Brazed diamond tools and methods for making the same
First Claim
Patent Images
1. A method of making a superabrasive tool, comprising the steps of:
- a) providing a substrate; and
b) brazing a plurality of superabrasive particles directly to an exposed surface of the substrate in accordance with a predetermined pattern.
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Abstract
Superabrasive tools and methods for the making thereof are disclosed and described. In one aspect, superabrasive particles are chemically bonded to a matrix support material according to a predetermined pattern by a braze alloy. The brazing alloy may be provided as a powder, thin sheet, or sheet of amorphous alloy. A template having a plurality of apertures arranged in a predetermined pattern may be used to place the superabrasive particles on a given substrate or matrix support material.
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Citations
45 Claims
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1. A method of making a superabrasive tool, comprising the steps of:
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a) providing a substrate; and
b) brazing a plurality of superabrasive particles directly to an exposed surface of the substrate in accordance with a predetermined pattern. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method of making a superabrasive tool, comprising the steps of:
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a) providing a substrate having an exposed surface;
b) providing a sheet of amorphous braze alloy having between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum;
c) affixing a plurality of superabrasive particles on the exposed surface of the substrate in accordance with a predetermined pattern;
d) applying the sheet of amorphous braze alloy on the superabrasive particles affixed to the exposed surface of the substrate; and
e) heating the sheet of amorphous braze alloy to a temperature below about 1,100°
C. that is sufficient to melt the sheet and braze the superabrasive particles directly to the exposed surface of the substrate.
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24. A method of making a superabrasive tool, comprising the steps of:
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a) providing a substrate having an exposed surface;
b) affixing a plurality of superabrasive particles in accordance with a predetermined pattern on the exposed surface of the substrate;
c) applying to the substrate and the superabrasive particles a powdered brazing alloy, having between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum; and
d) heating the brazing alloy to a temperature below about 1,100°
C. that is sufficient to melt the alloy and braze the superabrasive particles directly to the exposed surface of the substrate
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25. A method of making a superabrasive tool, comprising:
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a) providing a matrix support material; and
b) brazing a plurality of superabrasive particles directly to an exposed surface of the matrix support material using a sheet of amorphous brazing alloy. - View Dependent Claims (26, 27, 28, 29, 30)
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31. A method of making a superabrasive tool, comprising:
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a) providing a plurality of sheets of amorphous braze;
b) providing a plurality of matrix support material layers having exposed surfaces;
c) affixing the superabrasive particles on the plurality of amorphous braze sheets in a predetermined pattern;
d) applying the plurality of amorphous braze sheets having superabrasive particles thereon to the exposed surfaces of the matrix support material to form a plurality of individual superabrasive segments;
e) assembling the individual superabrasive segments into a tool precursor having a three-dimensional arrangement of superabrasive particles in accordance with a predetermined pattern; and
f) consolidating the tool precursor by heating it to a temperature sufficient to melt the braze alloy and sinter the matrix support material.
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32. A superabrasive tool comprising:
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a) a solid metal substrate;
b) a plurality of superabrasive particles; and
c) a sheet of amorphous braze alloy chemically bonding the plurality of superabrasive particles to the solid metal substrate. - View Dependent Claims (33, 34, 35, 36, 37, 38)
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39. A superabrasive tool precursor comprising:
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a) a metal support matrix;
b) a plurality of superabrasive particles placed in contact with the metal support matrix; and
c) a sheet of amorphous braze alloy placed in contact with the plurality of superabrasive particles. - View Dependent Claims (41, 42, 43, 44, 45)
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40. A superabrasive tool precursor comprising:
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a) a metal support matrix;
b) a sheet of amorphous braze alloy placed in contact with the metal support matrix; and
c) a plurality of superabrasive particles placed on the sheet of amorphous braze.
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Specification