Abrasive article and method of forming

Patent metadata

Field	Value
Publication number	US-9375826-B2
Application number	US-201213618328-A
Country	US
Kind code	B2
Filing date	Sep 14, 2012
Priority date	Sep 16, 2011
Publication date	Jun 28, 2016
Grant date	Jun 28, 2016

Abstract

An abrasive article including a substrate made of a wire, abrasive particles affixed to the substrate, the abrasive particles having a first coating layer overlying the abrasive particles, and a second coating layer different than the first coating layer overlying the first coating layer. The abrasive article further including a bonding layer overlying the substrate and abrasive particles.

First claim

What is claimed is:

1. An abrasive article comprising:
a substrate comprising a wire;
abrasive particles affixed to the substrate, the abrasive particles comprising:
a first coating layer overlying the abrasive particles; and
a second coating layer different than the first coating layer overlying the first coating layer, wherein the second coating layer has a melting point of not greater than about 450° C.; and

a bonding layer overlying the substrate and abrasive particles, wherein the bonding layer overlies all of the external surfaces of the abrasive particles and the substrate, and
wherein a diffusion bonding region is formed between the second coating layer and the substrate.

2. The abrasive article of claim 1 , wherein the substrate comprises an inorganic material.

3. The abrasive article of claim 1 , wherein the substrate comprises an elongated member having an aspect ratio of length:width of at least about 10:1.

4. The abrasive article of claim 1 , wherein the first coating layer comprises a metal selected from the group of metals consisting of titanium, vanadium, chromium, molybdenum, iron, cobalt, nickel, copper, silver, zinc, manganese, tantalum, tungsten, and a combination thereof.

5. The abrasive article of claim 1 , wherein the first coating layer overlies at least about 50% of an exterior surface area of each of the abrasive particles.

6. The abrasive article of claim 1 , wherein the first coating layer comprises at least about 5% of the total weight of each of the abrasive particles.

7. The abrasive article of claim 1 , wherein the first coating layer comprises an average thickness greater than an average thickness of the second coating layer.

8. The abrasive article of claim 1 , wherein the second coating layer comprises a metal alloy of tin and lead.

9. The abrasive article of claim 1 , wherein the second coating layer overlies at least about 50% of an exterior surface area of the first coating layer on each of the abrasive particles.

10. The abrasive article of claim 1 , wherein the second coating layer comprises at least about 10% of the total weight of each of the abrasive particle and the first coating layer.

11. The abrasive article of claim 1 , wherein the second coating layer comprises an average thickness of not greater than about 12 microns.

12. The abrasive article of claim 1 , wherein the second coating layer comprises an average thickness of not greater than about 80% of an average particle size of the abrasive particles.

13. The abrasive article of claim 1 , wherein the bonding layer directly contacts the second coating layer.

14. The abrasive article of claim 1 , wherein the bonding layer comprises a metal selected from the group of metals consisting of lead, silver, copper, zinc, tin, titanium, molybdenum, chromium, iron, manganese, cobalt, niobium, tantalum, tungsten, palladium, platinum, gold, ruthenium, and a combination thereof.

15. The abrasive article of claim 1 , wherein the bonding layer comprises an average thickness of at least about 10% and not greater than about 100% of the average particle size of the abrasive particles.

Assignees

• Tian Yinggang
• Khaund Arup K
• Pearlman John
• Saint Gobain Abrasives Inc
• Saint Gobain Abrasifs Sa

Inventors

• Tian Yinggang
• Khaund Arup K
• Pearlman John

Classifications

• B24D3/004 Primary

  with special coatings · CPC title

• B24D3/06 Primary

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

• C01P2004/84

  one phase coated with the other · CPC title

• C09C1/62

  Metallic pigments or fillers {(C09C1/0015 takes precedence)} · CPC title

• B24B27/0633

  using a cutting wire · CPC title