median particle size of the first type of abrasive particles and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D501/D502) is at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.93, or at least 0.95.
Embodiment 85 the abrasive article of embodiment 79, wherein the first region comprises a first content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the first content and the second content are different from each other.
Embodiment 86. the abrasive article of embodiment 79, wherein the first region comprises a first content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the first content and the second content are the same as each other.
Embodiment 87. the abrasive article of embodiment 79, wherein the first region is in the form of a layer.
Embodiment 88 the abrasive article of embodiment 79, wherein the second region is in the form of a layer.
Embodiment 89 the abrasive article of embodiment 79, wherein the second region directly contacts the first region.
Embodiment 90 the abrasive article of embodiment 79, wherein the first region comprises a first content of the first bond material, and wherein the second region comprises a second content of the second bond material, and wherein the second content of the second bond material is different than the first content of the first bond material.
Embodiment 91. the abrasive article of embodiment 90, wherein the first bond material and the second bond material have the same composition.
Embodiment 92 the abrasive article of embodiment 90, wherein the first bond material and the second bond material have different compositions from each other.
Embodiment 93 the abrasive article of embodiment 79, further comprising a third region comprising a third type of abrasive particles, wherein the third type is different from the second type.
Embodiment 94 the abrasive article of embodiment 93, wherein the second region is disposed between the first region and the third region.
Embodiment 95. the abrasive article of embodiment 93, wherein the first type and the third type are the same as each other.
Embodiment 96 the abrasive article of embodiment 93, further comprising a ratio (D503/D502) of not greater than 0.97, wherein D503 represents the median particle size of the third type of abrasive particles, and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D503/D502) is not greater than 0.95, or not greater than 0.93, or not greater than 0.90, or not greater than 0.87, or not greater than 0.85, or not greater than 0.83, or not greater than 0.80, or not greater than 0.77, or not greater than 0.75, or not greater than 0.73, or not greater than 0.70, or not greater than 0.67, or not greater than 0.65, or not greater than 0.63, or not greater than 0.60, or not greater than 0.57, or not greater than 0.55, or not greater than 0.53, or not greater than 0.50, or not greater than 0.47, or not greater than 0.45, or not greater than 0.43, or not greater than 0.40.
Embodiment 97 the abrasive article of embodiment 93, further comprising a ratio (D503/D502) of at least 0.1, wherein D503 represents the median particle size of the third type of abrasive particles and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D503/D502) is at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, or at least 0.5, or at least 0.55, or at least 0.6, or at least 0.65, or at least 0.7, or at least 0.75, or at least 0.8, or at least 0.85, or at least 0.9, or at least 0.93, or at least 0.95.
Embodiment 98. the abrasive article of embodiment 93, wherein the third region is in the form of a layer.
Embodiment 99 the abrasive article of embodiment 93, wherein the second region is in the form of a layer and directly contacts the third region.
Embodiment 100 the abrasive article of embodiment 93, wherein the third region comprises a third content of a third bond material and the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the third content of the third bond material.
Embodiment 101. the abrasive article of embodiment 100, wherein the third bond material and the second bond material have the same composition.
Embodiment 102. the abrasive article of embodiment 100, wherein the third bond material and the second bond material have different compositions from each other.
Embodiment 103 the abrasive article of embodiment 93, wherein the third region comprises a third content of abrasive particles and the second region comprises a second content of abrasive particles, and wherein the third content is different than the second content.
Embodiment 104. a method of forming an abrasive article, comprising:
forming a mixture comprising a precursor bond material and abrasive particles; and
heating the mixture to form a body comprising:
a bond material comprising a metal and further comprising a microporosity within the bond material, the microporosity comprising an average pore size (D50) of no greater than 10 microns and a pore size standard deviation of at least 0.2 microns;
abrasive particles contained within a bond material, the abrasive particles further comprising at least one of:
an ellipticity of not greater than 1.18; or
Average toughness of at least 11257 cycles.
Embodiment 105 the method of embodiment 104, wherein the mixture comprises a precursor bond material having an average particle size of no greater than 25 microns, or no greater than 10 microns, or no greater than 1 micron, or no greater than 0.75 microns, or no greater than 0.5 microns, or no greater than 0.25 microns, or no greater than 0.1 microns.
Embodiment 106 the method of embodiment 104, wherein the mixture comprises a precursor bonding material having an average particle size of at least 0.001 microns, such as at least 0.01 microns or even at least 0.1 microns.
Embodiment 107 the method of embodiment 104, wherein heating the mixture is performed at a temperature of at least 700 ℃, or at least 725 ℃, or at least 750 ℃, or at least 775 ℃, or at least 800 ℃, or at least 825 ℃, or at least 850 ℃, or at least 875 ℃, or at least 900 ℃, or at least 925 ℃, or at least 950 ℃, or at least 975 ℃, or at least 1000 ℃.
Embodiment 108 the method of embodiment 104, wherein heating the mixture is performed at a temperature of no greater than 1100 ℃, or no greater than 1050 ℃, or no greater than 1000 ℃, or no greater than 975 ℃, or no greater than 950 ℃, or no greater than 925 ℃, or no greater than 900 ℃.
Embodiment 109 the method of embodiment 104, wherein forming comprises hot pressing the mixture.
Embodiment 110 the method of embodiment 104, wherein forming comprises hot pressing the mixture at a pressure of at least 1000psi, or at least 1500psi, or at least 2000psi, or at least 2200 psi.
Embodiment 111 the method of embodiment 104, wherein forming comprises hot pressing the mixture at a pressure of no greater than 5000psi, or no greater than 4000psi, or no greater than 3000psi, or no greater than 2750 psi.
Example 1
The following samples were prepared and tested for comparison of their properties. A first sample, sample C1, was a commercially available glass grinding wheel having about 92 vol% metal bond material comprising about 93% cobalt, 2% tin, and 5% tungsten. Abrasive article sample C1 also included about 16 vol% diamond abrasive particles having a D50 of about 93 microns, a D10 of 76 microns, a D90 of 113 microns, an ellipticity of 1.19, an average toughness of about 11676 cycles, and 3 vol% abrasive particles having a particle size greater than 120 microns. Sample C1 had a porosity of about 1 vol% of the total volume of the body and had a mean pore diameter (D50) of 0.38 microns and a standard deviation of 0.19 microns. FIG. 2 includes a Scanning Electron Microscope (SEM) image of a portion of abrasive article sample C1 without abrasive particles.
A second sample, sample S2, was formed by preparing a mixture of abrasive particles, precursor bond material, and additives. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles had a D50 of 104 microns, a D90 of 113 microns, a D10 of 88 microns, and 1.5 vol% of the abrasive particles had a particle size greater than 120 microns. The abrasive particles had an average toughness of about 13135 cycles and an ellipticity of about 1.17.
The precursor bond material comprises Cobalt powder available from Umicore under the trade designation "Extrafine Cobalt" and further comprises Tin available from ACupower under the trade designation Tin 201.
The mixture was uniaxially hot pressed at a pressure of 2500psi and a temperature of 975 ℃ for 5 minutes. The resulting abrasive article sample S2 included about 16 vol% abrasive grains and about 81 vol% bond material. The bond material includes about 97 wt% cobalt and 3 wt% tin. The body further comprises about 3 vol% porosity, which is microporosity, having a mean pore diameter (D50) of about 0.51 microns, a D10 of about 0.25 microns, a D90 of about 1.25 microns, and a standard deviation of 0.42 microns.
A third sample, sample S3, was formed using the same method disclosed herein for making sample S2, except that the abrasive particles were titanium coated diamond abrasive particles available from ILJINs under the trade designation IMD-F. The abrasive particles had D50 of 97 microns, D90 of 113 microns, D10 of 84 microns, and 6 vol% of the abrasive particles had a particle size greater than 120 microns. The abrasive particles had an average toughness of about 10683 cycles and an ellipticity of about 1.15.
Abrasive article sample S3 was formed by hot pressing at a pressure of 2500psi and a temperature of 975 ℃ for about 5 minutes. The resulting abrasive article sample S3 included about 16 vol% abrasive grains and about 81 vol% bond material. The bond material includes about 97 wt% cobalt and 3 wt% tin. The body comprises about 3 vol% porosity, which is microporosity, having a mean pore diameter (D50) of about 0.51 microns, a D10 of about 0.25 microns, a D90 of about 1.25 microns, and a standard deviation of about 0.42 microns.
A fourth sample, sample S4, was formed using the same method disclosed for preparing sample S2, except that the abrasive particles were titanium coated diamond abrasive particles available from ILJIN. The abrasive particles had a D50 of 101 microns, a D90 of 113 microns, a D10 of 88 microns, and 1.5 vol% of the abrasive particles had a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15.
Abrasive article sample S4 was formed by hot pressing at a pressure of 2500psi and a temperature of 975 ℃ for about 5 minutes. The final formed abrasive article sample S4 included about 14 vol% abrasive grains and about 83 vol% bond material. The bond material included 97 wt% cobalt and 3 wt% tin. The body comprises about 3 vol% porosity.
The edge of the glass piece of white tempered glass was ground with each sample. The length of the working surface was about 4 linear meters for each glass workpiece sample. The samples were operated at a transverse velocity of 15m/min and a spindle speed of 45 m/s.
Fig. 4 and 5 include plots of current versus the number of finished glass pieces for each sample during two different finishing cycles, respectively. As shown in fig. 4, samples S2 and S3 have the lowest current. Sample S3 processed the most glass pieces before the current was increased to an undesirable current level and the sample required finishing. Each sample was trimmed according to the same conditions and tested again, resulting in the data shown in fig. 5. As shown in fig. 5, samples S2 and S3 have significantly lower current requirements and process more glass workpieces than samples C1 and S4. The results show a significant improvement in the number of finished glass pieces for sample S2.
Example 2
A sample (sample S5) was formed according to the disclosed method for preparing sample S2, except that the diamond was sieved using a stack of four screens with approximately micron-sized openings of 106 microns, 97 microns, 90 microns, and 75 microns. All abrasive particles above the 106 micron screen and below the 75 micron screen will be discarded. The abrasive particles were titanium coated diamond particles available from ILJINs under the trade name IMD-Mc. The abrasive particles have a D50 of about 95 microns, a D90 of about 103 microns, a D10 of about 80 microns, and about 0.1 vol% of the abrasive particles have a particle size greater than 120 microns. Fig. 6 includes an SEM image of a portion of sample S5 according to an embodiment.
Example 3
The sample (sample S6) was formed according to the method disclosed herein for preparing sample S2. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles have a D50 of about 104 microns, a D90 of about 113 microns, a D10 of about 88 microns, and about 1.5 vol% of the abrasive particles have a particle size greater than 120 microns. The abrasive particles had an average toughness of about 13135 cycles and an ellipticity of about 1.17. The final formed abrasive article sample S6 included about 14 vol% abrasive grains and about 83 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin. The body comprises about 3 vol% porosity, which is microporosity, having a mean pore diameter (D50) of about 0.51 microns, a D10 of about 0.25 microns, a D90 of about 1.25 microns, and a standard deviation of about 0.42 microns.
Example 4
The sample (sample S7) was formed according to the method disclosed herein for preparing sample S3, except that the amounts of abrasive particles and bond material were different. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles had a D50 of about 97 microns, a D90 of about 113 microns, a D10 of about 84 microns, and about 6 vol% of the abrasive particles had a particle size greater than 120 microns. The abrasive particles had an average toughness of about 10683 cycles and an ellipticity of about 1.15. The final formed abrasive article sample S7 included about 14.5 vol% abrasive grains and about 82.5 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin. The body comprises about 3 vol% porosity, which is microporosity, having a mean pore diameter (D50) of about 0.51 microns, a D10 of about 0.25 microns, a D90 of about 1.25 microns, and a standard deviation of about 0.42 microns.
Example 5
The sample (sample S8) was formed according to the method disclosed herein for preparing sample S4, except that the amounts of abrasive particles and bond material were different. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles have a D50 of about 101 microns, a D90 of about 113 microns, a D10 of about 88 microns, and about 1.5 vol% of the abrasive particles have a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15. The final formed abrasive article sample S8 included about 11 vol% abrasive grains and about 86 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin. The body comprises about 3 vol% porosity.
Example 6
The sample (sample S9) was formed according to the method disclosed herein for preparing sample S2, except that the amounts of abrasive particles and bond material were different. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles have a D50 of about 104 microns, a D90 of about 113 microns, a D10 of about 88 microns, and about 1.5 vol% of the abrasive particles have a particle size greater than 120 microns. The abrasive particles had an average toughness of about 13135 cycles and an ellipticity of about 1.17. The final formed abrasive article sample S9 included about 14.5 vol% abrasive grains and about 82.5 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin.
Example 7
The sample (sample S10) was formed according to the method for preparing sample S2 disclosed herein, except that the particle size and content of the abrasive particles and the content of the binding material were different. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles have a D50 of about 101 microns, a D90 of about 113 microns, a D10 of about 88 microns, and about 1.5 vol% of the abrasive particles have a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15. The final formed abrasive article sample S10 included about 11 vol% abrasive grains and about 86 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin.
Example 8
The sample (sample S11) was formed according to the method for preparing sample S2 disclosed herein, except that the particle size and content of the abrasive particles and the content of the binding material were different. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles have a D50 of about 101 microns, a D90 of about 113 microns, a D10 of about 88 microns, and about 1.5 vol% of the abrasive particles have a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15. The final formed abrasive article sample S11 included about 11 vol% abrasive grains and about 86 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin.
Example 9
The sample (sample S12) was formed according to the method for preparing sample S2 disclosed herein, except that the particle size and content of the abrasive particles and the content of the binding material were different. The abrasive particles are titanium coated diamond particles available from ILJINs. The abrasive particles had a D50 of about 106 microns, a D90 of about 115 microns, a D10 of about 92 microns, and about 2 vol% of the abrasive particles had a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15. The final formed abrasive article sample S12 included about 15 vol% abrasive grains and about 85 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin.
Example 10
The sample (sample S13) was made from multiple layers of abrasive sintered together according to the conditions provided in sample S2. In particular, the abrasive region is made of three layers, including a first layer, a third layer, and a second layer disposed between the first layer and the third layer. Each layer is formed separately as a green (i.e., unsintered) layer and combined together prior to final sintering and forming of the abrasive body. The first layer includes titanium coated diamond particles available from ILJINs. The abrasive particles had a D50 of about 97 microns, a D90 of about 105 microns, a D10 of about 76 microns, and 2 vol% of the abrasive particles had a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15. The first layer formed included about 14 vol% abrasive grains and about 86 vol% bond material. The bond material includes about 97 wt% cobalt and about 3 wt% tin.
The second layer comprises titanium coated diamond particles available from ILJINs. The abrasive particles have a D50 of about 104 microns, a D90 of about 113 microns, a D10 of about 88 microns, and about 1.5 vol% of the abrasive particles have a particle size greater than 120 microns. The abrasive particles had an average toughness of about 11939 cycles and an ellipticity of about 1.15. The second layer formed included about 14 vol% abrasive grains and about 83 vol% bond material. The bond material includes 97 wt% cobalt and about 3 wt% tin.
The third layer is formed to have the same configuration as the first layer. The three layers were co-sintered together according to the conditions provided in sample S2. The finally-formed abrasive body comprises a porosity of about 3 vol% of the total volume of the body.
Example 11
Use of
Figure GDA0002336588290000511
Grinder, on a laminated glass work piece having a thickness of 2.1mm, samples S2 and S6 and available from 3M under the trade name K20PTMThe conventional sample C2 of (a) was subjected to a grinding test. The sample was operated at a transverse velocity of 18m/min and a spindle speed of 38 m/s. The same trim was applied to the sample at the same frequency. The run length of the sample is shown in figure 7. Samples S2 and S6 were able to grind longer straight lengths compared to C2.
Example 12
On a laminated windshield, a grinding test was performed on sample S2 and conventional samples C3 and C4, available under the trade name GNAA from Dow-Tian-HighTech and Shanghai Xinpengpen industries, Inc. The tests were performed using a bystranic mill, the operating parameters and run lengths included in tables 1 and 2.
TABLE 1
Sample (I) Transverse velocity Spindle speed Frequency of trimming Length of linear travel
C3 16m/min 30m/s 13pcs 8000-11000m
S2 18m/min 36m/s 13pcs 9537m
TABLE 2
Sample (I) Transverse velocity Spindle speed Frequency of trimming Length of linear travel
C4 12m/min 22m/s 16pcs/2imp 6000-8000m
S2 16m/min 22m/s 16pcs/2imp 9680m
As listed in table 1, sample S2 was able to grind at a faster rate than C3 and achieved a similar straight line length for grinding. Sample S2 was able to grind a longer straight distance at a faster lateral speed than C4 (table 2).
Example 13
Sample S14 was formed using the method disclosed herein for preparing sample S2, except that the abrasive particles were titanium coated diamond particles (200/230 mesh) available from Warren Amplex supports. The abrasive particles had an average toughness of about 12392 cycles and an ellipticity of about 1.1176. The resulting abrasive article sample S14 included about 16 vol% diamond abrasive grains and about 81 vol% bond material. The bond material includes about 97 wt% cobalt and 3 wt% tin. The body further comprises about 3 vol% porosity, which is microporosity, having a mean pore diameter (D50) of about 0.51 microns, a D10 of about 0.25 microns, a D90 of about 1.25 microns, and a standard deviation of 0.42 microns.
Samples S6 and S14 were tested on glass workpieces under optimal low coolant flow conditions. For the optimum conditions, the coolant flow rate was 67l/min and sample S6 was operated at a lateral speed of 15m/min and a spindle speed of 30m/S, while samples S14 and S6 were operated at the same lateral speed and a grinding wheel speed of 37.5 m/S. For the low coolant flow conditions, the flow rate was 40l/min, and samples S6 and S14 were operated at a lateral velocity of 12m/min and a grinding wheel speed of 53 m/S.
Operation at low coolant flow rates can result in a burning effect of the glass workpiece (creating sparks during grinding) that can be addressed by adjusting the dressing frequency. As shown in fig. 8, samples S6 and S14 trimmed at similar frequencies at the optimum coolant flow rate, whereas sample S6 required trimming more frequently than sample S14 (once every 10 glass workpieces for S6; once every 25 glass workpieces for S14) at low flow rates to achieve the desired grinding results.
It is noted that not all of the activities in the general descriptions or examples above are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Further, the order in which activities are listed is not necessarily the order in which the activities are performed.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature or feature of any or all the claims.
The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and drawings are not intended to serve as an exhaustive or comprehensive description of all the elements and features of apparatus and systems that utilize the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values expressed as ranges includes each and every value within that range. Many other embodiments will be apparent to the skilled person only after reading this description. Other embodiments may be utilized and derived from the disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the disclosure. Accordingly, the present disclosure is to be considered as illustrative and not restrictive.

Claims (15)

1. An abrasive article comprising:
a body, the body comprising:
a bond material comprising a metal and further comprising a microporosity within the bond material, the microporosity comprising an average pore size (D50) of no greater than 10 microns and a pore size standard deviation of at least 0.2 microns;
abrasive particles contained within a bond material, the abrasive particles further comprising at least one of:
a) an ellipticity of not greater than 1.18; or
b) An average toughness of at least 11257 cycles as measured in accordance with ANSIB 74.23.
2. The abrasive article of claim 1, wherein the abrasive particles comprise a superabrasive material.
3. The abrasive article of claim 1 or 2, wherein the abrasive particles comprise diamond.
4. The abrasive article of claim 1 or 2, wherein the abrasive particles comprise a coating, wherein the coating comprises a metal or metal alloy comprising a transition metal element.
5. The abrasive article of claim 4, wherein the coating comprises titanium.
6. The abrasive article of claim 1 or 2, wherein the abrasive particles comprise a particle size distribution comprising at least one of:
d50 of at least 65 microns and no greater than 150 microns;
d10 of at least 57 microns and not greater than 127 microns; and
d90 of at least 97 microns and not greater than 165 microns.
7. The abrasive article of claim 1 or 2, wherein the abrasive particles comprise at least 2000kg/mm2Vickers hardness of (2).
8. The abrasive article of claim 1 or 2, wherein the abrasive particles have an average toughness of at least 11257 cycles and not greater than 16000 cycles.
9. The abrasive article of claim 1 or 2, wherein the abrasive particles have an ellipticity of at least 1.01 and not greater than 1.17.
10. The abrasive article of claim 1 or 2, wherein the body comprises:
abrasive particles in an amount of at least 2 wt% and not greater than 10 wt% of the total weight of the body;
a bonding material in an amount of at least 20 wt% and not greater than 95 wt% of the total weight of the body; and
a porosity of at least 0.5 vol% and not greater than 50 vol% of the total volume of the body.
11. The abrasive article of claim 1 or 2, wherein the bond material comprises:
cobalt in an amount of at least 0.1 wt% and not greater than 99 wt% of the total weight of the body;
tin in an amount of at least 1 wt% and not greater than 15 wt% of the total weight of the body;
tungsten in an amount of at least 0.05 wt% and not greater than 20 wt% of the total weight of the body;
copper in an amount of no greater than 20 wt% of the total weight of the body; or
Any combination thereof.
12. The abrasive article of claim 1 or 2, wherein at least 95 wt% of the bond material comprises cobalt, tin, and tungsten, and no greater than 5 wt% of the bond material comprises a second element selected from the group consisting of: aluminum, copper, manganese, lead, silicon, and titanium.
13. The abrasive article of claim 1 or 2, wherein the body comprises a first region and a second region, the first region comprising a first content of abrasive particles and the second region comprising a second content of abrasive particles, wherein the first content and the second content are different from each other, and wherein the first region and the second region are in the form of a layer.
14. A method of forming an abrasive article comprising:
forming a mixture comprising a precursor bond material and abrasive particles; and
heating the mixture to form a body comprising:
a bond material comprising a metal and further comprising a microporosity within the bond material, the microporosity comprising an average pore size (D50) of no greater than 10 microns and a pore size standard deviation of at least 0.2 microns;
abrasive particles contained within a bond material, the abrasive particles further comprising at least one of:
a) an ellipticity of not greater than 1.18; or
b) Average toughness of at least 11257 cycles.
15. The method of claim 14, wherein the mixture includes a precursor bond material having an average particle size of no greater than 25 microns.
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