LIQUID PHASE SINTERED SILICON CARBIDE ABRASIVE PARTICLES

• US 20130000212A1
• Filed: 06/30/2012
• Published: 01/03/2013
• Est. Priority Date: 06/30/2011
• Status: Active Grant

• Current Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain)
• Original Assignee: Saint-Gobain Ceramics & Plastics Incorporated (Compagnie De Saint-Gobain)
• Inventors: Wang, Guan, Boussant-Roux, Yves
• Granted Patent: US 8,840,694 B2
• Time in Patent Office: Days
• US Class Current: 51/298
• CPC Class Codes: C09K 3/1418 obtained by division of a mass agglomerated by sintering

Abstract

An abrasive article includes a bonded abrasive body having abrasive particles contained within a bond material. The abrasive particles include silicon carbide and are essentially free of carbon-based and boron-based sintering aid materials. In an embodiment, the bond material can include a phenolic resin. In another embodiment, the bonded abrasive body can include an oxide phase disposed interstitially between the silicon carbide abrasive particles. In an additional embodiment, the abrasive particles can consist essentially of silicon carbide and aluminum oxide in a ratio of silicon carbide to alumina of at least about 8:1.

Claims

1. An abrasive article comprising:

a bonded abrasive body having abrasive particles contained within a bond material, the abrasive particles comprising silicon carbide and essentially free of carbon-based and boron-based sintering aid materials.

2. The abrasive article of claim 1, wherein the abrasive particles are essentially free of silica, phosphates, phosphides, alkali elements, alkaline earth elements, transition metal elements, silicides, aluminides, or a combination thereof.

3. The abrasive article of claim 1, wherein the abrasive particles comprise at least about 90 wt % silicon carbide.

4. The abrasive article of claim 1, wherein the abrasive particles consist essentially of silicon carbide and alumina.

5. The abrasive article of claim 1, wherein the abrasive particles comprise a ratio of silicon carbide to alumina of at least about 8:

1.

6. The abrasive article of claim 1, wherein the abrasive particles comprise liquid phase sintered silicon carbide (LPS-SiC).

14. The abrasive article of claim 1, wherein the abrasive particles comprise a content of an oxide of not greater than about 5 wt % for the total weight of the abrasive particles.

16. The abrasive article of claim 1, wherein the abrasive particles comprise a theoretical density of at least about 96.

17. The abrasive article of claim 1, wherein the abrasive particles comprise a strength of at least about 400 MPa and not greater than about 1200 MPa, wherein strength is measured as a Modulus of Rupture by a 4 point bend test.

19. The abrasive article of claim 1, wherein the abrasive particles comprise a Knoop hardness of at least about 27 kgf/mm² and not greater than about 35 kfg/mm².

21. The abrasive article of claim 1, wherein the abrasive particles comprise silicon carbide grains, wherein the silicon carbide grains have an average grain size of at least about 0.1 microns and not greater than about 100 microns.

24. The abrasive article of claim 1, wherein the bond material comprises a polymer.

29. The abrasive article of claim 1, wherein the bond material comprises a hybrid bond comprising an inorganic material and an organic material.

30. The abrasive article of claim 1, wherein the bond material comprises a metal or metal alloy.

31. The abrasive article of claim 1, wherein the bond material comprises a vitreous material.

33. The abrasive article of claim 1, wherein at least a portion of the abrasive particles include a shaped abrasive grain.

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34. An abrasive article comprising:

a bonded abrasive body having abrasive particles contained within a bond material, wherein the abrasive particles include liquid phase sintered silicon carbide; and

wherein the body comprises a G-ratio of at least about 200 for grinding a workpiece comprising metal, at a constant infeed speed, for a depth of cut of at least about 0.0005 inches, wherein the G-ratio is a measure of weight of material removed from a workpiece to weight of material lost from the bonded abrasive body.

37. The abrasive article of claim 34, wherein the G-ratio is within a range between about 150 and 400 for a workpiece comprising Ti.

38. The abrasive article of claim 34, wherein the G-ratio is within a range between about 150 and about 800 for a workpiece comprising white cast iron.

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45. An abrasive article comprising:

a bonded abrasive body having abrasive particles contained within a bond material, the abrasive particle including silicon carbide grains and an oxide phase disposed interstitially between the grains of silicon carbide, wherein the bond material comprises a phenolic resin.