Abrasive articles including abrasive particles of silicon nitride

• US 8,986,409 B2
• Filed: 06/30/2012
• Issued: 03/24/2015
• Est. Priority Date: 06/30/2011
• Status: Active Grant

• Current Assignee: Fiven Norge As (Compagnie De Saint-Gobain S.A.)
• Original Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain S.A.)
• Inventors: Wang, Guan, Pujari, Vimal K., Boussant-Roux, Yves
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US13/539,369
• Publication Number:
  US 20130000216A1
• Time in Patent Office: 997 Days
• US Class Current: 51/307
• CPC Class Codes: B24D 11/001 Manufacture of flexible abrasive materials
• CPC Class Codes: B24D 3/14 ceramic, i.e. vitrified bondings
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25
• CPC Class Codes: C09K 3/1418 obtained by division of a mass agglomerated by sintering

Abstract

An abrasive article includes a body having abrasive particles contained within a bond material. The abrasive particles can include a majority content of silicon nitride and a minority content of sintering material including at least two rare-earth oxide materials. In an embodiment, the rare-earth oxide materials can include Nd₂O₃ and Y₂O₃. In a particular embodiment, the abrasive particles comprise a content (wt %) of Nd₂O₃ that is greater than a content of Y₂O₃ (wt %).

Claims

1. An abrasive article comprising:

a body comprising abrasive particles contained within a bond material, each of the abrasive particles comprising (i) a majority content of silicon nitride; and

(ii) a minority content of sintering material including Nd₂O₃ and Y₂O₃, wherein each of the abrasive particles comprises a content (wt %) of Nd₂O₃ greater than a content of Y₂O₃ (wt %), and wherein the body comprises no greater than about 5 vol % porosity.

2. The abrasive article of claim 1, wherein the body comprises a single-layered abrasive tool having a single layer of abrasive particles attached to a substrate with a layer of the bond material.

3. The abrasive article of claim 2, wherein a portion of the abrasive particles protrude from the bond material and are contacting the substrate underlying the bond material.

4. The abrasive article of claim 1, wherein each of the abrasive particles comprises a total content of rare earth oxide greater than a content of alumina.

5. The abrasive article of claim 1, wherein each of the abrasive particles comprises a content of alumina (wt %) that is between about 0.3 and about 0.7 of a content (wt %) of a rare earth oxide composition.

6. The abrasive article of claim 1, wherein each of the abrasive particles comprises no greater than about 10 wt % of a rare earth oxide for the total weight of the abrasive particles.

7. The abrasive article of claim 1, wherein each of the abrasive particles comprises no greater than about 3 wt % AlN for the total weight of the abrasive particles.

8. The abrasive article of claim 1, wherein each of the abrasive particles consists essentially of silicon nitride and a sintering phase comprising an oxide.

9. The abrasive article of claim 1, wherein each of the abrasive particles comprises liquid phase sintered silicon nitride.

10. The abrasive article of claim 1, wherein each of the abrasive particles comprises a majority content (>

50 wt %) of beta-phase silicon nitride.

11. The abrasive article of claim 1, wherein at least a portion of the abrasive particles are shaped abrasive particles.

12. An abrasive article comprising:

a body comprising abrasive particles contained within a bond material, the abrasive particles comprising a majority content of silicon nitride and a minority content of sintering material including Nd₂O₃ and Y₂O₃, wherein the abrasive particles comprise a content (wt %) of Nd₂O₃ greater than a content of Y₂O₃ (wt %), and wherein the abrasive particles comprise a total content of rare earth oxide greater than a content of alumina.

13. The abrasive article of claim 12, wherein the abrasive particles comprise no greater than about 10 wt % of a rare earth oxide.

14. The abrasive article of claim 12, wherein the abrasive particles comprise AlN.

15. The abrasive article of claim 12, wherein at least a portion of the abrasive particles are shaped abrasive particles.

16. The abrasive article of claim 12, wherein the abrasive particles comprise a content of alumina (wt %) that is between about 0.3 and about 0.7 of a content (wt %) of a rare earth oxide.

17. The abrasive article of claim 15, wherein each of the shaped abrasive particles comprises a body having a two-dimensional shape as viewed in a plane defined by a length and a width of the body, wherein the two-dimensional shape is selected from the group consisting of a polygonal shape, an ellipsoidal shape, a numeral, a Greek alphabet character, Latin alphabet character, Russian alphabet character, and a complex shape utilizing a combination of polygonal shapes.

19. The abrasive article of claim 16, wherein the abrasive particles comprise no greater than about 10 wt % of a rare earth oxide.

18. An abrasive article comprising:

a body comprising abrasive particles contained within a bond material, the abrasive particles comprising a majority content (>

50 wt %) of beta-phase silicon nitride and a minority content of sintering material including Nd₂O₃ and Y₂O₃, wherein the abrasive particles comprise a content (wt %) of Nd₂O₃ greater than a content of Y₂O₃ (wt %).

20. The abrasive article of claim 18, wherein at least a portion of the abrasive particles are shaped abrasive particles.