Brazed diamond tools and methods for making

• US 6,679,243 B2
• Filed: 08/22/2001
• Issued: 01/20/2004
• Est. Priority Date: 04/04/1997
• Status: Expired due to Term

• Current Assignee: Chien-Min Sung, Kinik Company
• Original Assignee: Kinik Company
• Inventors: Sung, Chien-Min
• Primary Examiner(s): SHAKERI, HADI
• Application Number:
  US09/935,204
• Publication Number:
  US 20020077054A1
• Time in Patent Office: 881 Days
• Field of Search: 512/97, 125/16.02, 125/21.12, 125/22, 451/527, 451/529, 451/533, 451/544
• 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 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: B23P 15/28 cutting tools sawing tools B23D63/00, B23D65/00; files or rasps B23D73/00
• CPC Class Codes: B24D 3/08 for close-grained structure, e.g. using metal with low melting point
• 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: 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 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: E21B 10/5676 : having a cutting face with different segments, e.g. mosaic-type inserts

Abstract

The present invention provides a superabrasive tools and methods for making the same. In one aspect, superabrasive particles are chemically bonded to a matrix support material according to a predetermined pattern by a braze alloy that contains Cr, Mn, Si, or Al or mixtures thereof.

Claims

1. A method of making a superabrasive impregnated tool comprising the steps of:

a) providing a matrix support material;

b) locating a plurality of superabrasive particles at individually specified positions on a top surface of the matrix support material according to a predetermined pattern; and

c) bonding the superabrasive particles to the matrix support material.

2. The method of claim 1, wherein the matrix support material comprises a brazing alloy containing between 2 and 50 weight percent of an element selected from the group consisting of:

chromium, manganese, silicon, titanium, and aluminum.

3. The method of claim 2, wherein the matrix support material is provided as a metallic powder.

4. The method of claim 3, wherein the matrix support material further comprises an organic binder mixed with the metallic powder.

5. The method of claim 3, wherein the metallic powder has an average particle size of greater than about 400 mesh.

6. The method of claim 5, wherein the metallic powder contains irregularly shaped particles.

7. The method of claim 1, wherein the matrix support material consists of a brazing alloy containing between 2 and 50 weight percent of an element selected from the group consisting of:

chromium, manganese, silicon, titanium, and aluminum.

8. The method of claim 2 or 7, wherein the brazing alloy is a diamond braze substantially free of zinc, lead, and tin.

9. The method of claim 2, wherein the brazing alloy includes at least 5 percent by weight of a carbide former selected from the group consisting of:

chromium, manganese, titanium, silicon, and mixtures thereof.

10. The method of claim 2, wherein the brazing alloy further includes one or more members selected from the group consisting essentially of:

boron, iron, copper, and nickel.

11. The method of claim 10, wherein the brazing alloy contains copper and manganese.

12. The method of claim 10, wherein the brazing alloy contains copper and silicon.

13. The method of claim 10, wherein the brazing alloy contains aluminum and silicon.

14. The method of claim 10, wherein the brazing alloy contains nickel and silicon.

15. The method of claim 10, wherein the brazing alloy contains copper and titanium.

16. The method of claim 10, wherein the brazing alloy contains titanium.

17. The method of claim 2, wherein the step of distributing superabrasive particles further comprises the steps of:

placing a template having a plurality of apertures corresponding to the predetermined pattern upon a top surface of the matrix support material;

filling the apertures with superabrasive particles;

pressing the superabrasive particles into the matrix support material; and

removing the template from the top surface of the matrix support material, such that the superabrasive particles remain embedded therein.

18. The method of claim 17, wherein the template is configured to hold one superabrasive particle in each aperture.

19. The method of claim 17, further comprising the step of:

pressing said superabrasive particles to a greater depth in the matrix support material after removing the template.

20. The method of claim 2, wherein the step of distributing superabrasive particles further comprises the steps of:

placing a template having a plurality of apertures corresponding to the predetermined pattern upon a transfer plate;

filling said apertures with superabrasive particles;

removing said template from said transfer plate; and

pressing said transfer plate having the superabrasive particles thereon against the matrix support material, such that the superabrasive particles remain embedded in the matrix support material.

21. The method of claim 20, wherein said template is a sieve which is configured to hold one superabrasive particle in each aperture.

22. The method of claim 20, further comprising the step of affixing the superabrasive particles to said transfer plate using an adhesive.

23. The method of claim 22, wherein the superabrasive particles are embedded in the matrix support material and removed from said transfer plate using an adhesive coated on the support material which more strongly binds the superabrasive particles to the support material than to the transfer plate.

24. The method of claim 20, wherein said transfer plate is plastic.

25. The method of claim 20, wherein said transfer plate is transparent plastic.

26. The method of claim 1, wherein the predetermined pattern is a uniform grid pattern.

27. The method of claim 1, wherein the superabrasive particles are selected from the group consisting of diamond, cubic boron nitride, and mixtures thereof.

28. The method of claim 1, wherein the step of bonding further comprises the steps of:

disposing a brazing alloy on the top surface of the matrix support material; and

heating the brazing alloy and matrix support material to a temperature sufficient to allow the brazing alloy to infiltrate into the matrix support material, and bond the superabrasive particles thereto.

29. The method of claim 28, further comprising the step of subjecting the matrix support material and superabrasive particles to a vacuum of at least 10⁻

3 torr during infiltration.

30. The method of claim 1, wherein the step of bonding further comprises the steps of:

mixing a powdered form of a brazing alloy with the metallic powder of the matrix support material; and

heating the brazing alloy and matrix support material to a temperature sufficient to bond the superabrasive particles to the matrix support material.

31. The method of claim 1, wherein the bonded matrix support material forms a single layer.

32. The method of claim 1, further comprising a plurality of layers formed from a matrix support material, each layer holding superabrasive particles, wherein the layers are bonded to one another to form a three-dimensional abrasive tool segment.

33. The method of claim 1, wherein said tool is a circular saw.

34. The method of claim 1, wherein said tool is a frame saw.

35. The method of claim 1, wherein said tool is a gang saw.

36. The method of claim 1, wherein said tool is a wire saw.

37. The method of claim 1, wherein said tool is a chain saw.

38. The method of claim 1, wherein said tool is a pad conditioner.

39. The method of claim 1, wherein said tool is a thin-walled cutoff saw.

40. The method of claim 1, wherein said tool is a dicing wheel.

41. A method of making a superabrasive impregnated tool comprising the steps of:

a) mixing a metallic matrix support material powder having irregularly shaped particles with an average particle size of greater than about 400 mesh, with a brazing alloy powder, and an organic binder;

b) placing a template having a plurality of apertures in a predetermined pattern upon a top surface of the mixture of matrix support material, distributing a plurality of superabrasive particles on a top surface of the matrix support material in a predetermined pattern said apertures being configured to hold one superabrasive particle each;

c) removing the template; and

d) binding the superabrasive particles to the matrix support material with a brazing alloy that contains between 2 and 50 percent of an element selected from the group consisting of chromium, manganese, silicon, titanium, and aluminum.

42. An abrasive tool consisting essentially of:

a) a tool substrate;

b) a plurality of superabrasive particles arranged at individually specified positions according to a predetermined pattern upon the tool substrate; and

c) a brazing alloy which bonds the superabrasive particles to the substrate, said brazing alloy having at least two elements of at least 2 weight percent each selected from the group consisting of;

chromium, manganese, silicon, aluminum, titanium, nickel, iron, cobalt, copper, and mixtures thereof.

43. An abrasive tool according to claim 42, wherein the brazing alloy contains between 2 and 50 percent of an element selected from the group consisting of chromium, manganese, silicon, titanium, aluminum, and mixtures thereof.

44. A method of making a superabrasive impregnated tool comprising the step of:

bonding a plurality of superabrasive particles at individually specified positions to a substrate according to a predetermined pattern with a material consisting of a brazing alloy having at least two elements of at least 2 weight percent each consisting essentially of chromium, manganese, silicon, aluminum, titanium, nickel, iron, cobalt, copper, and mixtures thereof.

45. The method of claim 44, wherein the brazing alloy contains between 2 and 50 weight percent of an element selected from the group consisting of chromium, manganese, silicon, titanium, aluminum, and mixtures thereof.