Abrasive article and method of making

• US 8,814,967 B2
• Filed: 06/29/2012
• Issued: 08/26/2014
• Est. Priority Date: 06/30/2011
• 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: Upadhyay, Rachana, Ramanath, Srinivasan
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US13/539,124
• Publication Number:
  US 20130000211A1
• Time in Patent Office: 788 Days
• Field of Search: 513/07, 512/95, 512/98
• US Class Current: 51/307
• CPC Class Codes: B24D 3/02 the constituent being used as bonding agent
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
• CPC Class Codes: B24D 3/20 and being essentially organic
• CPC Class Codes: B24D 3/342 incorporated in the bonding agent
• CPC Class Codes: B24D 5/02 Wheels in one piece

Abstract

An abrasive article includes a bonded abrasive having a body made of abrasive grains contained within a composite bond material. The composite bond material can include an organic material and a metal material. The body can also include a filler material made of a superabrasive material. In an embodiment, the filler material can have an average particle size at least about 10 times less than an average particle size of the abrasive grains.

Claims

1. An abrasive article comprising:

a bonded abrasive having a body comprising abrasive grains contained within a composite bond material including an organic material and a metal material, wherein the body further includes a filler material comprising a superabrasive material, the filler material having an average particle size at least about 10 times less than an average particle size of the abrasive grains; and

wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25.

2. The abrasive article as recited in claim 1, wherein the filler material has an average particle size at least about 12 times less than an average particle size of the abrasive grains.

3. The abrasive article as recited in claim 1, wherein the filler material comprises a metal coating including a transition metal element.

4. An abrasive article comprising:

a body comprising abrasive grains contained within a composite bond material including an organic material and a metal material, wherein the body further includes a filler material comprising titanium coated diamond particles, wherein the filler material is chemically bonded to the composite bond material; and

wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25.

5. The abrasive article of claim 4, wherein the titanium is chemically bonded to the metal material of the bond at an active region at the interface of the filler material and bond material.

6. The abrasive article of claim 5, wherein the active region comprises an interdiffusion of titanium and the metal material of the composite bond defining a bond region at the surface of the superabrasive particle.

7. The abrasive article as recited in claim 4, wherein an average particle size of the filler material is at least about 10 times less than an average particle size of the abrasive grains.

8. An abrasive article comprising:

a body comprising abrasive grains contained within a composite bond material including an organic material and a metal material, wherein the body further includes a filler material comprising metal-coated superabrasive particles, wherein an average particle size of the filler material and average particle size of the abrasive grains define a bimodal particle size distribution.

9. The abrasive article as recited in claim 8, wherein the average particle size of the filler material is at least about 10 times less than an average particle size of the abrasive grains.

10. The abrasive article as recited in claim 8, wherein the filler material comprises a metal coating including a transition metal element.

11. The abrasive article as recited in claim 8, wherein the bond material comprise a ratio (OM/MM) of organic material by volume (OM) to metal material by volume (MM) of not greater than about 0.25.

12. The abrasive article of claim 8, wherein the composite bond material has a fracture toughness within a range between about 1.5 MPa m^0.5 and about 3.0 MPa m^0.5.

13. The abrasive article of claim 8, wherein the organic material comprises polybenzimidazole (PBI).

14. The abrasive article of claim 8, wherein the bond material comprises between about 1 vol % and about 20 vol % organic bond material for the total volume of the bond material.

15. The abrasive article of claim 8, wherein the metal material consists essentially of bronze.

16. The abrasive article of claim 8, wherein the average particle size of the abrasive grains is within a range between about 50 microns and about 400 microns.

17. The abrasive article of claim 8, wherein the average particle size of the filler material is not greater than about 40 times less than an average particle size of the abrasive grains.

18. The abrasive article of claim 8, wherein the body comprises a ratio of filler material to abrasive grains (FM/AG) not greater than about 0.30, wherein FM is the volume percent of the filler material based on the total volume of the body and AG is the volume percent of the abrasive grain based on the total volume of the body.

19. The abrasive article of claim 8, wherein the body comprises at least about 2 vol % and not greater than about 16 vol % filler material for the total volume of the body.

20. The abrasive article of claim 8, wherein the average particle size of the filler material is not greater than about 25 microns and at least about 0.5 microns.