U.S. patent application number 15/940546 was filed with the patent office on 2018-10-04 for abrasive article and method for forming same.
The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Jiashu LI, Kelley McNEAL, Cecile O. MEJEAN, Srinivasan RAMANATH, Ji WANG.
Application Number | 20180281153 15/940546 |
Document ID | / |
Family ID | 63672794 |
Filed Date | 2018-10-04 |
United States Patent
Application |
20180281153 |
Kind Code |
A1 |
LI; Jiashu ; et al. |
October 4, 2018 |
ABRASIVE ARTICLE AND METHOD FOR FORMING SAME
Abstract
The present disclosure relates to an abrasive article including
a body having a bond material including metal and a micro-porosity
within the bond material with an average pore size (D50) of not
greater than 10 microns and a pore size standard deviation of at
least 0.2 microns, and the body further includes abrasive particles
contained within the bond material and having an ellipticity of not
greater than 1.18 or an average toughness of at least 11257
cycles.
Inventors: |
LI; Jiashu; (Worcester,
MA) ; McNEAL; Kelley; (Northborough, MA) ;
RAMANATH; Srinivasan; (Holden, MA) ; MEJEAN; Cecile
O.; (Acton, MA) ; WANG; Ji; (Shanghai,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
63672794 |
Appl. No.: |
15/940546 |
Filed: |
March 29, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62478253 |
Mar 29, 2017 |
|
|
|
62525261 |
Jun 27, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24D 3/10 20130101; B24D
5/063 20130101; B24D 18/0009 20130101; B24D 18/00 20130101; B24D
5/14 20130101 |
International
Class: |
B24D 5/06 20060101
B24D005/06; B24D 18/00 20060101 B24D018/00 |
Claims
1. An abrasive article comprising: a body comprising: a bond
material comprising metal and further comprising micro-porosity
within the bond material, the micro-porosity comprising an average
pore size (D50) of not greater than 10 microns and a pore size
standard deviation of at least 0.2 microns; abrasive particles
contained within bond material and 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 according to ANSIB74.23.
2. The abrasive article of claim 1, wherein the abrasive particles
comprise a material selected from the group consisting of oxides,
carbides, nitrides, borides, or any combination thereof.
3. The abrasive article of claim 1, wherein the abrasive particles
comprise a superabrasive material.
4. The abrasive article of claim 1, wherein the abrasive particles
comprise diamond.
5. The abrasive article of claim 1, wherein the abrasive particles
consist essentially of diamond.
6. The abrasive article of claim 1, wherein the abrasive particles
comprise a coating.
7. The abrasive article of claim 6, wherein the coating comprises a
metal or metal alloy including a transition metal element.
8. The abrasive article of claim 6, wherein the coating comprises
titanium.
9. The abrasive article of claim 1, wherein the abrasive particles
comprise a particle size distribution including at least one of: a
D50 of at least 65 microns and not greater than 150 microns; a D10
of at least 57 microns and not greater than 127 microns; and a D90
of at least 97 microns and not greater than 165 microns.
10. The abrasive article of claim 1, wherein the abrasive particles
comprise a Vickers hardness of at least 2000 kg/mm.sup.2.
11. The abrasive article of claim 1, wherein the abrasive particles
have an average toughness of at least 11850 cycles and not greater
than 16000 cycles.
12. The abrasive article of claim 1, wherein the abrasive particles
have an ellipticity of at least 1.01 and not greater than 1.17.
13. The abrasive article of claim 1, wherein the body comprises a
content of: the abrasive particles of at least 2 wt % and not
greater than 10 wt % for a total weight of the body; the bond
material of at least 20 wt % and not greater than 95 wt % for the
total weight of the body; and a porosity of at least 0.5 vol % and
not greater than 50 vol % for a total volume of the body.
14. The abrasive article of claim 1, wherein the bond material
comprises: cobalt in a content of at least 0.1 wt % and not greater
than 99 wt % for a total weight of the body; tin in a content of at
least 1 wt % and not greater than 15 wt % for the total weight of
the body, tungsten in a content of at least 0.05 wt % and not
greater than 20 wt % for the total weight of the body; copper in a
content of not greater than 20 wt % for the total weight of the
body; or any combination thereof.
15. The abrasive article of claim 1, wherein at least 95 wt % of
the bond material comprises cobalt, tin and tungsten, and not
greater than 5 wt % of the bond material comprises secondary
elements selected from the group consisting of aluminum, copper,
manganese, lead, silicon, and titanium.
16. The abrasive article of claim 1, wherein the body comprises a
first region comprising a first content of abrasive particles and a
second region comprising a second content of abrasive particles,
wherein the first content and second content are different compared
to each other.
17. The abrasive article of claim 16, wherein the first region and
the second region are in the form of a layer, wherein the second
region is directly contacting the first region.
18. The abrasive article of claim 16, wherein the first region
comprises a first content of a first bond material, and wherein 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 first content of the first bond material.
19. A method for forming an abrasive article including forming a
mixture including precursor bond material and abrasive particles;
and heating the mixture to form a body comprising: a bond material
comprising metal and further comprising micro-porosity within the
bond material, the micro-porosity comprising an average pore size
(D50) of not greater than 10 microns and a pore size standard
deviation of at least 0.2 microns; abrasive particles contained
within bond material and 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.
20. The method of claim 19, wherein the mixture includes a
precursor bond material having an average particle size of not
greater than 25 microns.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 62/478,253, filed Mar. 29, 2017, entitled
"ABRASIVE ARTICLE AND METHOD FOR FORMING SAME," naming as inventors
Jiashu Li et al., and claims priority to U.S. Provisional Patent
Application No. 62/525,261, filed Jun. 27, 2017, entitled "ABRASIVE
ARTICLE AND METHOD FOR FORMING SAME," naming as inventors Jiashu Li
et al., both of which are incorporated by reference herein in their
entireties.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to abrasive articles, and in
particular, bonded abrasive articles including abrasive particles
contained within a bond material including a metal or metal
alloy.
BACKGROUND
[0003] Abrasives used in machining applications typically include
bonded abrasive articles and coated abrasive articles. Coated
abrasive articles are generally layered articles having a backing
and an adhesive coat to fix abrasive particles to the backing, the
most common example of which is sandpaper. Bonded abrasive tools
consist of rigid, and typically monolithic, three-dimensional,
abrasive composites in the form of wheels, discs, segments, mounted
points, hones and other tool shapes, which can be mounted onto a
machining apparatus, such as a grinding or polishing apparatus.
[0004] Bonded abrasive tools usually have at least two phases
including abrasive particles and bond material. Certain bonded
abrasive articles can have an additional phase in the form of
porosity. Bonded abrasive tools can be manufactured in a variety of
`grades` and `structures` that have been defined according to
practice in the art by the relative hardness and density of the
abrasive composite (grade) and by the volume percentage of abrasive
grain, bond, and porosity within the composite (structure).
[0005] Some bonded abrasive tools may be particularly useful in
grinding and shaping certain types of workpieces, including for
example, metals, ceramics and crystalline materials, used in the
electronics and optics industries. In other instances, certain
bonded abrasive tools may be used in shaping of superabrasive
materials for use in industrial applications. In the context of
grinding and shaping certain workpieces with metal-bonded abrasive
articles, generally the process involves a significant amount of
time and labor directed to maintaining the bonded abrasive article.
That is, generally, metal-bonded abrasive articles require regular
truing and dressing operations to maintain the grinding
capabilities of the abrasive article.
[0006] The industry continues to demand improved methods and
articles capable of grinding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Embodiments are illustrated by way of example and are not
limited to the accompanying figures.
[0008] FIG. 1A includes a cross-sectional illustration of an
abrasive article according to an embodiment.
[0009] FIG. 1B includes a cross-sectional illustration of an
abrasive article according to an embodiment.
[0010] FIG. 2 includes a scanning electron microscope (SEM) image
of a portion of a conventional abrasive article.
[0011] FIG. 3 includes a SEM image of a portion of an abrasive
article according to an example.
[0012] FIG. 4 includes a plot of current versus number of
workpieces for samples described herein.
[0013] FIG. 5 includes a plot of current versus number of
workpieces for samples described herein.
[0014] FIG. 6 includes a SEM image of a portion of Sample S5
according to an embodiment.
[0015] FIG. 7 includes a graph of run lengths for samples disclosed
herein.
[0016] FIG. 8 includes a plot of coolant flow rates versus dressing
frequencies for samples disclosed herein.
[0017] Skilled artisans appreciate that elements in the figures are
illustrated for simplicity and clarity and have not necessarily
been drawn to scale.
DETAILED DESCRIPTION
[0018] The following discussion will focus on specific
implementations and embodiments of the teachings. The detailed
description is provided to assist in describing certain embodiments
and should not be interpreted as a limitation on the scope or
applicability of the disclosure or teachings. It will be
appreciated that other embodiments can be used based on the
disclosure and teachings as provided herein.
[0019] The terms "comprises," "comprising," "includes,"
"including," "has," "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 only to those features but may include other
features not expressly listed or inherent to such method, article,
or apparatus. Further, unless expressly stated to the contrary,
"or" refers to an inclusive-or and not to an exclusive-or. For
example, a condition A or B is satisfied by any one of the
following: 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).
[0020] Also, the use of "a" or "an" is employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one, at least
one, or the singular as also including the plural, or vice versa,
unless it is clear that it is meant otherwise. 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 that more
than one item.
[0021] An abrasive article can be formed according to the following
method. A mixture is formed including abrasive particles in a
precursor bond material. The precursor bond material can include a
raw material powder including a metal, metal alloy, or metal
forming material or compound. In one embodiment, the precursor bond
material, which may be a powder material, can have an average
particle size (D50) of not greater than 25 microns or not greater
than 10 microns or not greater than 1 micron or not greater than
0.75 microns or not greater than 0.5 microns or not greater than
0.25 microns or not greater than 0.1 microns. Still, in one
embodiment, the precursor bond 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 particles size of the
precursor bond material can be within a range including any of the
minimum and maximum values noted above.
[0022] According to one embodiment, the mixture can include a
precursor bond material, which may be formed of one or more
powdered metal materials. For example, in one embodiment, the
precursor bond material, which forms the bond material of the body
of the abrasive article, can include at least one of cobalt, tin,
tungsten, copper, or any combination thereof. In a more particular
embodiment, the precursor bond material can include cobalt, tin and
tungsten.
[0023] According to a particular embodiment, the precursor bond
material may have a particular content of cobalt and tin that may
facilitate improved formation and/or performance of the abrasive
article. For example, the precursor bond material can include
cobalt (CCo) and tin (CSn) in a ratio [CSn/CCo] of not greater than
0.2, wherein CCo is the weight percent of cobalt for the entire
weight of the precursor bond material and CSn is the weight percent
of tin for the entire weight of the precursor bond material. In
other instances, the ratio [CSn/CCo] can be not greater than 0.19,
such as 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. 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 be within a range
including any of the minimum and maximum values noted above.
[0024] According to a particular embodiment, the precursor bond
material may have a particular content of cobalt and tungsten that
may facilitate improved 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 not
greater than 0.9, wherein CCo is the weight percent of cobalt for
the entire weight of the precursor bond material and CW is the
weight percent of tungsten for the entire weight of the precursor
bond material. In another embodiment, the ratio [CW/CCo] can be not
greater than 0.8, such as 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. In another embodiment, the ratio [CW/CCo] can 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 be within a range
including any of the minimum and maximum values noted above.
[0025] According to a particular embodiment, the precursor bond
material may have a particular content of tungsten and tin that may
facilitate improved 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 not greater than 1,
wherein CW is the weight percent of tungsten for the entire weight
of the precursor bond material and CSn is the weight percent of tin
for the entire weight of the precursor bond material. In another
embodiment, the ratio [CSn/CW] can 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] can 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 be within a range including
any of the minimum and maximum values noted above.
[0026] The precursor bond material may have a particular content of
cobalt that may facilitate improved formation and/or performance of
the abrasive article. For example, the precursor bond material may
include at least 40 wt % cobalt for a total weight of the precursor
bond 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 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 for the weight of the precursor bond material. In
one non-limiting embodiment, the precursor bond material can
include a content of cobalt of not greater than 99 wt % for the
total weight of the precursor bond material, such as 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 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 for the entire weight of the precursor
bond material. It will be appreciated that the content of cobalt in
the precursor bond material can be within a range including any of
the minimum and maximum values noted above.
[0027] The precursor bond material may have a particular content of
tin that may facilitate improved formation and/or performance of
the abrasive article. For example, the precursor bond material may
include at least 0.1 wt % tin for a total weight of the precursor
bond material 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 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 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 for the total weight of the precursor
bond material. In one non-limiting embodiment, the precursor bond
material can include a content of tin of not greater than 15 wt %
for a total weight of the precursor bond material 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 % tin for the total weight of the precursor
bond material. It will be appreciated that the content of tin in
the precursor bond material can be within a range including any of
the minimum and maximum values noted above.
[0028] The precursor bond material may have a particular content of
tungsten that may facilitate improved formation and/or performance
of the abrasive article. For example, the precursor bond material
may include at least 1 wt % tungsten for a total weight of the
precursor bond 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 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 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 for the total weight of the
precursor bond material. Still, in at least one non-limiting
embodiment, the precursor bond material may include greater than 20
wt % tungsten for a total weight of the precursor bond material,
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 weight of the precursor bond material. It
will be appreciated that the content of tungsten in 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 may be essentially free of tungsten.
[0029] The mixture may include a particular content of iron that
may facilitate improved formation and/or performance of the
abrasive article. For example, the precursor bond material can
include a content of iron of at least 0.05 wt % for a 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 a
total weight of the precursor bond material. In another
non-limiting embodiment, the precursor bond material can include a
content of iron of not greater than 5 wt % for a total weight of
the precursor bond material, such as 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 %. It will be appreciated
that the content of iron in the precursor bond material can be
within a range including any of the minimum and maximum values
noted above. Still, in one embodiment, the precursor bond material
may be essentially free of iron.
[0030] The mixture may include a particular content of aluminum
that may facilitate improved formation and/or performance of the
abrasive article. For example, the precursor bond material can
include a content of aluminum of not greater than 1 wt % for a
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 % or not greater than 0.05 wt % or not greater than
0.01 wt %. Still, in another non-limiting embodiment, the precursor
bond material can include a content of aluminum of at least 0.001
wt % or at least 0.01 wt % for the total weight of the precursor
bond material. It will be appreciated that the content of aluminum
in the precursor bond material can be within a range including any
of the minimum and maximum values noted above. Still, in one
embodiment, the precursor bond material may be essentially free of
aluminum.
[0031] The mixture may include a particular content of copper that
may facilitate improved formation and/or performance of the
abrasive article. For example, the precursor bond material can
include a content of copper of not greater than 20 wt % for a 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 % or not greater than 0.09
wt % or not greater than 0.05 wt % or not greater than 0.01 wt %.
Still, in another non-limiting embodiment, the precursor bond
material can include a content of copper of at least 0.001 wt % or
at least 0.01 wt % for the total weight of the precursor bond
material. It will be appreciated that the content of copper in the
precursor bond material can be within a range including any of the
minimum and maximum values noted above. Still, in one embodiment,
the precursor bond material may be essentially free of copper.
[0032] The mixture may include a particular content of manganese
that may facilitate improved formation and/or performance of the
abrasive article. For example, the precursor bond material can
include a content of manganese of not greater than 1 wt % for a
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 % or not greater than 0.05 wt % or not greater than
0.01 wt %. Still, in another non-limiting embodiment, the precursor
bond material can include a content of manganese of at least 0.001
wt % or at least 0.01 wt % for the total weight of the precursor
bond material. It will be appreciated that the content of manganese
in the precursor bond material can be within a range including any
of the minimum and maximum values noted above. Still, in one
embodiment, the precursor bond material may be essentially free of
manganese.
[0033] The mixture may include a particular content of titanium
that may facilitate improved formation and/or performance of the
abrasive article. For example, the precursor bond material can
include a content of titanium of not greater than 1 wt % for a
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 %. Still, in another non-limiting embodiment, the
precursor bond material can include a content of titanium of at
least 0.001 wt % or at least 0.01 wt % for the total weight of the
precursor bond material. It will be appreciated that the content of
titanium in the precursor bond material can be within a range
including any of the minimum and maximum values noted above. Still,
in one embodiment, the precursor bond material may be essentially
free of titanium.
[0034] In still another embodiment, the precursor bond material may
have a particular content of certain metals that may facilitate
improved formation and/or performance of the abrasive article. For
example, the precursor bond material can have a total content of
aluminum, copper, manganese, lead, silicon, and titanium (i.e., sum
total of weight percent for each of the listed elements) of not
greater than 20 wt % for a 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 %. Still, in one non-limiting embodiment, the
precursor bond material can include a total content of aluminum,
copper, manganese, lead, silicon, and titanium of at least 0.001 wt
% or at least 0.01 wt % for the total weight of the precursor bond
material. It will be appreciated that the total content of
aluminum, copper, manganese, lead, silicon, and titanium in the
precursor bond material can be within a range including any of the
minimum and maximum values noted above.
[0035] In at least one embodiment, the precursor bond material can
be essentially free of aluminum, copper, manganese, lead, silicon,
and/or titanium. As used herein the term essentially free is
intended to include minimum amounts of the material limited to
impurity contents, including for example, but not necessarily
limited to, contents of not greater than 0.01 wt %.
Correspondingly, if a composition is described as consisting of or
consisting essentially of components X, Y, and Z, the composition
should be interpreted as including components X, Y, and Z and only
impurity amounts of other components or such minimal amounts of
said other components, that said other components do not affect the
properties or performance of the composition. Such statements are
applicable to the description of any of the embodiments herein.
[0036] In another embodiment, the precursor bond material can be
formed to include at least 95 wt % of cobalt, tin and tungsten for
the total weight of the precursor bond material. Moreover, in such
an embodiment, not greater than 5 wt % of the precursor bond
material can include secondary elements selected from the group
consisting of including aluminum, copper, manganese, lead, silicon,
and titanium. In yet embodiment, the precursor bond material can be
formed to include at least 95 wt % of 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.
[0037] The mixture may include one or more other additives,
including for example, fillers that may be present in the final
abrasive article and facilitate improved operations of the abrasive
article. Suitable fillers can include those 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 can include mixing agents (e.g., dispersants,
surfactants, etc.).
[0038] According to one embodiment, the abrasive particles can
include a material selected from the group consisting of oxides,
carbides, nitrides, borides, or any combination thereof. For
example, the abrasive particles can include a superabrasive
material, such as diamond. In one particular instance, the abrasive
particles can consist essentially of diamond. It will also be
appreciated that the abrasive particles can include a mixture of
abrasive particles, which may 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 can include a blend
of two different types of diamond particles including a first type
of diamond particles and a second type of diamond particles,
wherein the first type of diamond particles are different from the
second type of diamond particles based on average particle size,
average toughness, hardness, ellipticity, or any combination
thereof.
[0039] In another aspect, the abrasive particles can have a coating
overlying the exterior surface. The coating may facilitate improved
formation and performance of the abrasive article. In certain
instances, the coating can include a material that reduces chemical
changes to the abrasive particles during formation, such as
oxidation of the abrasive particles. In other instances, the
coating may limit the chemical interactions between the abrasive
particle and the bond material during forming. The coating can
include a metal or metal alloy. Some suitable metal materials can
include one or more transition metal elements. In a particular
embodiment, the coating can include titanium, and may consist
essentially of titanium.
[0040] The weight and/or thickness of the coating can be varied to
facilitate suitable processing and/or performance of the abrasive
article. Moreover, the coating can be formed such that it overlies
a majority of the exterior surfaces of the abrasive particles, such
as at least 60% or at least 70% or at least 80% or at least 90% or
at least 95% of the exterior surfaces of the abrasive
particles.
[0041] The abrasive particles may have a particular particle size
distribution that can facilitate improved 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
the 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. Still, 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 including any of the minimum and maximum values
noted above.
[0042] The abrasive particles may also have a particular D10 that
may define the maximum particle size of the particles in the lowest
10% of the distribution (i.e., the particle size of the abrasive
particles in the 10.sup.th percentile 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 can have a 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. It will be
appreciated that the abrasive particles can have a D10 within a
range including any of the minimum and maximum values noted
above.
[0043] The abrasive particles may also have a particular D90 that
may define the minimum particle size of the particles in the
greatest 10% of the distribution (i.e., the particle size for the
abrasive particles in the 90.sup.th percentile of the
distribution). For example, the abrasive particles can 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 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 abrasive particles can have a D90 within a
range including any of the minimum and maximum values noted
above.
[0044] The abrasive particles may also define a particle size
distribution having a particularly limited size of particles
greater than 120 microns. For example, in one instance, the
abrasive particles define a particle size distribution having not
greater than 10 vol % of abrasive particles with a particle size
greater than 120 microns for the total volume of abrasive particles
in the distribution, such as 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 1.8 vol % or not greater than 1.5 vol % of abrasive
particles with a particle size greater than 120 microns for the
total volume of abrasive particles in the distribution. Still, in
at least one instance, the content of abrasive particles with a
particle size greater than 120 microns for the total volume of
abrasive particles in the distribution may be at least 0.1 vol % or
at least 0.5 vol % or even at least 0.8 vol %. It will be
appreciated that the content of abrasive particles with a particle
size greater than 120 microns for the total volume of abrasive
particles in the distribution can be within a range including any
of the minimum and maximum percentages noted above.
[0045] The abrasive particles may have a particular Vickers
hardness that may facilitate improved performance of the abrasive
article. For example, the abrasive particles can have a Vickers
hardness of at least 2000 kg/mm.sup.2 or at least 3000 kg/mm.sup.2
or at least 4000 kg/mm.sup.2 or at least 5000 kg/mm.sup.2. In
another non-limiting embodiment, the abrasive particles can have a
Vickers hardness of not greater than 12,000 kg/mm.sup.2. It will be
appreciated that the abrasive particles can have a Vickers hardness
within a range including any of the minimum and maximum values
noted above.
[0046] According to another aspect, the abrasive particles can have
a particular average toughness that may facilitate improved
performance of the abrasive article. Toughness of the abrasive
particles is measured according to ANSIB74.23 on abrasive grains as
obtained from the supplier under the ambient condition without
subjecting the grains to processing or treatment, such as heating,
prior to the measurement. Average toughness, as used herein, is to
be appreciated as an average calculated based upon the toughness
test data that appears to have a variation of 5% or less. For
example, the abrasive particles can have an average toughness of
11257 cycles, which may include a variation of up to .+-.563. In
another embodiment, the average toughness can be at least 11850
cycles or at least 11900 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 can have an average toughness of
not greater than 16000 cycles or not greater than 15000 cycles or
not greater than 14500 cycles or not greater than 14000 cycles or
not greater than 13900 cycles or not greater than 13800 cycles or
not greater than 13700 cycles or not greater than 13600 cycles or
not greater than 13500 cycles or not greater than 13400 cycles or
not greater than 13300 cycles. It will be appreciated that the
abrasive particles can have an average toughness within a range
including any of the minimum and maximum values noted above.
[0047] In still another aspect, the abrasive particles may have a
particular shape, as measured by ellipticity that may facilitate
improved performance of the abrasive article. For example, the
abrasive particles can have an ellipticity of 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. Still, 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 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. It will be appreciated that
the abrasive particles can have an ellipticity within a range
including any of the minimum and maximum values noted above.
[0048] The ellipticity is measured using imaging analysis of a
suitable number of randomly sampled particles. A random sampling of
at least 2000 discrete abrasive particles is obtained and placed
onto an adhesive side of a tape. Care should be taken to distribute
the particles uniformly across the tape and avoid clumping of the
particles. The tape may be attached to a slide or other surface
that can facilitate imaging of the particles contained on the tape.
Using a Pro-scanner 7200 commercially available from Reflecta, GmbH
scan the diamonds contained on the tape of the slide. Multiple
scans may be required until the scanner produces a clear image of
each of the particles. Using Diashape software, the image is
analyzed. 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 Diashape software calculates the
ellipticity of each of the particles and then calculates and
average ellipticity for the sample of particles.
[0049] The mixture may be formed to include a particular content of
the abrasive particles, which may facilitate formation and
performance of the abrasive article. For example, in one instance,
the mixture can include at least 2 wt % abrasive particles for a
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 % for the total weight of the mixture. In one
non-limiting embodiment, the mixture may include not greater than
10 wt % abrasive particles for a total weight of the mixture, such
as 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 % for the total weight of the mixture. It will be
appreciated that the mixture can include a content of abrasive
particles within a range including any of the minimum and maximum
values noted above.
[0050] The mixture may be formed to include a particular content of
the bond material or precursor bond material, which may facilitate
formation and performance of the abrasive article. For example, in
one instance, the mixture can include at least at least 20 wt %
bond material or precursor bond material for a total weight of the
mixture, 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 % for the
total weight of the mixture. In one non-limiting embodiment, the
mixture may include not greater than 99 wt % bond material or
precursor bond material for a total weight of the mixture, such as
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 % for the total
weight of the mixture. It will be appreciated that the mixture can
include a content of bond material or precursor bond material
within a range including any of the minimum and maximum percentages
noted above. It will also be appreciated that the bond material or
precursor bond material may be a total content of raw material
powder particulate that will for the bond material.
[0051] After the mixture is created to combine the desired
components, the mixture can be shaped into a green body. Some
suitable processes for shaping of the green body from the mixture
can include molding, pressing, casting, punching, cutting,
printing, spraying, depositing, or any combination thereof.
[0052] After or during the process for forming the green body, the
body may undergo treatment to form the finally-formed abrasive
article. Some suitable treatments can include drying, curing,
heating, sintering, or any combination thereof. In at least one
embodiment, the mixture is placed into a mold and subject to a
suitable pressure and temperature to facilitate formation of the
finally-formed abrasive article.
[0053] According to one embodiment, the process of forming the
abrasive article can include heating of the mixture to form the
body of the finally-formed abrasive article. Heating may be
conducted at a particular temperature to ensure suitable formation
of a microstructure that may facilitate improved performance. For
example, heating the mixture can be conducted at a temperature of
at least 700.degree. C. or at least 725.degree. C. or at least
750.degree. C. or at least 775.degree. C. or at least 800.degree.
C. or at least 825.degree. C. or at least 850.degree. C. or at
least 875.degree. C. or at least 900.degree. C. or at least
925.degree. C. or at least 950.degree. C. or at least 975.degree.
C. or at least 1000.degree. C. Still, in one non-limiting
embodiment, heating of the mixture can be conducted at a
temperature of not greater than 1100.degree. C. or not greater than
1050.degree. C. or not greater than 1000.degree. C. or not greater
than 975.degree. C. or not greater than 950.degree. C. or not
greater than 925.degree. C. or not greater than 900.degree. C. It
will be appreciated that the heating can be completed at a
temperature within a range including any of the minimum and maximum
values noted above. The heating temperature noted above, may be the
maximum temperature at which the mixture is sintered to facilitate
formation of the abrasive article. The heating temperature may also
be the maximum temperature that coincides with a maximum pressure
applied to the mixture, in those instances where a combination of
heat and pressure are applied to the mixture to facilitate
formation of the abrasive article.
[0054] According to one embodiment, the process for forming the
body of the finally-formed abrasive article can include hot
pressing the mixture, wherein a combination of pressure and
temperature are applied to the mixture to facilitate formation. In
one embodiment, the hot pressing operation can be conducted at a
temperature within a range for any of the temperatures noted above.
In one embodiment, the process for forming the body can include hot
pressing the mixture at a pressure of at least 1000 psi, such as at
least 1500 psi or at least 2000 psi or at least 2200 psi. In
another non-limiting embodiment, hot pressing can be conducted at a
pressure of not greater than 5000 psi, such as not greater than
4000 psi or not greater than 3000 psi or not greater than 2750 psi.
It will be appreciated that the pressure can be within a range
including any of the minimum and maximum values noted above. The
pressure noted above, may be the maximum pressure applied to the
mixture during forming. The pressure noted above may also be the
maximum pressure that coincides with a maximum temperature applied
to the mixture during the forming process. The hot pressing can be
unidirectional or isostatic pressing.
[0055] The resulting abrasive article can be a bonded abrasive body
including a three dimensional body including a three-dimensional
bond of the bond material defining a matrix of material as a
continuous phase and containing abrasive particles therein. In
certain instances, the body of the abrasive article may include
some phase or porosity.
[0056] According to one embodiment, the body may have a particular
content of porosity that may facilitate improved performance of the
abrasive article. For example, the body can include a content of
porosity of at least 0.5 vol % for a 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 content of porosity in the body can be not greater
than 50 vol % for a total volume of the body 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 %. It will be
appreciated that the content of porosity within the body can be
within a range including any of the minimum and maximum values
noted above.
[0057] The body of the abrasive article may be formed to include a
particular content of the abrasive particles, which may facilitate
improved performance of the abrasive article. For example, in one
instance, the body can include at least 2 wt % abrasive particles
for a total weight of the body 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 % for the total weight of the mixture. In one
non-limiting embodiment, the body may include not greater than 10
wt % abrasive particles for a total weight of the body, such as 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 % for the total weight of the body. It will be
appreciated that the body can include a content of abrasive
particles within a range including any of the minimum and maximum
values noted above.
[0058] The body may be formed to include a particular content of
the bond material, which may facilitate improved performance of the
abrasive article. For example, in one instance, the body can
include at least at least 20 wt % bond material or material for a
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 % for the total weight of the body. In one non-limiting
embodiment, the body may include not greater than 99 wt % bond
material for a total weight of the body, such as 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 % for the total weight of the body. It
will be appreciated that the body can include a content of bond
material within a range including any of the minimum and maximum
values noted above.
[0059] The abrasive particles contained in the body can have any of
the features described in the embodiments herein with respect to
the abrasive particles included in the mixture used to form the
abrasive article. Notably, the abrasive particles of the
finally-formed abrasive article can have any of the same features
of composition, coating, coating composition, coating content,
particle size distribution (i.e., D10, D50, D90, and percent volume
greater than 120 microns), Vickers hardness, average toughness,
and/or ellipticity as noted herein.
[0060] The bond material contained in the body can have any of the
features described in the embodiments herein with respect to the
bond material or precursor bond material included in the mixture
used to form the abrasive article. According to a particular
embodiment, the bond material may have a particular content of
cobalt and tin that may facilitate improved performance of the
abrasive article. For example, the bond material can include cobalt
(CCo) and tin (CSn) in a ratio [CSn/CCo] of not greater than 0.2,
wherein CCo is the weight percent of cobalt for the entire weight
of the bond material and CSn is the weight percent of tin for the
entire weight of the bond material. In other instances, the ratio
[CSn/CCo] can be not greater than 0.19, such as 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. 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 be within a range including any of the
minimum and maximum values noted above.
[0061] According to a particular embodiment, the bond material may
have a particular content of cobalt and tungsten that may
facilitate improved formation and/or performance of the abrasive
article. For example, the bond material can include cobalt (CCo)
and tungsten (CW) in a ratio [CW/CCo] of not greater than 0.9,
wherein CCo is the weight percent of cobalt for the entire weight
of the bond material and CW is the weight percent of tungsten for
the entire weight of the bond material. In another embodiment, the
ratio [CW/CCo] can be not greater than 0.8, such as 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. In another
embodiment, the ratio [CW/CCo] can 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 be within a range including any of the minimum and
maximum values noted above.
[0062] According to a particular embodiment, the bond material may
have a particular content of tungsten and tin that may facilitate
improved 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 not greater than 1, wherein CW is the weight
percent of tungsten for the entire weight of the bond material and
CSn is the weight percent of tin for the entire weight of the bond
material. In another embodiment, the ratio [CSn/CW] can 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] can 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
be within a range including any of the minimum and maximum values
noted above.
[0063] The bond material may have a particular content of cobalt
that may facilitate improved performance of the abrasive article.
For example, the bond material may include at least 40 wt % cobalt
for a total weight of the bond 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 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 for the weight of the bond
material. In one non-limiting embodiment, the bond material can
include a content of cobalt of not greater than 99 wt % for the
total weight of the bond material, such as 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 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 for the entire weight of the bond material. It
will be appreciated that the content of cobalt in the bond material
can be within a range including any of the minimum and maximum
values noted above.
[0064] The bond material of the finally formed abrasive article may
have a particular content of tin that may facilitate improved
performance of the abrasive article. For example, the bond material
may include at least 0.1 wt % tin for a total weight of the bond
material 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 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 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 for the total weight of the bond
material. In one non-limiting embodiment, the bond material can
include a content of tin of not greater than 15 wt % for a total
weight of the bond material 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 % tin for
the total weight of the bond material. It will be appreciated that
the content of tin in the bond material can be within a range
including any of the minimum and maximum values noted above.
[0065] The bond material of the finally-formed abrasive article may
have a particular content of tungsten that may facilitate improved
performance of the abrasive article. For example, the bond material
may include at least 1 wt % tungsten for a total weight of the bond
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 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 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 for the total weight of the bond
material. Still, in at least one non-limiting embodiment, the bond
material may include greater than 20 wt % tungsten for a total
weight of the bond material, 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 weight of the bond
material. It will be appreciated that the content of tungsten in
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 can be essentially free
of tungsten.
[0066] The bond material of the finally-formed abrasive article may
include a particular content of iron that may facilitate improved
performance of the abrasive article. For example, the bond material
can include a content of iron of at least 0.05 wt % for a total
weight of the 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 a total
weight of the bond material. In another non-limiting embodiment,
the bond material can include a content of iron of not greater than
5 wt % for a total weight of the bond material, such as 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 %. It
will be appreciated that the content of iron in the bond material
can be within a range including any of the minimum and maximum
values noted above.
[0067] The bond material of the finally-formed abrasive article may
include a particular content of aluminum that may facilitate
improved performance of the abrasive article. For example, the bond
material can include a content of aluminum of not greater than 1 wt
% for a total weight of the 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 % or not greater than 0.05 wt % or not greater than 0.01 wt %.
Still, in another non-limiting embodiment, the bond material can
include a content of aluminum of at least 0.001 wt % or at least
0.01 wt % for the total weight of the bond material. It will be
appreciated that the content of aluminum in 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 can be essentially free of aluminum.
[0068] The bond material of the finally-formed abrasive may include
a particular content of copper that may facilitate improved
performance of the abrasive article. For example, the bond material
can include a content of copper of not greater than 20 wt % for a
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 % or not greater than 0.09
wt % or not greater than 0.05 wt % or not greater than 0.01 wt %.
Still, in another non-limiting embodiment, the bond material can
include a content of copper of at least 0.001 wt % or at least 0.01
wt % for the total weight of the bond material. It will be
appreciated that the content of copper in 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 can be essentially free of copper.
[0069] The bond material of the finally-formed abrasive may include
a particular content of manganese that may facilitate improved
performance of the abrasive article. For example, the bond material
can include a content of manganese of not greater than 1 wt % for a
total weight of the 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 % or
not greater than 0.05 wt % or not greater than 0.01 wt %. Still, in
another non-limiting embodiment, the bond material can include a
content of manganese of at least 0.001 wt % or at least 0.01 wt %
for the total weight of the bond material. It will be appreciated
that the content of manganese in 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 can be
essentially free of manganese.
[0070] The bond material of the finally-formed abrasive may include
a particular content of titanium that may facilitate improved
performance of the abrasive article. For example, the bond material
can include a content of titanium of not greater than 1 wt % for a
total weight of the 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 %.
Still, in another non-limiting embodiment, the bond material can
include a content of titanium of at least 0.001 wt % or at least
0.01 wt % for the total weight of the bond material. It will be
appreciated that the content of titanium in 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 can be essentially free of titanium.
[0071] In still another embodiment, the bond material of the
finally-formed abrasive may have a particular content of certain
metals that may facilitate improved performance of the abrasive
article. For example, the bond material can have a total content of
aluminum, copper, manganese, lead, silicon, and titanium (i.e., sum
total of weight percent for each of the listed elements) of not
greater than 20 wt % for a 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 %. Still, in one non-limiting embodiment, the bond material can
include a total content of aluminum, copper, manganese, lead,
silicon, and titanium of at least 0.001 wt % or at least 0.01 wt %
for the total weight of the bond material. It will be appreciated
that the total content of aluminum, copper, manganese, lead,
silicon, and titanium in 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 can be essentially free of
aluminum, copper, manganese, lead, silicon, and/or titanium.
[0072] According to another aspect, the bond material of the
finally-formed abrasive can be formed to include at least 95 wt %
of cobalt, tin and tungsten. Moreover, in such an embodiment, not
greater than 5 wt % of the bond material can include secondary
elements selected from the group consisting of including aluminum,
copper, manganese, lead, silicon, and titanium. In yet embodiment,
the bond material can be formed to include at least 95 wt % of
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.
[0073] The finally-formed body of the abrasive article may have a
particular microstructure that can facilitate improved performance.
For example, the body may have micro-porosity that includes
discontinuous porosity in the shape of isolated pores contained
within the bond material. The micro-porosity may consist
essentially of discontinuous porosity. The entire body can include
micro-porosity, and in certain instances, the body may include only
micro-porosity having the features described herein. That is, in
one embodiment, all of the porosity of the body is micro-porosity
having the features described herein.
[0074] In at least one aspect, the micro-porosity can have a
particular pore size distribution that may facilitate improved
performance of the abrasive article. For example, the
micro-porosity 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. Still, in one non-limiting
embodiment, the micro-porosity can have 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 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 (D50) of the
micro-porosity within the body can be within a range including any
of the minimum and maximum values noted above.
[0075] The micro-porosity may also have a particular standard
deviation, which is the first standard deviation of the
distribution of porosity within the body as calculated from a
distribution of porosity as measured from images taken from samples
of the finally-formed abrasive article. A finally-formed sample of
an abrasive article is obtained, and four cubic samples having
dimensions of 0.3 inches per side are removed from the abrasive
article. The samples are taken from random locations of the
abrasive article. The cube samples are mounted in epoxy and
polished to reveal the surface of the abrasive for image analysis.
For each cube sample, using a scanning electron microscope in
backscatter mode (10 kv), a portion of the sample having an area of
at least 50.times.40 microns is identified that does not include
abrasive particles. Several images of the representative area is
obtained and then analyzed further using suitable imaging
processing software (e.g., ImageJ) to create a binary image of the
representative area. The imaging software is used to identify the
number and sizes of the pores and create a pore size distribution
plot. The average pore size and standard deviation of the pore size
is then calculated from the pore size distribution plot.
[0076] According to one embodiment, the micro-porosity 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 micro-porosity can have a pore size standard
deviation of not greater than 2 microns, such as 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
microns or not greater than 0.8 microns or not greater than 0.6
microns or not greater than 0.5 microns. It will be appreciated
that the micro-porosity can have a pores size standard deviation
within a range including any of the minimum and maximum values
noted above.
[0077] The abrasive particles may have a particular particle size
distribution that can facilitate improved 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
the average particle size, of at least 65 microns, such as at least
75 microns or at least 90 microns at least 95 microns, such as at
least 97 microns or at least 100 microns or at least 105 microns or
at least 110 microns or at least 120 microns. Still, 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 including any of the minimum and maximum values
noted above.
[0078] The abrasive particles of the abrasive article may also have
a particular D10 corresponding to any of the D10 values of the
abrasive particles in the mixture used to form the abrasive article
as described in other embodiments herein. Furthermore, the abrasive
particles in the abrasive body may have a D90 corresponding to any
of the D90 values of the abrasive particles included in the mixture
used to form the abrasive article.
[0079] FIG. 1A includes a cross-sectional illustration of an
abrasive article according to an embodiment. The abrasive article
100 formed by the above-described method comprises a core 101 and
an abrasive body 103 disposed on a peripheral surface of the core
101. In one particular instance, such as illustrated in FIG. 1A the
abrasive body 103 may be disposed within an interior recess of a
peripheral surface of the core 101. The core 101 may further
include an opening 107, which can be configured to engage a spindle
and facilitate rotation of the abrasive article 100.
[0080] As also shown in the embodiments of FIG. 1A, the abrasive
body 103 may include a profiled surface 105, which may have a
particular shape suitable for grinding the edges of workpieces.
While the profiled surface 105 of FIG. 1A is shown as generally
having or U-shaped contour or concave contour, other shapes can be
used, including for example, but not limited to a planar profile,
V-shaped profile, and the like.
[0081] The core 101 may include various materials, including but
not limited to inorganic materials (e.g., metal, metal alloy,
ceramic, etc.), organic materials or a combination thereof. In one
embodiment, the core 101 may include an organic material that may
facilitate improved performance of the bonded abrasive body,
including but not limited to, aspects of strength, wear resistance,
vibration damping, and manufacturability.
[0082] In one embodiment the core 101 can include a polymer
material selected from the group of a polyamide (PA), a
polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS),
ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a
polyester (PE), a polyethyleneimine (PEI), a polyethersulfone
(PESU), a polyethylene terephthalate (PET), a polyphthalamide
(PPA), a poly (p-phenylene sulfide), a polycarbonate (PC),
acrylonitrile-butadiene-styrene (ABS), PC-ABS, or any combination
thereof. In an aspect, the polymer material may be a nylon, a PBT,
a PPS, or a 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 a
particular embodiment, 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 polymer material of the core may be essentially
free of nylon.
[0083] In another embodiment, the core 101 may further contain
reinforcing fibers and/or a powder distributed within the polymer
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.
[0084] FIG. 1B includes a cross-sectional illustration of a portion
of an abrasive article according to an embodiment. Like the
abrasive article illustrated in FIG. 1A, the portion of the
abrasive article of FIG. 1B includes a core 101 and an abrasive
body 103 disposed on a peripheral surface of the core 101. The
abrasive body 103 may include a profiled surface 105, which may
have a particular shape suitable for grinding the edges of
workpieces.
[0085] As further illustrated in FIG. 1B, the abrasive body 103
includes a first region 151, a second region 161 and a third region
171. It will be appreciated that the embodiment of FIG. 1B includes
three regions, but other abrasive bodies may be formed to have a
fewer or greater number of regions. According to one aspect, the
grade and/or structure of the regions may differ from each other.
For example, the regions may have different contents of abrasive
particles, different sizes (e.g., D10, D50 and/or D90) of abrasive
particles, different compositions of the abrasive particles,
different content of bond material, different composition of bond
material, different porosity, different microstructural features,
or any combination thereof. It is thought that such controlled
differences between the regions may facilitate improved operations
of the abrasive article. Any one of the regions can have one or
more of the features of any of the embodiments herein.
[0086] According to one embodiment, the first region 151 can have a
first content of abrasive particles 153 contained within a bond
material 152 and the second region 161 can have a second content of
abrasive particles 163 contained within a bond material 162, and
further the first content and second content can be different
compared to each other. In one particular instance, the second
content can be greater than the first content. The content of
abrasive particles may be measured as the volume percent or weight
percent of abrasive particles in a given region. If the distinction
between the regions is not clearly visible, at least three random
samplings of material may be selected from portions of the body
suspected as being part of different regions, the content of
abrasive particles can be measured and averaged. The average
content can be representative of the content for a given region.
The volume percent or weight percent may be based on the weight or
volume sampled from the region.
[0087] In one particular embodiment, the abrasive body 103 with the
first and second regions 151 and 161 may define a ratio (C1/C2) of
not greater than 0.97, wherein C1 represents the first content of
abrasive particles in the first region (vol % or wt %) and C2
represents the second content (vol % or wt %) of abrasive particles
in the second region. According to one embodiment, the ratio
(C1/C2) can 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 0.45 or not greater than 0.43 or not greater than 0.40. Still,
in another non-limiting embodiment, the ratio (C1/C2) can 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 be within a range including
any of the minimum and maximum values noted above.
[0088] In certain instances, 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 the type of
abrasive particle can be reference to at least one characteristic
selected from the group of median particle size (D50), D10, D90,
Vickers hardness, ellipticity, average toughness, composition, or
any combination thereof. For example, the abrasive particles 153
and 163 can have the same composition relative to each other.
However, it will be appreciated that in other embodiments, the
composition of the abrasive particles 153 can be different compared
to the composition of the abrasive particles 163. In another
aspect, the abrasive particles 153 of the first region 151 can be
the same size (e.g., D10, D50, and/or D90) as the abrasive
particles 163 contained in the second region 161. For example, the
abrasive particles 153 and 163 can have the average particle size
(i.e., D50) relative to each other. However, it will be appreciated
that in other embodiments, the composition of the abrasive
particles 153 can have a different average particle size (i.e.,
D50) compared to the abrasive particles 163.
[0089] In certain instances, and as illustrated in FIG. 1B, the
first region 151 can be in the form of a layer that extends
radially between an inner wall 112 of the cavity and the profiled
surface 105. Additionally, the second region 161 can be in the form
of a layer, such as a layer extending radially between the inner
wall 112 and the profiled surface 105. The second region 161 can be
in direct contact with the first region 151, such that there are no
intervening layers or objects positioned between the first and
second regions 151 and 161.
[0090] In another aspect, the first region 151 can have a first
content of a first bond material 152 and the second region 161 can
have a second content of a second bond material 162. For certain
abrasive articles of the embodiments herein, the second content of
the second bond material 162 can be different than the first
content of the first bond material 152. Still, in an alternative
design, the second content of the second bond material 162 can be
the same as the first content of the first bond material 152.
[0091] For certain embodiments, the first bond material 152 of the
first region 151 can have the same composition as the second bond
material 162 of the second region 161. The first and second bond
materials 152 and 162 can have any of the compositions for bond
materials as noted in the embodiments herein. In one particular
instance, the first and second bond materials 152 and 162 can be an
inorganic material, such as a metal, metal alloy, amorphous
material, glass, ceramic, or a combination thereof. Still, as will
be appreciated, in certain instances, the first and second bond
materials 152 and 162 can have different compositions compared to
each other. Compositions may be considered different from each
other when at least one component (e.g., element, compound or
complex) differs by at least 5% between the two compositions.
[0092] As illustrated in FIG. 1B, certain abrasive bodies may
include a third region 171 having a third content of abrasive
particles 173. As also illustrated in FIG. 1B, the second region
161 can be disposed between the first region 151 and the third
region 171. In at least one embodiment, the third content of
abrasive particles 173, as measured in volume percent or weight
percent, can be different compared to the second content of
abrasive particles 163 contained within the second region 161. In
still other instances, the first content of abrasive particles 153
and the third content of abrasive particles 173 may be the same
with respect to each other.
[0093] For one particular embodiment, the second content of
abrasive particles 163 in the second region 161 may be greater than
the third content of abrasive particles 173 in the third region
171. This may be advantageous as the second region 161 may conduct
the majority of the material removal operations compared to the
third region 171. Moreover, the second content of abrasive
particles 163 in the second region 161 can be greater than the
first content of abrasive particles 153 in the first region
151.
[0094] The abrasive body 103 may include a ratio (C3/C2) of not
greater than 0.97, wherein C3 represents the third content of
abrasive particles 173 in the third region 171 and C2 represents
the second content of abrasive particles 163 in the second region
161. In one embodiment, the ratio (C3/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 0.45 or not greater than 0.43
or not greater than 0.40. Still, 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 a range including any of the minimum and
maximum values noted above.
[0095] According to another aspect, the abrasive particles 173 of
the third region 171 can be the same type of abrasive particles 163
as contained in the second region 161. Reference herein to a type
in the context of abrasive particles is reference to at least one
characteristic selected from the group of median particle size
(D50), D10, D90, Vickers hardness, ellipticity, average toughness,
composition, or any combination thereof. For example, the abrasive
particles 173 and 163 can have the same composition relative to
each other. However, it will be appreciated that in other
embodiments, the abrasive particles 163 and 173 can be different
types compared to each other. For example, in one embodiment, the
composition of the abrasive particles 173 can be different compared
to the composition of the abrasive particles 163. In another
aspect, the abrasive particles 173 of the third region 171 can be
the same size (e.g., D10, D50, and/or D90) as the abrasive
particles 163 contained in the second region 161. For example, the
abrasive particles 173 and 163 can have the average particle size
(i.e., D50) relative to each other. However, it will be appreciated
that in other embodiments, the composition of the abrasive
particles 173 can have a different average particle size (i.e.,
D50) compared to the abrasive particles 163.
[0096] Like the first region 151 in certain embodiments, the third
region 171 can be in the form of a layer that extends radially
between the inner wall 112 and the profiled surface 105.
Additionally, the second region 161 may be in the form of a layer.
The second region 161 can be in direct contact with the third
region 171, such that there are no intervening layers or objects
positioned between the third and second regions 171 and 161.
[0097] In another aspect, the third region 171 can have a third
content of a third bond material 172 and the second region 161 can
have a second content of a second bond material 162. For certain
abrasive articles of the embodiments herein, the second content of
the second bond material 162 can be different than the third
content of the third bond material 172. Still, in an alternative
design, the second content of the second bond material 162 can be
the same as the third content of the third bond material 172.
Additionally, the first content of the first bond material 152 can
be the same as the third content of the third bond material 172.
Still, in a non-limiting embodiment, the second content of the
second bond material 162 can be the same as the third content of
the third bond material 172.
[0098] For certain embodiments, the third bond material 172 of the
third region 171 can have the same composition as the second bond
material 162 of the second region 161. The second and third bond
materials 162 and 172 can have any of the compositions for bond
materials as noted in the embodiments herein. In one particular
instance, the second and third bond materials 162 and 172 can be an
inorganic material, such as a metal, metal alloy, amorphous
material, glass, ceramic, or a combination thereof. Still, as will
be appreciated, in certain instances, the second and third bond
materials 162 and 172 can have different compositions compared to
each other. Compositions may be considered different from each
other when at least one component (e.g., element, compound or
complex) differs by at least 5% between the two compositions.
[0099] According to one particular embodiment, the first region 151
includes a first type of abrasive particle having a first median
particle size (D50.sub.1) and the second region 161 can include a
second type of abrasive particle having a second median particle
size (D50.sub.2) In certain instances, the first median particle
size (D50.sub.1) can be different than the second median particle
size (D50.sub.2). In one particular embodiment, the second type of
abrasive particles have a greater median particle size (D50.sub.2)
compare to the first type of abrasive particles (D50.sub.1). For
one aspect, the abrasive body can have a ratio
(D50.sub.1/D50.sub.2) 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 0.40. Still, in one non-limiting embodiment,
the ratio (D50.sub.1/D50.sub.2) can 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
(D50.sub.1/D50.sub.2) can be within a range including any of the
minimum and maximum values provided above.
[0100] As described in the embodiments herein, the third region 171
may include a third type of abrasive particle 173. In at least one
instance, the third type of abrasive particle 173 can be different
from the second type of abrasive particle 163 in the second region
161. In particular instances, the abrasive body 103 can have a
ratio (D50.sub.3/D50.sub.2) of not greater than 0.97, wherein
D50.sub.3 represents the median particle size of the third type of
abrasive particles 173 and D50.sub.2 represents the median particle
size of the second type of abrasive particles 163. For example, the
ratio (D50.sub.3/D50.sub.2) can 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 0.45 or not greater than 0.43 or not
greater than 0.40. Still, in one non-limiting embodiment, the ratio
(D50.sub.3/D50.sub.2) can 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
(D50.sub.3/D50.sub.2) can be within a range including any of the
minimum and maximum values provided above.
[0101] In yet 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. Accordingly, 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.
EMBODIMENTS
Embodiment 1
[0102] An abrasive article comprising:
a body comprising: a bond material comprising metal and further
comprising micro-porosity within the bond material, the
micro-porosity comprising an average pore size (D50) of not greater
than 10 microns and a pore size standard deviation of at least 0.2
microns; abrasive particles contained within bond material and
further comprising at least one of: an ellipticity of not greater
than 1.18; or an average toughness of at least 11257 cycles
according to ANSIB74.23.
Embodiment 2
[0103] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a material selected from the group consisting of
oxides, carbides, nitrides, borides, or any combination
thereof.
Embodiment 3
[0104] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a superabrasive material.
Embodiment 4
[0105] The abrasive article of embodiment 1, wherein the abrasive
particles comprise diamond.
Embodiment 5
[0106] The abrasive article of embodiment 1, wherein the abrasive
particles consist essentially of diamond.
Embodiment 6
[0107] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a coating.
Embodiment 7
[0108] The abrasive article of embodiment 6, wherein the coating
comprises a metal or metal alloy including a transition metal
element.
Embodiment 8
[0109] The abrasive article of embodiment 6, wherein the coating
comprises titanium.
Embodiment 9
[0110] The abrasive article of embodiment 6, wherein the coating
overlies a majority of the exterior surfaces of the abrasive
particles or at least 60% or at least 70% or at least 80% or at
least 90% or at least 95%.
Embodiment 10
[0111] 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
[0112] 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
[0113] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a 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
[0114] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a 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
[0115] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a 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.
Embodiment 15
[0116] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a 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
[0117] The abrasive article of embodiment 1, wherein the abrasive
particles comprise a Vickers hardness of at least 2000 kg/mm2 or at
least 3000 kg/mm2 or at least 4000 kg/mm2 or at least 5000
kg/mm2.
Embodiment 17
[0118] The abrasive article of embodiment 16, wherein the abrasive
particles comprise diamond.
Embodiment 18
[0119] The abrasive article of embodiment 1, wherein the abrasive
particles have an average toughness of at least 11900 cycles or at
least 12000 cycles 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
[0120] 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
[0121] 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
[0122] 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
[0123] The abrasive article of embodiment 1, wherein the body
comprises a content of the abrasive particles 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
[0124] The abrasive article of embodiment 1, wherein the body
comprises a content of abrasive particles of 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 %.
Embodiment 24
[0125] The abrasive article of embodiment 1, wherein the body
comprises a content of the bond material 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
[0126] The abrasive article of embodiment 1, wherein the body
comprises a content of bond material of not greater than 99 wt %
for a total weight of the body 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 %
Embodiment 26
[0127] 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
[0128] 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, wherein CCo is the weight percent of
cobalt for the entire weight of the body and CSn is the weight
percent of tin for the entire weight of the body 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.
Embodiment 28
[0129] 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
[0130] The abrasive article of embodiment 1, wherein the bond
material comprises a ratio [CW/CCo] of not greater than 0.9,
wherein CCo is the weight percent of cobalt for the entire weight
of the body and CW is the weight percent of tungsten for the entire
weight of the body 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.
Embodiment 30
[0131] The abrasive article of embodiment 1, wherein the bond
material comprises a ratio [CW/CCo] of at least about 0.001,
wherein CCo is the weight percent of cobalt for the entire weight
of the body and CW is the weight percent of tungsten for the entire
weight of the body 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.
Embodiment 31
[0132] 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, wherein CW is the weight percent of tungsten
for the entire weight of the body and CSn is the weight percent of
tin for the entire weight of the bond, 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.
Embodiment 32
[0133] 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, wherein CW is the weight percent of tungsten for
the entire weight of the body and CSn is the weight percent of tin
for the entire weight of the body, 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.
Embodiment 33
[0134] The abrasive article of embodiment 1, wherein the bond
material comprises cobalt in a content of at least 40 wt % for a
total weight of the body 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 % 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 %.
Embodiment 34
[0135] The abrasive article of embodiment 1, wherein the bond
material comprises cobalt in a content 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 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 %.
Embodiment 35
[0136] The abrasive article of embodiment 1, wherein the bond
material comprises tin in a content of at least 0.1 wt % for a
total weight of the body 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 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 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 %.
Embodiment 36
[0137] The abrasive article of embodiment 1, wherein the bond
material comprises tin in a content of not greater than 15 wt % for
a total weight of the body 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 %.
Embodiment 37
[0138] The abrasive article of embodiment 1, wherein the bond
material comprises tungsten in a content of at least 1 wt % for a
total weight of the body 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
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 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
%.
Embodiment 38
[0139] The abrasive article of embodiment 1, wherein the bond
material comprises tungsten in a content of not greater than 20 wt
% for a total weight of the body 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 %.
Embodiment 39
[0140] The abrasive article of embodiment 1, wherein the bond
material comprises iron in a content of at least 0.05 wt % for a
total weight of the body 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 %.
Embodiment 40
[0141] The abrasive article of embodiment 1, wherein the bond
material comprises iron in a content of not greater than 5 wt % for
a total weight of the body 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 %.
Embodiment 41
[0142] The abrasive article of embodiment 1, wherein the bond
material comprises aluminum in a content of not greater than 1 wt %
for a total weight of the body 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 %
Embodiment 42
[0143] The abrasive article of embodiment 1, wherein the bond
material comprises copper in a content of not greater than 20 wt %
for a total weight of the body 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 %.
Embodiment 43
[0144] The abrasive article of embodiment 1, wherein the bond
material comprises manganese in a content of not greater than 1 wt
% for a total weight of the body 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 %
Embodiment 44
[0145] The abrasive article of embodiment 1, wherein the bond
material comprises titanium in a content of not greater than 1 wt %
for a total weight of the body 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 %.
Embodiment 45
[0146] The abrasive article of embodiment 1, wherein the body
comprises a total content of aluminum, copper, manganese, lead,
silicon, and titanium not greater than 20 wt % for a total weight
of the body 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 %.
Embodiment 46
[0147] The abrasive article of embodiment 1, wherein at least 95 wt
% of the bond material comprises cobalt, tin and tungsten, and not
greater than 5 wt % of the bond material comprises secondary
elements selected from the group consisting of including aluminum,
copper, manganese, lead, silicon, and titanium.
Embodiment 47
[0148] The abrasive article of embodiment 1, wherein the
micro-porosity 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 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
[0149] The abrasive article of embodiment 1, wherein the
micro-porosity comprises 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.
Embodiment 49
[0150] The abrasive article of embodiment 1, wherein the
micro-porosity 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
[0151] The abrasive article of embodiment 1, wherein the
micro-porosity 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 microns or not
greater than 0.8 microns or not greater than 0.6 microns or not
greater than 0.5 microns.
Embodiment 51
[0152] The abrasive article of embodiment 1, wherein the body
comprises a content of porosity of at least 0.5 vol % for a total
volume of the body or 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 %.
Embodiment 52
[0153] The abrasive article of embodiment 1, wherein the body
comprises a content of porosity of not greater than 50 vol % for a
total volume of the body 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 %.
Embodiment 53
[0154] The abrasive article of embodiment 1, wherein the body
comprises a first region comprising a first content of abrasive
particles and a second region comprising a second content of
abrasive particles, wherein the first content and second content
are different compared to each other.
Embodiment 54
[0155] The abrasive article of embodiment 53, wherein the second
content is greater than the first content.
Embodiment 55
[0156] 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
[0157] The abrasive article of embodiment 53, further comprising a
ratio (C1/C2) of at least 0.1, 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
[0158] 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
[0159] 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
[0160] The abrasive article of embodiment 53, wherein the first
region is in the form of a layer.
Embodiment 60
[0161] The abrasive article of embodiment 53, wherein the second
region is in the form of a layer.
Embodiment 61
[0162] The abrasive article of embodiment 53, wherein the second
region is directly contacting the first region.
Embodiment 62
[0163] The abrasive article of embodiment 53, wherein the first
region comprises a first content of a first bond material, and
wherein 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 first content of the first bond
material.
Embodiment 63
[0164] The abrasive article of embodiment 62, wherein the first
bond material and second bond material have the same
composition.
Embodiment 64
[0165] The abrasive article of embodiment 62, wherein the first
bond material and second bond material have a different composition
compared to each other.
Embodiment 65
[0166] The abrasive article of embodiment 62, further comprising a
third region comprising a third content of abrasive particles,
wherein the third content is different than the second content.
Embodiment 66
[0167] The abrasive article of embodiment 65, wherein the second
region is disposed between the first region and the third
region.
Embodiment 67
[0168] The abrasive article of embodiment 65, wherein the first
content and the third content are the same with respect to each
other.
Embodiment 68
[0169] The abrasive article of embodiment 65, wherein the second
content is greater than the third content.
Embodiment 69
[0170] 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
[0171] The abrasive article of embodiment 65, further comprising a
ratio (C3/C2) of at least 0.1, 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
[0172] 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
[0173] 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
[0174] 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
[0175] The abrasive article of embodiment 65, wherein the third
region is in the form of a layer.
Embodiment 75
[0176] The abrasive article of embodiment 65, wherein the second
region is in the form of a layer and is directly contacting the
third region.
Embodiment 76
[0177] 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
[0178] The abrasive article of embodiment 76, wherein the third
bond material and second bond material have the same
composition.
Embodiment 78
[0179] The abrasive article of embodiment 76, wherein the third
bond material and second bond material have a different composition
compared to each other.
Embodiment 79
[0180] The abrasive article of embodiment 1, wherein the body
comprises a first region comprising a first type of abrasive
particles and a second region comprising a second type of abrasive
particles, wherein the first type and second type of abrasive
particles are different compared to each other.
Embodiment 80
[0181] The abrasive article of embodiment 79, wherein the first
type and second type are different compared to each other based on
at least one characteristic selected from the group of median
particle size (D50), D10, D90, Vickers hardness, ellipticity,
average toughness, composition, or any combination thereof.
Embodiment 81
[0182] The abrasive article of embodiment 79, wherein the first
type and second type are different compared to each other based on
median particle size.
Embodiment 82
[0183] The abrasive article of embodiment 79, wherein the second
type of abrasive particles have a greater median particle size
compare to the first type of abrasive particles.
Embodiment 83
[0184] 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
[0185] 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
[0186] 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 second content are different compared
to each other.
Embodiment 86
[0187] 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 second content are the same compared
to each other.
Embodiment 87
[0188] The abrasive article of embodiment 79, wherein the first
region is in the form of a layer.
Embodiment 88
[0189] The abrasive article of embodiment 79, wherein the second
region is in the form of a layer.
Embodiment 89
[0190] The abrasive article of embodiment 79, wherein the second
region is directly contacting the first region.
Embodiment 90
[0191] The abrasive article of embodiment 79, wherein the first
region comprises a first content of a first bond material, and
wherein 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 first content of the first bond
material.
Embodiment 91
[0192] The abrasive article of embodiment 90, wherein the first
bond material and second bond material have the same
composition.
Embodiment 92
[0193] The abrasive article of embodiment 90, wherein the first
bond material and second bond material have a different composition
compared to each other.
Embodiment 93
[0194] The abrasive article of embodiment 79, further comprising a
third region comprising a third type of abrasive particles, wherein
the third type is different than the second type.
Embodiment 94
[0195] The abrasive article of embodiment 93, wherein the second
region is disposed between the first region and the third
region.
Embodiment 95
[0196] The abrasive article of embodiment 93, wherein the first
type and the third type are the same with respect to each
other.
Embodiment 96
[0197] 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
[0198] 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
[0199] The abrasive article of embodiment 93, wherein the third
region is in the form of a layer.
Embodiment 99
[0200] The abrasive article of embodiment 93, wherein the second
region is in the form of a layer and is directly contacting the
third region.
Embodiment 100
[0201] 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
[0202] The abrasive article of embodiment 100, wherein the third
bond material and second bond material have the same
composition.
Embodiment 102
[0203] The abrasive article of embodiment 100, wherein the third
bond material and second bond material have a different composition
compared to each other.
Embodiment 103
[0204] 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
[0205] A method for forming an abrasive article including forming a
mixture including precursor bond material and abrasive particles;
and heating the mixture to form a body comprising:
a bond material comprising metal and further comprising
micro-porosity within the bond material, the micro-porosity
comprising an average pore size (D50) of not greater than 10
microns and a pore size standard deviation of at least 0.2 microns;
abrasive particles contained within bond material and further
comprising at least one of: an ellipticity of not greater than
1.18; or an average toughness of at least 11257 cycles.
Embodiment 105
[0206] The method of embodiment 104, wherein the mixture includes a
precursor bond material having an average particle size of not
greater than 25 microns or not greater than 10 microns or not
greater than 1 micron or not greater than 0.75 microns or not
greater than 0.5 microns or not greater than 0.25 microns or not
greater than 0.1 microns.
Embodiment 106
[0207] The method of embodiment 104, wherein the mixture includes a
precursor bond material having an average particles size of at
least 0.001 microns, such as at least 0.01 microns or even at least
0.1 microns.
Embodiment 107
[0208] The method of embodiment 104, wherein heating the mixture is
conducted at a temperature of at least 700.degree. C. or at least
725.degree. C. or at least 750.degree. C. or at least 775.degree.
C. or at least 800.degree. C. or at least 825.degree. C. or at
least 850.degree. C. or at least 875.degree. C. or at least
900.degree. C. or at least 925.degree. C. or at least 950.degree.
C. or at least 975.degree. C. or at least 1000.degree. C.
Embodiment 108
[0209] The method of embodiment 104, wherein heating mixture is
conducted at a temperature of not greater than 1100.degree. C. or
not greater than 1050.degree. C. or not greater than 1000.degree.
C. or not greater than 975.degree. C. or not greater than
950.degree. C. or not greater than 925.degree. C. or not greater
than 900.degree. C.
Embodiment 109
[0210] The method of embodiment 104, wherein forming comprises hot
pressing the mixture.
Embodiment 110
[0211] The method of embodiment 104, wherein forming comprises hot
pressing the mixture at a pressure of at least 1000 psi or at least
1500 psi or at least 2000 psi or at least 2200 psi.
Embodiment 111
[0212] The method of embodiment 104, wherein forming comprises hot
pressing the mixture at a pressure of not greater than 5000 psi or
not greater than 4000 psi or not greater than 3000 psi or not
greater than 2750 psi.
Example 1
[0213] The following samples were created and tested for comparison
in performance. A first sample, Sample C1, is a commercially
available glass grinding wheel having approximately 92 vol % metal
bond of approximately 93% cobalt, 2% tin and 5% tungsten. The
abrasive article of Sample C1 also includes approximately 16 vol %
diamond abrasive particles having a D50 of approximately 93
microns, a D10 of 76 microns, a D90 of 113 micron, an ellipticity
of 1.19, an average toughness of approximately 11676 cycles, and 3
vol % of the abrasive particles have a particle size greater than
120 microns. The porosity of Sample C1 is approximately 1 vol % for
the total volume of the body, and has an average pore size (D50) of
0.38 microns with a standard deviation of 0.19 microns. FIG. 2
includes a scanning electron microscope (SEM) image of a portion of
the abrasive article of Sample C1 without the abrasive
particles.
[0214] A second sample, Sample S2 is formed by creating a mixture
of abrasive particles, precursor bond material, and additives. The
abrasive particles are titanium-coated diamond particles available
as from ILJIN. The abrasive particles have D50 of approximately 104
microns, a D90 of 113 microns, a D10 of 88 microns, and 1.5 vol %
of the abrasive particles have a particle size greater than 120
microns. The abrasive particles have an average toughness of
approximately 13135 cycles and an ellipticity of approximately
1.17.
[0215] The precursor bond material includes cobalt powder
commercially available as "Extrafine Cobalt" from Umicore and
further includes tin commercially available as Tin201 from
ACupowder.
[0216] The mixture was uniaxially hot pressed at a temperature of
975.degree. C. for a duration of approximately 5 minutes under a
pressure of 2500 psi. The finally-formed abrasive article of Sample
S2 includes approximately 16% vol % abrasive particles and
approximately 81 vol % bond material. The bond material includes
approximately 97 wt % cobalt and 3 wt % tin. The body further
includes approximately 3 vol % porosity, which is micro-porosity
having an average pore size (D50) of approximately 0.51 microns, a
D10 of approximately 0.25 microns, a D90 of approximately 1.25
microns, and a standard deviation of 0.42 microns.
[0217] A third sample, Sample S3 is formed using the same process
disclosed for making Sample S2, except the abrasive particles are
titanium-coated diamond particles available as IMD-F from ILJIN.
The abrasive particles have D50 of approximately 97 microns, a D90
of 113 microns, a D10 of 84 microns, and 6 vol % of the abrasive
particles have a particle size greater than 120 microns. The
abrasive particles have an average toughness of approximately 10683
cycles and an ellipticity of approximately 1.15.
[0218] The abrasive article of Sample S3 is formed via hot pressing
at a temperature of 975.degree. C. for a duration of approximately
5 minutes under a pressure of 2500 psi. The finally formed abrasive
article of Sample S3 includes approximately 16 vol % abrasive
particles and approximately 81 vol % bond material. The bond
material includes approximately 97 wt % cobalt and 3 wt % tin. The
body includes approximately 3 vol % porosity, which is
micro-porosity having an average pore size (D50) of approximately
0.51 microns, a D10 of approximately 0.25 microns, a D90 of
approximately 1.25 microns, and a standard deviation of
approximately 0.42 microns.
[0219] A fourth sample, Sample S4 is formed using the same process
disclosed for making Sample S2, except the abrasive particles are
titanium-coated diamond particles available from ILJIN. The
abrasive particles have D50 of approximately 101 microns, a D90 of
113, a D10 of 88, and 1.5 vol % of the abrasive particles have a
particle size greater than 120 microns. The abrasive particles have
an average toughness of approximately 11939 cycles and an
ellipticity of approximately 1.15.
[0220] The abrasive article of Sample S4 is formed via hot pressing
at a temperature of 975.degree. C. for a duration of approximately
5 minutes under a pressure of 2500 psi. The finally formed abrasive
article of Sample S4 includes approximately 14 vol % abrasive
particles and approximately 83 vol % bond material. The bond
material includes 97 wt % cobalt and 3 wt % tin. The body includes
approximately 3 vol % porosity.
[0221] Each of the samples was used to grind the edge of a glass
workpiece of white tempered glass. The length of the worked surface
was approximately 4 linear meters for each glass workpiece sample.
The samples were operated at a traverse speed of 15 m/min and a
spindle speed of 45 m/s.
[0222] FIGS. 4 and 5 include plots of current versus number of
glass workpieces finished for each of the samples for two different
dressing cycles, respectively. As illustrated in FIG. 4, samples S2
and S3 had the lowest current. Sample S3 finished the most glass
samples before the current peaked to an undesirable level and the
sample required dressing. Each of the samples were dressed
according to the same conditions and tested again to generate the
date provided in FIG. 5. As illustrated in FIG. 5, Sample S2 and S3
had notably lower current requirements and finished more glass
workpieces than Samples C1 and S4. Sample S2 demonstrated a notable
improvement in the number of glass workpieces finished.
Example 2
[0223] A sample (Sample S5) is formed according to the process
disclosed for Sample S2, except that the diamonds were sub-sieved
using a stack of four screens having approximate 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
microns screen were discarded. The abrasive particles are
titanium-coated diamond particles available as IMD-Mc from ILJIN.
The abrasive particles have a D50 of approximately 95 microns, a
D90 of approximately 103 microns, a D10 of approximately 80
microns, and approximately 0.1 vol % of the abrasive particles have
a particle size greater than 120 microns. FIG. 6 includes a SEM
image of a portion of sample S5 according to an embodiment.
Example 3
[0224] A sample (Sample S6) is formed according to the process
disclosed for Sample S2. The abrasive particles are titanium-coated
diamond particles available from ILJIN. The abrasive particles have
D50 of approximately 104 microns, a D90 of approximately 113
microns, a D10 of approximately 88 microns, and approximately 1.5
vol % of the abrasive particles have a particle size greater than
120 microns. The abrasive particles have an average toughness of
approximately 13135 cycles and an ellipticity of approximately
1.17. The finally formed abrasive article of Sample S6 includes
approximately 14 vol % abrasive particles and approximately 83 vol
% bond material. The bond material includes approximately 97 wt %
cobalt and approximately 3 wt % tin. The body includes
approximately 3 vol % porosity, which is micro-porosity having an
average pore size (D50) of approximately 0.51 microns, a D10 of
approximately 0.25 microns, a D90 of approximately 1.25 microns,
and a standard deviation of approximately 0.42 microns.
Example 4
[0225] A sample (Sample S7) is formed according to the process
disclosed for Sample S3, except for a difference in the content of
abrasive particles and bond material. The abrasive particles are
titanium-coated diamond particles available from ILJIN. The
abrasive particles have D50 of approximately 97 microns, a D90 of
approximately 113 microns, a D10 of approximately 84 microns, and
approximately 6 vol % of the abrasive particles have a particle
size greater than 120 microns. The abrasive particles have an
average toughness of approximately 10683 cycles and an ellipticity
of approximately 1.15. The finally formed abrasive article of
Sample S7 includes approximately 14.5 vol % abrasive particles and
approximately 82.5 vol % bond material. The bond material includes
approximately 97 wt % cobalt and approximately 3 wt % tin. The body
includes approximately 3 vol % porosity, which is micro-porosity
having an average pore size (D50) of approximately 0.51 microns, a
D10 of approximately 0.25 microns, a D90 of approximately 1.25
microns, and a standard deviation of approximately 0.42
microns.
Example 5
[0226] A sample (Sample S8) is formed according to the process
disclosed for Sample S4, except for a difference in the content of
abrasive particles and bond material. The abrasive particles are
titanium-coated diamond particles available from ILJIN. The
abrasive particles have D50 of approximately 101 microns, a D90 of
approximately 113, a D10 of approximately 88, and approximately 1.5
vol % of the abrasive particles have a particle size greater than
120 microns. The abrasive particles have an average toughness of
approximately 11939 cycles and an ellipticity of approximately
1.15. The finally formed abrasive article of Sample S8 includes
approximately 11 vol % abrasive particles and approximately 86 vol
% bond material. The bond material includes approximately 97 wt %
cobalt and approximately 3 wt % tin. The body includes
approximately 3 vol % porosity.
Example 6
[0227] A sample (Sample S9) is formed according to the process
disclosed for Sample S2, except for a difference in the content of
abrasive particles and bond material. The abrasive particles are
titanium-coated diamond particles available from ILJIN. The
abrasive particles have D50 of approximately 104 microns, a D90 of
approximately 113 microns, a D10 of approximately 88 microns, and
approximately 1.5 vol % of the abrasive particles have a particle
size greater than 120 microns. The abrasive particles have an
average toughness of approximately 13135 cycles and an ellipticity
of approximately 1.17. The finally-formed abrasive article of
Sample S9 includes approximately 14.5% vol % abrasive particles and
approximately 82.5 vol % bond material. The bond material includes
approximately 97 wt % cobalt and approximately 3 wt % tin.
Example 7
[0228] A sample (Sample S10) is formed according to the process
disclosed for Sample S2, except for a difference in the size and
content of abrasive particles and the content of the bond material.
The abrasive particles are titanium-coated diamond particles
available from ILJIN. The abrasive particles have D50 of
approximately 101 microns, a D90 of approximately 113, a D10 of
approximately 88, and approximately 1.5 vol % of the abrasive
particles have a particle size greater than 120 microns. The
abrasive particles have an average toughness of approximately 11939
cycles and an ellipticity of approximately 1.15. The finally-formed
abrasive article of Sample S10 includes approximately 11% vol %
abrasive particles and approximately 86 vol % bond material. The
bond material includes approximately 97 wt % cobalt and
approximately 3 wt % tin.
Example 8
[0229] A sample (Sample S11) is formed according to the process
disclosed for Sample S2, except for a difference in the size and
content of abrasive particles and the content of the bond material.
The abrasive particles are titanium-coated diamond particles
available from ILJIN. The abrasive particles have D50 of
approximately 101 microns, a D90 of approximately 113, a D10 of
approximately 88, and approximately 1.5 vol % of the abrasive
particles have a particle size greater than 120 microns. The
abrasive particles have an average toughness of approximately 11939
cycles and an ellipticity of approximately 1.15. The finally-formed
abrasive article of Sample S11 includes approximately 11% vol %
abrasive particles and approximately 86 vol % bond material. The
bond material includes approximately 97 wt % cobalt and
approximately 3 wt % tin.
Example 9
[0230] A sample (Sample S12) is formed according to the process
disclosed for Sample S2, except for a difference in the size and
content of abrasive particles and the content of the bond material.
The abrasive particles are titanium-coated diamond particles
available from ILJIN. The abrasive particles have D50 of
approximately 106 microns, a D90 of approximately 115 microns, a
D10 of approximately 92 microns, and approximately 2 vol % of the
abrasive particles have a particle size greater than 120 microns.
The abrasive particles have an average toughness of approximately
11939 cycles and an ellipticity of approximately 1.15. The
finally-formed abrasive article of Sample S12 includes
approximately 15 vol % abrasive particles and approximately 85 vol
% bond material. The bond material includes approximately 97 wt %
cobalt and approximately 3 wt % tin.
Example 10
[0231] A sample (Sample S13) is made from multiple layers of
abrasive material, which are 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 and third
layers. Each of the layers are created separately as green (i.e.,
unsintered) layers and combined prior to final sintering and
formation of the abrasive body. The first layer includes
titanium-coated diamond particles available as from ILJIN. The
abrasive particles have D50 of approximately 97 microns, a D90 of
approximately 105 microns, a D10 of approximately 76 microns, and 2
vol % of the abrasive particles have a particle size greater than
120 microns. The abrasive particles have an average toughness of
approximately 11939 cycles and an ellipticity of approximately
1.15. The first layer is formed to include approximately 14 vol %
abrasive particles and approximately 86 vol % bond material. The
bond material includes approximately 97 wt % cobalt and
approximately 3 wt % tin.
[0232] The second layer includes titanium-coated diamond particles
available from ILJIN. The abrasive particles have D50 of
approximately 104 microns, a D90 of approximately 113 microns, a
D10 of approximately 88 microns, and approximately 1.5 vol % of the
abrasive particles have a particle size greater than 120 microns.
The abrasive particles have an average toughness of approximately
11939 cycles and an ellipticity of approximately 1.15. The second
layer is formed to include approximately 14 vol % abrasive
particles and approximately 83 vol % bond material. The bond
material includes 97 wt % cobalt and approximately 3 wt % tin.
[0233] The third layer was formed to have the same construction as
the first layer. The three layers were co-sintered together
according to the conditions provided in Sample S2. The finally
formed abrasive body included approximately 3 vol % porosity for
the total volume of the body.
Example 11
[0234] Samples S2 and S6, and a conventional sample C2 obtained
from 3M.TM. under the commercial name K20P were subjected to a
grinding tested on a laminated glass workpiece having a thickness
of 2.1 mm using a Bystronic.RTM. grinding machine. The samples were
operated at the traverse speed of 18 m/min and spindle speed of 38
m/s. The same dressing was applied at the same frequency to the
samples. The run lengths for the samples are illustrated in FIG. 7.
Comparing to C2, Samples S2 and S6 was able to grind longer linear
lengths.
Example 12
[0235] Sample S2 and conventional samples, C3 and C4, obtained from
Daotian High Technology Co. Ltd under the commercial name GNAA, and
Shanghai Xingsheng Industrial Co., Ltd, were subjected to a
grinding test on laminated windshield glass. The test was conducted
using a Bystronic grinding machine, and operation parameters and
run lengths are included in Tables 1 and 2.
TABLE-US-00001 TABLE 1 Dressing Sample traverse speed spindle speed
frequency Linear run length C3 16 m/min 30 m/s 13pcs 8000-11000 m
S2 18 m/min 36 m/s 13pcs 9537 m
TABLE-US-00002 TABLE 2 Dressing Linear Sample traverse speed
spindle speed frequency run length C4 12 m/min 22 m/s 16pcs/2imp
6000-8000 m S2 16 m/min 22 m/s 16pcs/2imp 9680 m
[0236] As disclosed in Table 1, Sample S2 was able to grind at a
faster speed and finish grinding a similar linear length, as
compared to C3. Sample S2 was able to grind a longer linear
distance at a faster traverse speed, as compared to C4 (Table
2).
Example 13
[0237] Sample S14 is formed using the same process disclosed for
making Sample S2, except the abrasive particles are titanium coated
diamond particles (200/230 mesh size) available from Warren Amplex
Superabrasives. The abrasive particles have an average toughness of
approximately 12392 cycles and an ellipticity of approximately
1.1176. The finally formed abrasive article of Sample S14 includes
approximately 16 vol % diamond abrasive particles and approximately
81 vol % bond material. The bond material includes approximately 97
wt % cobalt and 3 wt % tin. The body further includes approximately
3 vol % porosity, which is micro-porosity having an average pore
size (D50) of approximately 0.51 microns, a D10 of approximately
0.25 microns, a D90 of approximately 1.25 microns, and a standard
deviation of 0.42 microns.
[0238] Samples S6 and S14 were tested on glass workpieces under
optimal and low coolant flow conditions. For the optimal condition,
the coolant flow rate was 67 l/min, and Sample S6 was operated at
the traverse speed of 15 m/min and spindle speed of 30 m/s, while
Sample S14 was operated at the same traverse speed as S6 and the
wheel speed of 37.5 m/s. For the low coolant flow condition, the
flow rate was 40 l/min, and Samples S6 and S14 were operated at the
traverse speed of 12 m/min and wheel speed of 53 m/s.
[0239] Operation at low coolant flow rate can cause a burning
effect on glass workpieces (generation of sparkles during
grinding), which can be resolved by adjusting the dressing
frequency. As illustrated in FIG. 8, under the optimal coolant
flow, Samples S6 and S14 were dressed at the similar frequency,
while at the low flow rate condition, Sample S6 needed to be
dressed more frequently than Sample S14, every 10 glass pieces for
S6 versus every 25 pieces for S14, to achieve a desirable grinding
result.
[0240] Note that not all of the activities described above in the
general description or the examples 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.
Still further, the order in which activities are listed is not
necessarily the order in which they are performed.
[0241] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims.
[0242] The specification and illustrations of the embodiments
described herein are intended to provide a general understanding of
the structure of the various embodiments. The specification and
illustrations are not intended to serve as an exhaustive and
comprehensive description of all of the elements and features of
apparatus and systems that use 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 stated in ranges includes each and every value
within that range. Many other embodiments may be apparent to
skilled artisans only after reading this specification. Other
embodiments may be used and derived from the disclosure, such that
a structural substitution, logical substitution, or another change
may be made without departing from the scope of the disclosure.
Accordingly, the disclosure is to be regarded as illustrative
rather than restrictive.
* * * * *