BONDED ABRASIVE ARTICLES AND METHODS OF FORMING

• US 20100154315A1
• Filed: 12/15/2009
• Published: 06/24/2010
• Est. Priority Date: 12/19/2008
• Status: Active Grant

• Current Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Original Assignee: Saint-Gobain Abrasives Incorporated (Compagnie De Saint-Gobain), Saint-Gobain Abrasifs (Compagnie de Saint-Gobain SA)
• Inventors: Hall, Richard W.J., Ramanath, Srinivasan, Querel, Gilles, Wu, Jianhui
• Granted Patent: US 8,435,316 B2
• Time in Patent Office: Days
• US Class Current: 51/296
• 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 3/18 for porous or cellular structure

Abstract

A method of forming an abrasive article includes forming a mixture comprising a liquid carrier and a glass precursor material, wherein the glass precursor material comprises a material selected from the group of materials consisting of a hydrated metal compound, an organic silicate compound, or a combination thereof. The method further includes providing abrasive grains within the mixture, forming the mixture into a green ceramic body, and heating the green ceramic body to form a bonded abrasive article comprising the abrasive grains contained within a bond matrix, wherein the bond matrix comprises an amorphous phase formed from the glass precursor material.

Claims

1. A method of forming an abrasive article comprising:

forming a mixture comprising a liquid carrier and a glass precursor material, wherein the glass precursor material comprises a material selected from the group of materials consisting of a hydrated metal compound, an organic silicate compound, or a combination thereof;

providing abrasive grains within the mixture;

forming the mixture into a green ceramic body; and

heating the green ceramic body to form a bonded abrasive article comprising the abrasive grains contained within a bond matrix, wherein the bond matrix comprises an amorphous phase formed from the glass precursor material.

9. The method of claim 1, further comprising gelling the mixture.

14. The method of claim 1, further comprising providing a foaming agent to the mixture.

21. The method of claim 1, wherein heating the green ceramic body comprises heating the green ceramic body to a glass forming temperature of not greater than about 1000°

C. to form a bonded abrasive article comprising the bond material including an amorphous phase.

25. The method of claim 21, wherein heating further comprises heating the bonded abrasive article to a sintering temperature to form a bond material comprising a crystalline phase and an amorphous phase.

26. The method of claim 25, wherein the sintering temperature is at least about 650°

C.

29. The method of claim 1, wherein the hydrated metal compound comprises a metal nitrate compound.

30. The method of claim 29, wherein the metal nitrate compound comprises a material selected from the group of materials consisting of aluminum nitrate nonahydrate (Al(NO₃)₃.9H₂O), calcium nitrate tetrahydrate (Ca(NO₃)₂.4H₂O), magnesium nitrate hexahydrate (Mg(NO₃)₂.6H₂O), and a combination thereof.

31. The method of claim 1, wherein the organic silicate material comprises an orthosilicate.

32. The method of claim 31, wherein the organic silicate material comprises a material selected from the group of materials consisting of tetraethylorthosilicate (TEOS), tetramethylorthosilicate (TMOS), and a combination thereof.

48. The method of claim 1, wherein the amorphous phase comprises at least about 10 wt % of the total weight of the bond material.

52. The method of claim 1, wherein the bond material includes a crystalline phase comprising at least about 10 wt % of the total weight of the bond material.

60. The method of claim 1, wherein the bonded abrasive article is a foamed abrasive article comprising abrasive grains contained within a bond matrix, wherein the foamed abrasive article has a porosity of at least about 60 vol %, and the majority of the porosity is open porosity defining an interconnected network of channels extending through the foamed abrasive article.

2-8. -8. (canceled)

10-13. -13. (canceled)

15-20. -20. (canceled)

22-24. -24. (canceled)

27-28. -28. (canceled)

33-47. -47. (canceled)

49-51. -51. (canceled)

53-59. -59. (canceled)

61-62. -62. (canceled)

63. A method of forming an abrasive article comprising:

forming a sol comprising a liquid carrier and a glass precursor material;

providing abrasive grains within the sol;

gelling the sol to form a gelled ceramic body; and

heating the gelled ceramic body to form a bonded abrasive article comprising the abrasive grains contained within a bond matrix, wherein the bond matrix comprises an amorphous phase formed from the glass precursor material.

64. The method of claim 63, wherein the glass precursor material is selected from the group of materials consisting of aluminum nitrate nonahydrate (Al(NO₃)₃.9H₂O), calcium nitrate tetrahydrate (Ca(NO₃)₂.4H₂O), magnesium nitrate hexahydrate (Mg(NO₃)₂.6H₂O), tetraethylorthosilicate (TEOS), tetramethylorthosilicate (TMOS), and a combination thereof.

66. The method of claim 63, wherein the sol comprises not greater than about 30 wt % of the glass precursor material.

67. The method of claim 63, wherein the sol comprises at least about 50 wt % of the liquid carrier.

65. (canceled)

68-72. -72. (canceled)

73. A method of forming an abrasive article comprising:

forming a mixture comprising a liquid carrier and a glass precursor material selected from the group of materials consisting of aluminum nitrate nonahydrate (Al(NO₃)₃.9H₂O), calcium nitrate tetrahydrate (Ca(NO₃)₂.4H₂O), magnesium nitrate hexahydrate (Mg(NO₃)₂.6H₂O), tetraethylorthosilicate (TEOS), tetramethylorthosilicate (TMOS), and a combination thereof;

providing abrasive grains within the mixture;

forming the mixture into a green ceramic body; and

heating the green ceramic body to form a bonded abrasive article comprising the abrasive grains contained within a bond matrix, wherein the bond matrix comprises an amorphous phase formed from the glass precursor material.

74. The method of claim 73, wherein the glass precursor material comprises a combination of calcium nitrate tetrahydrate (Ca(NO₃)₂.4H₂O) and tetraethylorthosilicate (TEOS).

77. The method of claim 74, wherein the glass precursor material comprises an amount of tetraethylorthosilicate (TEOS) of at least about 20 wt %.

75-76. -76. (canceled)

78-89. -89. (canceled)