Bonded abrasive article and method of forming

• US 9,676,077 B2
• Filed: 12/30/2015
• Issued: 06/13/2017
• Est. Priority Date: 09/03/2010
• 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: Ramanath, Srinivasan, Saucier, Kenneth A., Upadhyay, Rachana
• Primary Examiner(s): Parvini, Pegah
• Application Number:
  US14/984,576
• Publication Number:
  US 20160129553A1
• Time in Patent Office: 531 Days
• CPC Class Codes: B24D 3/06 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
• CPC Class Codes: B24D 3/10 for porous or cellular structure, e.g. for use with diamonds as abrasives
• CPC Class Codes: B24D 3/14 ceramic, i.e. vitrified bondings
• CPC Class Codes: B24D 3/342 incorporated in the bonding agent
• CPC Class Codes: C09K 3/1409 Abrasive particles per se preparation of diamond C01B32/25

Abstract

An abrasive article includes a body having abrasive grains contained within a bond material comprising a metal or metal alloy, wherein the body comprises a ratio of V_AG/V_BM of at least about 1.3, wherein V_AG is the volume percent of abrasive grains within the total volume of the body and V_BM is the volume percent of bond material within the total volume of the body.

Claims

1. An abrasive article comprising:

a body, wherein the body comprises;

abrasive grains contained within a bond material comprising a metal,

at least about 1 vol % and not greater than about 40 vol % of an active bond composition of the total volume of the bond material, wherein the active bond composition comprises a precipitated phase and an interfacial phase and wherein the interfacial phase is dispersed as a distinct phase throughout the bond material, and

a porosity of at least about 5 vol % and not greater than about 35 vol. %.

2. The abrasive article of claim 1, wherein the bond material comprises an average fracture toughness (K_1c) within a range between about 0.6 MPa m^0.5 and about 4.0 MPa m^0.5.

3. The abrasive article of claim 2, wherein the bond material comprises an average fracture toughness (K_1c) within a range between about 0.6 MPa m^0.5 and about 3.0 MPa m^0.5.

4. The abrasive article of claim 1, wherein the ratio of V_P/V_BM is within a range between about 1.5 and about 9.0, wherein V_P is a volume percent of particulate material including abrasive grains and fillers within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body.

5. The abrasive article of claim 4, wherein the ratio of V_P/V_BM is within a range between about 1.7 and about 6.0, wherein V_P is a volume percent of particulate material including abrasive grains and fillers within a total volume of the body and V_BM is a volume percent of bond material within the total volume of the body.

6. The abrasive article of claim 1, wherein the body comprises a ratio of V_AG/V_BM of at least about 1.3, wherein V_AG is a volume percent of abrasive grains within the total volume of the body and V_BM is a volume percent of bond material within the total volume of the body.

7. The abrasive article of claim 6, wherein the ratio of V_AG/V_BM is within a range between about 1.3 and about 9.0.

8. The abrasive article of claim 1, wherein the active bond composition comprises a compound including a metal.

9. The abrasive article of claim 1, wherein the active bond composition comprises a compound selected from the group consisting of carbides, nitrides, oxides and a combination thereof.

10. The abrasive article of claim 1, wherein the active bond composition comprises a metal element selected from the group of metal elements consisting of titanium, vanadium, chromium, zirconium, hafnium, tungsten, and a combination thereof.

11. The abrasive article of claim 1, wherein a majority of the porosity is interconnected porosity defining a network of interconnected pores extending through the volume of the body.

12. The abrasive article of claim 1, wherein the bond material comprises at least one transition metal element.

13. The abrasive article of claim 12, wherein the bond material comprises a metal selected from the group of metals consisting of copper, tin, silver, molybdenum, zinc, tungsten, iron, nickel, antimony, and a combination thereof.

14. The abrasive article of claim 13, wherein the bond material comprises a metal alloy including copper and tin.

15. The abrasive article of claim 1, wherein the body comprises a bimodal distribution of abrasive grains including fine grains having a fine average grit size and coarse grains having a coarse average grit size, wherein the coarse grit size is greater than the fine average grit size.

16. The abrasive article of claim 4, wherein the fillers comprise a material selected from the group of materials consisting of oxides, carbides, borides, silicides, nitrides, oxynitrides, oxycarbides, silicates, graphite, silicon, inter-metallics, ceramics, hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass spheres, and a combination thereof.

17. The abrasive article of claim 4, wherein the fillers comprise a fracture toughness (K_1c) of not greater than about 10 MPa m^0.5.

18. The abrasive article of claim 4, wherein the fillers comprise not greater than about 75 vol % of the total volume of the body.

19. The abrasive article of claim 1, wherein the abrasive grains comprise a coating.