Abrasive tool
First Claim
1. An abrasive tool comprising superabrasive grain and an active metal bond composition, wherein the active metal bond composition comprises 2-40 wt % active phase, 5-78 wt % hard phase, and 20-93 wt % of a binder phase selected from the group consisting of cobalt, iron, nickel and their alloys, and combinations thereof, and wherein a majority of the superabrasive grain is chemically bonded with at least a portion of the active phase during sintering to form a metal bond.
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Accused Products
Abstract
The present invention provides a metal bonded abrasive tool wherein the tool has improved life and mechanical properties. The invention further includes the bond composition which allows for improved life and mechanical properties, particularly in diamond blade dressing tools.
61 Citations
23 Claims
- 1. An abrasive tool comprising superabrasive grain and an active metal bond composition, wherein the active metal bond composition comprises 2-40 wt % active phase, 5-78 wt % hard phase, and 20-93 wt % of a binder phase selected from the group consisting of cobalt, iron, nickel and their alloys, and combinations thereof, and wherein a majority of the superabrasive grain is chemically bonded with at least a portion of the active phase during sintering to form a metal bond.
- 8. A dressing tool for reconditioning grinding tools, comprising superabrasive grain and an active metal bond composition, wherein the active metal bond composition comprises 2-40 wt % active phase, 50-83 wt % hard phase, and 15-30 wt % of a binder phase selected from the group consisting of cobalt, iron, nickel and their alloys, and combinations thereof, and wherein a majority of the superabrasive grain is chemically bonded with at least a portion of the active phase during sintering to form a metal bond.
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23. A method of manufacturing a dressing tool, comprising the steps:
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a) providing a powder mixture of an active metal bond composition consisting of 2-40 wt % of an active phase, 50-88 wt % of a hard phase and 10-30 wt % of a binder phase selected from the group consisting of cobalt, nickel, iron, and alloys and combinations thereof; b) pressing a portion of the mixture into a die cavity formed in the shape of the dressing tool; c) setting superabrasive grain in a desired pattern into the pressed mixture; d) pressing the remaining portion of the mixture into the die cavity over the superabrasive grain; e) sintering the bond mixture and the superabrasive grain in the die cavity at 1150°
to 1200°
C., under vacuum at 1.0 to 0.1 microns Hg pressure to form a composite structure;f) infiltrating the composite structure under vacuum with 10-30%, on a powder mixture weight basis, of an infiltrant phase selected from the group consisting of copper, tin, zinc, phosphorus, aluminum, silver and their alloys and combinations thereof, until essentially all void volume within the composite structure has been filled with infiltrant phase; whereby the active phase is chemically reacted with the superabrasive grain prior to infiltration and the dressing tool is substantially free of porosity.
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Specification