Brazed diamond tools and methods for making the same

• US 20070051354A1
• Filed: 09/08/2006
• Published: 03/08/2007
• Est. Priority Date: 04/04/1997
• Status: Abandoned Application

• Current Assignee: Chien-Min Sung
• Original Assignee: Chien-Min Sung
• Inventors: Sung, Chien-Min
• Application Number:
  US11/517,802
• Publication Number:
  US 20070051354A1
• Time in Patent Office: Days
• US Class Current: 125/12
• CPC Class Codes: B01J 2203/061 Graphite
• CPC Class Codes: B01J 2203/062 Diamond
• CPC Class Codes: B01J 2203/0645 Boronitrides
• CPC Class Codes: B01J 2203/0655 Diamond
• CPC Class Codes: B01J 2203/066 Boronitrides
• CPC Class Codes: B01J 2203/068 Crystal growth
• CPC Class Codes: B01J 2203/0685 Crystal sintering
• CPC Class Codes: B01J 3/062 characterised by the composition of the materials to be processed
• CPC Class Codes: B22F 1/05 Metallic powder characterised by the size or surface area of the particles
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: B22F 2003/1046 with separating means for articles to be sintered
• CPC Class Codes: B22F 2005/001 Cutting tools, earth boring or grinding tool other than table ware
• CPC Class Codes: B22F 2207/03 of the metallic binder phase in cermets
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/004 Filling molds with powder feeding material to presses in general B30B15/302
• CPC Class Codes: B23D 61/028 of special material
• CPC Class Codes: B23D 61/04 with inserted saw teeth the teeth being individually inserted
• CPC Class Codes: B23D 61/18 Sawing tools of special type, e.g. wire saw strands, saw blades or saw wire equipped with diamonds or other abrasive particles in selected individual positions cut-off wheels of bonded abrasive or with inserted abrasive blocks B24D5/12
• CPC Class Codes: B23D 65/00 Making tools for sawing machines or sawing devices for use in cutting any kind of material
• CPC Class Codes: B23K 35/0233 Sheets, foils B23K35/0244 takes precedence
• CPC Class Codes: B23P 15/28 : cutting tools sawing tools B23D63/00, B23D65/00; files or rasps B23D73/00
• CPC Class Codes: B24B 53/017 : Devices or means for dressing, cleaning or otherwise conditioning lapping tools
• CPC Class Codes: B24B 53/12 : Dressing tools; Holders therefor
• CPC Class Codes: B24D 18/00 : Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
• CPC Class Codes: B24D 2203/00 : Tool surfaces formed with a pattern
• CPC Class Codes: B24D 3/06 : metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
• CPC Class Codes: B24D 3/08 : for close-grained structure, e.g. using metal with low melting point
• CPC Class Codes: B24D 5/066 : with segments mounted axially one against the other
• CPC Class Codes: B24D 7/02 : Wheels in one piece
• CPC Class Codes: B24D 7/066 : Grinding blocks; their mountings or supports
• CPC Class Codes: B24D 99/005 : Segments of abrasive wheels
• CPC Class Codes: B28D 1/041 : with cylinder saws, e.g. trepanning; saw cylinders, e.g. having their cutting rim equipped with abrasive particles
• CPC Class Codes: C04B 35/52 : based on carbon, e.g. graphite
• CPC Class Codes: C22C 1/051 : Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
• CPC Class Codes: C22C 21/06 : with magnesium as the next major constituent
• CPC Class Codes: C22C 2204/00 : End product comprising different layers, coatings or parts of cermet
• CPC Class Codes: C22C 26/00 : Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
• CPC Class Codes: C22C 45/00 : Amorphous alloys making amorphous non-ferrous alloys C22C1/11
• CPC Class Codes: E21B 10/5676 : having a cutting face with different segments, e.g. mosaic-type inserts

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.

Claims

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 with a brazing alloy.

2. The method of claim 1, wherein the brazing is accomplished using a brazing alloy that includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon, aluminum and mixtures or alloys thereof.

3. The method of claim 2, wherein the brazing alloy includes between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.

4. The method of claim 3, wherein the material is chromium.

5. The method of claim 1, wherein prior to the step of brazing, the method further comprises the steps of:

a) affixing a plurality of superabrasive particles in a predetermined pattern either on the substrate or the brazing alloy in the form of a sheet of amorphous braze alloy; and

b) placing the sheet of amorphous braze alloy on an exposed surface of the substrate, such that the superabrasive particles are positioned between the sheet of amorphous braze and the exposed surface.

6. The method of claim 1, wherein prior to the step of brazing, the method further comprises the steps of:

a) placing the brazing alloy in the form of a sheet of amorphous braze alloy upon an exposed surface of the substrate; and

b) affixing a plurality of superabrasive particles in a predetermined pattern on the sheet of amorphous braze alloy, such that the sheet of amorphous braze is disposed between the superabrasive particles and the exposed surface.

7. The method of claim 1, wherein the step of brazing includes heating the brazing alloy and substrate to a temperature of less than about 1,100°

C. which is sufficient to braze the superabrasive particles directly to the substrate.

8. The method of claim 1, wherein prior to the step of affixing, the method further comprises:

a) providing a template having a predetermined pattern of apertures therein;

b) placing the template on the brazing alloy or substrate prior to affixing the superabrasive particles thereto;

c) filling the apertures with the superabrasive particles; and

d) removing the template, such that the superabrasive particles remain affixed in place on the brazing alloy or substrate in accordance with the predetermined pattern of the template.

9. The method of claim 8, wherein the superabrasive particles are affixed to the brazing alloy or substrate using an adhesive.

10. The method of claim 8, wherein each aperture is configured to hold only one superabrasive particle.

11. The method of claim 10, wherein some of the apertures are larger than other apertures.

12. The method of claim 1, wherein prior to the step of affixing, the method further comprises the steps of:

a) mixing a powdered brazing alloy with a carrier agent to form a slurry;

b) applying the slurry to an exposed surface of the substrate;

c) providing a template having a predetermined pattern of apertures therein;

d) placing the template on the brazing alloy;

e) filling the apertures with superabrasive particles; and

f) removing the template, such that the superabrasive particles remain in place on the brazing alloy in accordance with the predetermined pattern of the template during the step of brazing.

13. The method of claim 1, wherein prior to the step of brazing, the method further comprises the steps of:

a) affixing the superabrasive particles in a predetermined pattern on an exposed surface of the substrate; and

b) applying the braze alloy to the substrate and the superabrasive particles.

14. The method of claim 1, wherein prior to the step of brazing, the method further comprises the steps of:

a) providing a template having a plurality of apertures corresponding to the predetermined pattern;

b) placing the template on a transfer sheet;

c) filling the apertures with the superabrasive particles;

d) removing the template, such that the superabrasive particles remain in place on the transfer sheet in accordance with the predetermined pattern of the template; and

e) transferring the superabrasive particles to the exposed surface of the substrate or the brazing alloy using the transfer sheet, such that the superabrasive particles become affixed to the substrate in accordance with the predetermined pattern.

15. The method of claim 14, wherein the superabrasive particles are affixed to the exposed surface of the substrate by applying an adhesive to the exposed surface prior to pressing the transfer of the superabrasive particles thereto with the transfer sheet, wherein the adhesive on the substrate is stronger than forces holding the superabrasive particles in place on the transfer sheet.

16. A method of making a superabrasive tool, comprising:

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.

17. The method of claim 16, wherein the step of brazing includes heating the brazing alloy and substrate to a temperature of less than about 1,100°

C. which is sufficient to braze the superabrasive particles directly to the substrate.

18. The method of claim 16, wherein the brazing is accomplished using a brazing alloy that includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.

19. The method of claim 16, wherein the superabrasive particles are placed in a predetermined pattern.

20. A superabrasive tool comprising:

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.

21. The superabrasive tool of claim 20, wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.

22. The superabrasive tool of claim 20, wherein the brazing alloy includes between about 2% and 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.

23. The superabrasive tool of claim 20, wherein bonding of the superabrasive particles avoids damage to the superabrasive particles.

24. The superabrasive tool of claim 20, wherein superabrasive particles are oriented in a predetermined pattern.

25. The superabrasive tool of claim 24, wherein the predetermined pattern consists of superabrasive particles positioned substantially along an exterior edge of the superabrasive tool.

26. The superabrasive tool of claim 24, wherein the predetermined pattern comprises an exterior portion concentration of superabrasive particles that is higher than an interior portion concentration of superabrasive particles.

27. The superabrasive tool of claim 24, wherein the predetermined pattern is a uniform grid.

28. A superabrasive tool precursor comprising:

a) a metal support matrix;

b) a plurality of superabrasive particles placed on the metal support matrix; and

c) a sheet of amorphous braze alloy placed in contact with either the plurality of superabrasive particles or the metal support matrix.

29. The superabrasive tool precursor of claim 28, wherein the plurality of superabrasive particles are arranged in accordance with a predetermined pattern.

30. The superabrasive tool precursor of claim 28, wherein the superabrasive particles extend a predetermined height above the metal support matrix.

31. The superabrasive tool precursor of claim 28, wherein the sheet of amorphous braze has a liquidus temperature of less than 1,100°

C.