Bonded abrasive article and method of forming

Patent metadata

Field	Value
Publication number	US-9254553-B2
Application number	US-201414221515-A
Country	US
Kind code	B2
Filing date	Mar 21, 2014
Priority date	Sep 3, 2010
Publication date	Feb 9, 2016
Grant date	Feb 9, 2016

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.

First claim

What is claimed is:

1. An abrasive article comprising:
a body comprising abrasive grains contained within a bond material comprising a metal, wherein the body comprises a ratio of V P /V BM of at least about 1.5, 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, wherein the body comprises greater than 20 vol % porosity and wherein the bond material comprises an average fracture toughness (K 1c ) of not greater about 4.0 MPa m 0.5 .

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.

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.

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 body comprises an active bond composition comprising at least 1 vol % of an active bond composition of the total volume of the bond material.

9. The abrasive article of claim 8 , wherein the active bond composition is present in an amount within a range between about 1 vol % and about 40 vol % of the total volume of the bond material.

10. The abrasive article of claim 1 , wherein the body comprises at least 25 vol % porosity.

11. The abrasive article of claim 8 , wherein the active bond composition comprises a compound selected from the group consisting of carbides, nitrides, oxides and a combination thereof.

12. The abrasive article of claim 10 , 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.

13. 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.

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

15. The abrasive article of claim 14 , 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.

16. The abrasive article of claim 15 , wherein the bond material comprises a metal alloy including copper and tin.

17. 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.

18. The abrasive article of claim 1 , 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.

19. The abrasive article of claim 1 , wherein the fillers comprise a fracture toughness (K 1c ) of not greater than about 10 MPa m 0.5 .

20. The abrasive article of claim 1 , wherein the fillers comprise not greater than about 75 vol % of the total volume of the body.

Assignees

• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Ramanath Srinivasan
• Saucier Kenneth A
• Upadhyay Rachana

Classifications

• B24D3/10 Primary

  for porous or cellular structure, e.g. for use with diamonds as abrasives · CPC title

• B24D3/06 Primary

  metallic {or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements} · CPC title

• C09K3/1409

  Abrasive particles per se (preparation of diamond C01B32/25) · CPC title

• C09K3/14

  Anti-slip materials; Abrasives {(products specifically intended for the fabrication of abrasive tools, blocks or papers, or for operations of the kind of sand-blasting and barrelling B24B31/14, B24C1/00; polishing compositions containing abrasive or grinding agents C09G1/02; friction compositions for brakes or clutches F16D69/02; polishing of semi-conductors H10P52/40)} · CPC title

• B24D18/009

  Tools not otherwise provided for · CPC title