Brazed diamond tools and methods for making the same

• US 8,104,464 B2
• Filed: 05/11/2009
• Issued: 01/31/2012
• Est. Priority Date: 04/04/1997
• Status: Expired due to Fees

• Current Assignee: Kinik Company
• Original Assignee: Kinik Company
• Inventors: Sung, Chien-Min
• Primary Examiner(s): Eley, Timothy V
• Application Number:
  US12/463,897
• Publication Number:
  US 20090283089A1
• Time in Patent Office: 995 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 2203/0635 Silicon carbide
• 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: 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: B23P 15/28 cutting tools sawing tools B23D63/00, B23D65/00; files or rasps B23D73/00
• 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 3/08 : 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: 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

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 solid metal substrate having a continuous and uninterrupted surface; and

b) brazing a plurality of superabrasive particles directly to the continuous and uninterrupted surface of the substrate in accordance with a predetermined pattern with a sheet of amorphous 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 2, wherein the brazing alloy includes chromium.

5. 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.

6. 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.

7. 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 a transfer sheet of amorphous braze alloy; and

b) applying the transfer sheet to the substrate.

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

9. A superabrasive tool comprising:

a) a solid metal substrate having a continuous and uninterrupted surface;

b) a plurality of superabrasive particles; and

c) a layer of amorphous braze alloy chemically bonding the plurality of superabrasive particles to the continuous and uninterrupted surface of the solid metal substrate, wherein the plurality of superabrasive particles have been brazed to the solid metal substrate as in claim 1.

10. The superabrasive tool of claim 9, wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.

11. The superabrasive tool of claim 9, 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.

12. The superabrasive tool of claim 9, wherein bonding of the superabrasive particles avoids damage to the superabrasive particles.

13. The superabrasive tool of claim 9, wherein superabrasive particles are oriented in a predetermined pattern.

14. The superabrasive tool of claim 13, wherein the predetermined pattern consists of superabrasive particles positioned substantially along an exterior edge of the superabrasive tool.

15. The superabrasive tool of claim 13, wherein the predetermined pattern comprises an exterior portion concentration of superabrasive particles that is higher than an interior portion concentration of superabrasive particles.

16. The superabrasive tool of claim 13, wherein the predetermined pattern is a uniform grid.

17. The super abrasive tool of claim 9, further comprising a layer of overlay material affixed to a working surface of the brazing alloy to create a smooth working surface.

18. A superabrasive tool precursor comprising:

a) a solid metal support matrix having a continuous and uninterrupted surface;

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

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