CN117801788A

CN117801788A - Abrasive particles including coatings, abrasive articles including abrasive particles, and methods of forming

Info

Publication number: CN117801788A
Application number: CN202211169190.0A
Authority: CN
Inventors: 施泽华; 李大铭; 宋晓超; 张剑锋; 牛浩然
Original assignee: Saint Gobain Abrasifs SA; Saint Gobain Abrasives Inc
Current assignee: Saint Gobain Abrasifs SA; Saint Gobain Abrasives Inc
Priority date: 2022-09-23
Filing date: 2022-09-23
Publication date: 2024-04-02

Abstract

The present application relates to abrasive particles including coatings, abrasive articles including abrasive particles, and methods of forming. The present invention relates to an abrasive particle having a body comprising a core and a coating over at least a portion of the core, the coating having one or more of: 1) a specific lithium/silicon percentage, 2) a specific potassium/silicon percentage, and/or 3) a specific sodium/silicon percentage.

Description

Abrasive particles including coatings, abrasive articles including abrasive particles, and methods of forming

Technical Field

The following relates to abrasive particles including a coating overlying a portion of a core, abrasive articles including the abrasive particles, and methods of forming.

Background

Abrasive articles are used in material removal operations, such as cutting, grinding, or shaping various materials. The fixed abrasive article comprises abrasive particles held in a bond material. The bonding material may comprise an organic material and/or an inorganic material. Organic bonded abrasive articles often perform poorly under wet-milling conditions. Specifically, in wet milling operations. There is a continuing need in the industry for improved abrasive articles.

Disclosure of Invention

The present application provides an abrasive particle comprising: a body, the body comprising: a core, and a coating overlying at least a portion of the core, wherein the coating comprises at least one of: a) A lithium/silicon percentage in the range of at least 0.01% to no more than 25%; b) A potassium/silicon percentage in the range of at least 0.01% to not more than 40%; c) A sodium/silicon percentage in the range of at least 0.01% to no more than 40%; or d) any combination thereof.

The present application also provides a fixed abrasive article comprising the abrasive particles described above.

The present application further provides an abrasive particle comprising: a body, the body comprising: a core, and a coating overlying at least a portion of the core, wherein the coating comprises a total crystal content of no more than 60vol% of the total volume of the coating, wherein the coating comprises at least one silicate-containing compound and at least one silica-containing compound; and wherein the coating comprises a silicate/silica percentage of at least 10% and not more than 1000%.

Drawings

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

Fig. 1 includes a flow chart illustrating a process for forming abrasive particles, wherein each abrasive particle may include a coating overlying a core, according to one embodiment.

Fig. 2A and 2B include illustrations of cross-sections of abrasive particles according to one embodiment.

Fig. 3 includes an atomic force microscope image of abrasive particles.

FIG. 4 includes an illustration of a cross-section of a consolidated abrasive article according to an embodiment.

Fig. 5 includes an illustration of a process of forming an abrasive article according to an embodiment.

Fig. 6 includes an illustration of a cross-section of a coated abrasive article according to an embodiment.

Fig. 7 includes a photograph of comparative example 7.

Those skilled in the art will appreciate that the elements illustrated in the drawings are not necessarily drawn to scale for simplicity and clarity. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present invention.

Detailed Description

The following description, taken in conjunction with the accompanying drawings, is provided to aid in the understanding of the teachings provided herein. The following disclosure will focus on the specific implementations and examples of the present teachings. This emphasis is provided to aid in the description of the teachings and should not be construed as limiting the scope or applicability of the present teachings. However, other teachings may of course be used in this application.

As used herein, the terms "comprises," "comprising," "includes," "including," "having," "has," "with" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent to such method, article, or apparatus. In addition, unless explicitly stated otherwise, "or" refers to an inclusive "or" rather than an exclusive "or". For example, either of the following conditions a or B may be satisfied: a is true (or present) and B is false (or absent), a is false (or absent) and B is true (or present), and both a and B are true (or present).

Moreover, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. Unless expressly stated otherwise, such description should be construed as including one or at least one and the singular also includes the plural or vice versa. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may replace more than one item.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. Regarding certain detailed information about specific materials and processing methods that is not described, such detailed information may include conventional methods, which may be found in references to manufacturing arts, as well as other sources.

Embodiments relate to abrasive particles, wherein each abrasive particle may include a coating overlying a core. The abrasive particles may comprise batches of abrasive particles or otherwise have a suitable sample amount that is statically related. The abrasive particles may be suitable for forming a variety of abrasive articles including, for example, fixed abrasive articles such as bonded abrasive articles, coated abrasive articles, and super-abrasive articles. The abrasive particles can have improved bonding with the bond material contained in the abrasive article and promote improved performance of the abrasive article.

Embodiments also relate to a process of forming abrasive particles. The process may include a drying treatment to promote the formation of a coating having improved properties. For example, the process may allow for the formation of abrasive particles having an improved average coating thickness, an improved standard deviation of coating thickness, and an improved morphology of the abrasive particles. In another example, the coating can promote improved moisture resistance of the abrasive particles and formation of an interface having improved moisture resistance between the abrasive particles and the bond material in the abrasive article.

Further embodiments relate to abrasive articles including a bond material and abrasive particles. The abrasive article may have improved bonding between the bond material and the abrasive particles, which in turn may help improve performance and/or properties of the abrasive article. For example, the abrasive articles of embodiments herein may have improved abrasive performance under wet conditions, improved performance after aging, and extended service life.

The abrasive article may include fixed abrasive articles including, for example, coated abrasives (such as belts and discs), bonded abrasives (including organic and/or inorganic bond materials), and super-abrasive tools. Exemplary consolidated abrasive articles can include, for example, abrasive wheels, cutoff wheels, ultra-thin wheels, combination wheels, cutting wheels, cutoff saws, or any combination thereof.

Fig. 1 includes a flow chart illustrating an exemplary process of forming abrasive particles, where each abrasive particle may include a coating overlying a core. At block 101, the process may include forming a coating. Forming the coating may include forming a mixture including the first material, the second material, and optionally the third material. Suitable mixing operations may be utilized to achieve uniform dispersion of the components within the mixture.

The forming of the coating may include forming a mixture including a first material including silica. For example, the first material may comprise a dispersion of silica in a solvent. The solvent may be an aqueous solvent or an organic solvent. In one aspect, the first material may comprise silica nanoparticles. In one embodiment, the first material may be a dispersion of silica nanoparticles in water.

In another aspect, the coating may include a specific amount of a first material including silicon (i.e., silica) based on the total weight of the mixture or based on the total weight of the first portion of the coating (e.g., 202), which may facilitate improved formation and properties of the coating. For example, the mixture and the resulting coating may comprise at least 10wt.% of the first material comprising silicon, such as at least 15wt.%, at least 20wt.%, at least 30wt.%, at least 40wt.%, at least 50wt.%, at least 60wt.%, at least 70wt.%, or at least 80wt.% of the total weight of the mixture. In another example, the mixture may include no greater than 95wt.% of the first material including silicon, such as no greater than 90wt.%, or no greater than 85wt.%, based on the total weight of the mixture. It should be understood that the mixture may comprise a first material comprising silicon in an amount including any minimum and maximum percentages mentioned herein. Unless otherwise indicated, the content of any substance (e.g., silicon, lithium, potassium, sodium, aluminum, etc.) was calculated by ICP analysis, as described in the measurement of abrasive particles of example 1 (sample S1) provided herein.

The forming of the coating may include forming a mixture including a second material including lithium. For example, the second material may comprise lithium silicate. In a particular embodiment, the coating may comprise a specific content of a second material comprising lithium, based on the total weight of the mixture, which may promote improved formation and properties of the coating. For example, the mixture may comprise at least 10wt.% of the second material comprising lithium, such as at least 15wt.%, at least 20wt.%, at least 30wt.%, at least 40wt.%, at least 50wt.%, at least 60wt.%, at least 70wt.%, or at least 80wt.% of the total weight of the mixture. In another example, the mixture may include no greater than 95wt.% of the second material comprising lithium, such as no greater than 90wt.%, or no greater than 85wt.%, based on the total weight of the mixture. It should be understood that the mixture may comprise the second material comprising lithium in an amount including any minimum and maximum percentages mentioned herein.

In one non-limiting embodiment, the formation of the coating (e.g., the first portion of the coating) can include forming a mixture including an optional third material including potassium. For example, the third material may comprise potassium silicate. In a particular embodiment, the coating may include a particular amount of a third material, based on the total weight of the mixture, which may promote improved formation and properties of the coating. For example, the mixture may comprise at least 0.01 wt.% of a third material comprising potassium, such as at least 2wt.%, at least 4wt.%, at least 6wt.%, at least 8wt.%, at least 10wt.%, at least 15wt.%, at least 20wt.%, at least 25wt.%, at least 30wt.%, at least 35wt.%, at least 40wt.%, at least 45wt.%, or at least 50wt.% of the total weight of the mixture. In another example, the mixture may include no greater than 70wt.% of the third material including potassium, such as no greater than 65wt.%, no greater than 60wt.%, or no greater than 55wt.% of the total weight of the mixture. Furthermore, the mixture may include a third material comprising potassium in an amount including any minimum and maximum percentages mentioned herein.

In still other embodiments, forming the coating may include forming a mixture including an optional fourth material including sodium. For example, the fourth material may comprise sodium silicate. In a particular embodiment, the coating may include a particular amount of a fourth material, based on the total weight of the mixture, that may promote improved formation and properties of the coating. For example, the mixture may comprise at least 0.01 wt.% of a fourth material comprising sodium, such as at least 2wt.%, at least 4wt.%, at least 6wt.%, at least 8wt.%, at least 10wt.%, at least 15wt.%, at least 20wt.%, at least 25wt.%, at least 30wt.%, at least 35wt.%, at least 40wt.%, at least 45wt.%, or at least 50wt.% of the total weight of the mixture. In another example, the mixture may include no greater than 70wt.% of a fourth material comprising sodium, such as no greater than 65wt.%, no greater than 60wt.%, or no greater than 55wt.% of the total weight of the mixture. Furthermore, the mixture may include a fourth material comprising sodium in an amount including any minimum and maximum percentages mentioned herein.

Referring now to block 102 or fig. 1, the process may further include applying a coating to at least a portion of the core. Applying the coating on at least a portion of the core may include mixing the core with the mixture formed in block 101. Mixing devices may be used to promote the formation of a homogeneous mixture of the core and the mixture. Examples of mixing devices may include a jobat mixer, hadson mixer, etc., or other mixing apparatus.

In a next step of block 103 of fig. 1, the process may further include drying the mixture coated core. Drying may include drying at a temperature sufficient to form a coating over at least a portion of the core. In particular, the drying may be performed at a temperature of at least 15 ℃, or at least 20 ℃, or at least 30 ℃, or at least 40 ℃, or at least 50 ℃, such as at least 60 ℃, or at least 70 ℃, or at least 80 ℃, or at least 90 ℃, or at least 100 ℃, such as at least 120 ℃, or at least 150 ℃. In yet another example, the drying temperature may be no greater than 400 ℃, such as no greater than 350 ℃, no greater than 300 ℃, no greater than 250 ℃, no greater than 200 ℃, such as no greater than 190 ℃, no greater than 180 ℃, no greater than 170 ℃, or no greater than 160 ℃. Furthermore, the drying temperature may be within a range including any of the minimum and maximum temperatures described herein. In a particular example, the drying temperature may be in the range of 100 ℃ to 180 ℃, or in the range of 140 ℃ to 150 ℃.

In one aspect, the drying may be performed in an oven. In another aspect, drying may be performed for a period of time sufficient to form a dried coating on the core. For example, drying may include drying the coated core for at least 2 hours, such as at least 4 hours, at least 6 hours, at least 8 hours, at least 10 hours, at least 12 hours, or at least 14 hours. In another example, drying the coated core may be performed for no more than 20 hours, such as no more than 18 hours, or no more than 16 hours. Further, drying may include drying the coated core for a period of time within a range including any of the minimum and maximum values mentioned herein. In a particular example, drying may include drying the coated core for 12 hours to 16 hours.

Notably, the formation processes disclosed in the embodiments herein may allow for improved formation of abrasive particles. For example, the dried abrasive particles can include agglomerated abrasive particles that comprise 30wt% of the total weight of the dried abrasive particles, such as not greater than 25wt%, not greater than 20wt%, not greater than 15wt%, not greater than 10wt%, not greater than 5wt%, not greater than 2wt%, not greater than 1wt%, not greater than 0.8wt%, not greater than 0.5wt%, not greater than 0.3wt%, or not greater than 0.1wt% of the total weight of the dried abrasive particles. In certain examples, the dry abrasive particles may consist essentially of loose abrasive particles.

In an embodiment, the core may comprise an abrasive material comprising a crystalline material, such as a polycrystalline material, a single crystal material, or a combination thereof, an amorphous material, a ceramic material, a glass-ceramic material, a superabrasive material, a mineral, a carbon-based material, or any combination thereof. In yet another aspect, the sintered ceramic material may include an oxide, carbide, nitride, boride, oxycarbide, oxynitride, silicate, or any combination thereof. For example, the core may comprise a material selected from the group consisting of: silica, silicon carbide, alumina, zirconia, flint, garnet, carborundum, rare earth oxides, rare earth-containing materials, ceria, sol-gel prepared particles, gypsum, iron oxide, glass-containing particles, and any combination thereof. In another example, the abrasive particles may also include silicon carbide (e.g., green 39C and Black 37C), brown fused alumina (57A), seeded gel abrasives, additive-containing sintered alumina, shaped and sintered alumina, pink alumina, ruby alumina (e.g., 25A and 86A), fused single crystal alumina 32A, MA88, alumina-zirconia abrasives (e.g., NZ, NV, and ZF brands from Saint-Gobain corporation), extruded bauxite, sintered bauxite, cubic boron nitride, diamond, aluminum oxynitride, sintered alumina (e.g., flibacher's), extruded alumina (e.g., SR1, TG, and TGII available from Saint-Gobain corporation), or any combination thereof. In another example, the core may have a mohs hardness of at least 7, such as at least 8, or even at least 9.

In another embodiment, the core may include non-agglomerated particles, non-shaped abrasive particles, or any combination thereof. For example, the core may comprise shaped abrasive particles, such as disclosed in US 20150291865, US 20150291866 and US 20150291867. The shaped abrasive particles are formed such that for shaped abrasive particles having the same two-dimensional shape and three-dimensional shape, each particle has substantially the same surface and edge arrangement relative to each other. Thus, the shaped abrasive particles can have high shape fidelity and stability in surface and edge placement relative to other shaped abrasive particles having the same two-dimensional shape and three-dimensional shape set. Conversely, non-shaped abrasive particles can be formed by different processes and have different shape properties. For example, non-shaped abrasive particles are typically formed by a comminution process, in which a mass of material is formed, and then crushed and sieved to obtain abrasive particles of a certain size. However, the non-shaped abrasive particles will have a generally random arrangement of surfaces and edges, and generally lack any identifiable two-dimensional or three-dimensional shape in the arrangement of surfaces and edges around the body. Furthermore, the same set or batch of non-shaped abrasive particles typically lack a consistent shape relative to each other such that the surfaces and edges are randomly arranged when compared to each other. Thus, the non-shaped grains or broken grains have significantly lower shape fidelity than the shaped abrasive particles.

In a particular embodiment, the core may comprise a sintered ceramic material having a particular average grain size. In one aspect, the average grain size may be less than 1 micron, such as not greater than 0.9 micron, not greater than 0.8 micron, not greater than 0.7 micron, not greater than 0.6 micron, not greater than 0.5 micron, not greater than 0.4 micron, not greater than 0.3 micron, not greater than 0.2 micron, not greater than 0.1 micron, not greater than 0.09 micron, not greater than 0.08 micron, not greater than 0.07 micron, not greater than 0.06 micron, not greater than 0.05 micron, not greater than 0.04 micron, not greater than 0.03 micron, not greater than 0.02 micron, or not greater than 0.01 micron. In another aspect, the core 201 may include a sintered ceramic material having an average grain size of at least 0.01 microns, such as at least 0.02 microns, at least 0.03 microns, at least 0.04 microns, at least 0.05 microns, at least 0.06 microns, at least 0.07 microns, at least 0.08 microns, at least 0.09 microns, at least 0.1 microns, at least 0.11 microns, at least 0.12 microns, at least 0.13 microns, at least 0.14 microns, at least 0.15 microns, at least 0.16 microns, at least 0.17 microns, at least 0.18 microns, at least 0.19 microns, at least 0.2 microns, at least 0.3 microns, at least 0.4 microns, or at least 0.5 microns. Furthermore, the core may comprise a sintered ceramic material comprising an average grain size within a range including any of the minima and maxima mentioned herein. For example, the core may comprise a sintered ceramic material having an average grain size within the following ranges: including a range of at least 0.01 microns and less than 1 micron, including a range of at least 0.03 microns and no more than 0.8 microns, including a range of at least 0.05 microns and no more than 0.6 microns, including a range of at least 0.08 microns and no more than 0.4 microns, or including a range of at least 0.1 microns and no more than 0.2 microns. The average grain size can be measured by an uncorrected intercept method from SEM micrographs.

One particular example of a sintered ceramic material may include alumina (Al ₂ O ₃ ) Including, for example, microcrystalline alumina (e.g., sol-gel alumina), nanocrystalline alumina, fused alumina such as brown fused alumina, or combinations thereof. In particular, alumina (Al ₂ O ₃ ) May include alpha alumina (alpha-Al) ₂ O ₃ )。

In particular aspects, the core may comprise polycrystalline alpha alumina (alpha-Al ₂ O ₃ ) And more specifically, polycrystalline alpha alumina (alpha-Al ₂ O ₃ ) An average grain size of less than 1 micron, such as described with respect to sintered ceramic materials, may be included. In an even more particular aspect, the core may consist essentially of polycrystalline alpha alumina (alpha-Al) comprising an average grain size of less than 1 micron ₂ O ₃ ) Composition is prepared.

In an embodiment, the core may comprise a density of at least 80% of its theoretical density, such as at least 85%, at least 88%, at least 90%, at least 92%, at least 95%, or at least 98% of its theoretical density. In another embodiment, the core may include a porosity of no greater than 10vol% of the total volume of the core, such as no greater than 9vol%, no greater than 8vol%, no greater than 7vol%, no greater than 6vol%, no greater than 5vol%, no greater than 4vol%, no greater than 3vol%, no greater than 2vol%, or no greater than 1vol% of the total volume of the core. In a particular embodiment, the core may contain substantially no voids. The true density of the core is measured by first measuring the bulk density of the core. The bulk density of the core was measured by pycnometer (Quantachrome Ultrapycnometer 1000) in which ultra-high purity compressed helium was adjusted to a pressure of 20 psig. The cores were then crushed to a powder state and the true density was measured using a pycnometer in the same manner as described above. The porosity of the core was calculated by the following calculation method (porosity= [ true density-bulk density ]/[ true density ]).

In yet another embodiment, the core may have a density of sintered ceramic material forming the core. For example, depending on the sintered ceramic material, the core may comprise at least 2.10g/cm ³ At least 2.20g/cm ³ 、2.30g/cm ³ At least 2.40g/cm ³ At least 2.50g/cm ³ At least 2.60g/cm ³ At least 2.70g/cm ³ 、2.80g/cm ³ At least 2.90g/cm ³ At least 3.00g/cm ³ At least 3.10g/cm ³ At least 3.20g/cm ³ At least 3.30g/cm ³ At least 3.40g/cm ³ 、3.50g/cm ³ At least 3.55g/cm ³ At least 3.60g/cm ³ At least 3.65g/cm ³ At least 3.70g/cm ³ At least 3.75g/cm ³ At least 3.80g/cm ³ At least 3.85g/cm ³ At least 3.90g/cm ³ Or at least 3.95g/cm ³ Is a density of (3). Additionally or alternatively, the core may comprise no more than 5.80g/cm ³ Not more than 5.70g/cm ³ Not more than 5.60g/cm ³ Not more than 5.50g/cm ³ Not more than 5.40g/cm ³ Not more than 5.30g/cm ³ Not more than 5.20g/cm ³ Not more than 5.10g/cm ³ Not more than 5.00g/cm ³ Not more than 4.90g/cm ³ Not more than 4.80g/cm ³ Not more than 4.70g/cm ³ Not more than 4.60g/cm ³ Not more than 4.50g/cm ³ Not more than 4.40g/cm ³ Not more than 4.30g/cm ³ Not more than 4.20g/cm ³ Not more than 4.10g/cm ³ Not more than 4.00g/cm ³ Or not more than 3.97g/cm ³ Is a density of (3). In yet another example, the core may have a density within a range including any of the minima and maxima mentioned herein.

In one embodiment, the formation process may be stopped at step 103, wherein the particles have the structure generally provided in fig. 2A, including a core 201 and a coating 202, wherein the coating comprises an inorganic material.

In an alternative embodiment, the process may continue after step 103 to step 104, which includes an optional process of applying an organic material. Such a process may be performed prior to incorporation of the abrasive particles into the fixed abrasive. According to one embodiment, the process of step 104 includes forming a second portion (e.g., 203) of the coating covering at least some of the first portion (e.g., 202) of the coating. In one example, the second portion may comprise an organic-containing material. In one non-limiting embodiment, the organic-containing material may include a material that may promote bonding of the abrasive particles to the bond material, such as an organic-containing binder composition (e.g., phenolic resin, epoxy resin, etc.). In one particular process, the organic-containing material that may be included in the second portion may be a silane-containing material and/or a silanol-containing material. For example, according to the process of fig. 1, the process of step 104 may include forming a second portion of the coating on the abrasive particles, wherein such particles may have a general structure as provided in the embodiment of fig. 2B. The content of inorganic materials referred to herein, such as the composition from the first portion 202 of the coating, is based on the weight percent of the first portion.

The coating 202 may be in direct contact with the core 201. As shown, the coating 202 may be a layer that covers the entire surface of the core 201. In at least one embodiment, the coating 202 may cover a majority of the surface of the core 201, and a portion of the core surface may not be covered by the coating 202. In a particular embodiment, the coating may comprise a dry material. In yet another embodiment, the coating may comprise unsintered material.

In an embodiment, the coating may have a specific percentage of lithium content to silicon content, which may promote improved formation and properties of the abrasive particles 200. In one embodiment, the lithium may include a lithium-containing compound. In another aspect, the lithium-containing compound may include an oxide. In yet another embodiment, the lithium-containing compound may include lithium oxide. In one embodiment, the silicon may comprise a silicon-containing compound. In another aspect, the silicon-containing compound may include an oxide. In yet another embodiment, the silicon-containing compound may comprise silicon dioxide. In one aspect, the lithium/silicon percentage is at least 0.02%, or at least 0.03%, or at least 0.04%, or at least 0.05%, or at least 0.06%, or at least 0.07%, or at least 0.08%, at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.2%, or at least 3.4%, or at least 3.6%, or at least 3.8%, or at least 4.0%. In still other embodiments, the lithium/silicon percentage is no greater than 25%, or no greater than 24%, or no greater than 23%, or no greater than 22%, or no greater than 21%, or no greater than 20%, or no greater than 19%, no greater than 18%, or no greater than 17%, or no greater than 16%, or no greater than 15%, or no greater than 14%, or no greater than 13%, or no greater than 12%, or no greater than 11%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%, or no greater than 3%. In yet another example, the coating may have a lithium/silicon percentage within a range including any of the minimum and maximum values mentioned herein. It should be understood that all of the above ratios apply to lithium and elemental silicon and compounds thereof, including, for example, oxides. For example, the coating may have a percentage of lithium oxide/silicon oxide (SiOx) within a range including any of the minimum and maximum values described above for the percentage of lithium/silicon. The lithium/silicon percentage is calculated by dividing the weight percent of lithium in the coating by the weight percent of silicon in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% lithium and 90wt% silicon will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% lithium/silicon percentage.

In an embodiment, the coating may have a specific content of lithium, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the amount of lithium in the coating is at least 0.01wt%, or at least 0.02wt%, at least 0.03wt%, at least 0.04wt%, at least 0.05wt%, at least 0.06wt%, at least 0.07wt%, at least 0.08wt%, or at least 0.09wt%, or at least 0.1wt%, or at least 0.15wt%, or at least 0.2wt%, or at least 0.25wt%, or at least 0.3wt%, or at least 0.35wt%, or at least 0.4wt%, or at least 0.5wt%, or at least 0.6wt%, or at least 0.7wt%, or at least 0.8wt%, or at least 0.9wt%, or at least 1.0wt%, or at least 1.1wt%, or at least 1.2wt%, or at least 1.3wt%, or at least 1.4wt%, or at least 1.5wt%, or at least 1.6wt%, or at least 1.7wt%, or at least 1.8wt%, or at least 1.9wt%, or at least 2.0wt%, or at least 2.2.3 wt%, or at least 2.2.5 wt%, or at least 2.3wt%, based on the total weight of the coating. In yet other embodiments, the lithium content is no greater than 20wt%, or no greater than 19wt%, or no greater than 18wt%, or no greater than 17wt%, or no greater than 16wt%, or no greater than 15wt%, or no greater than 14wt%, or no greater than 13wt%, or no greater than 12wt%, or no greater than 11wt%, or no greater than 10wt%, or no greater than 9wt%, or no greater than 8wt%, or no greater than 7wt%, or no greater than 6wt%, or no greater than 5wt%, or no greater than 4wt%, or no greater than 3wt%, or no greater than 2wt%. It should be understood that the coating may have a lithium content in a range that includes between any of the minimum and maximum values mentioned herein. As will be appreciated, the weight percent of lithium is calculated according to ICP analysis techniques as described herein.

In yet another embodiment, the coating may have a specific percentage of potassium content to silicon content, which may promote improved formation and properties of the abrasive particles 200. In one embodiment, the potassium may include a potassium-containing compound. In another aspect, the potassium-containing compound can include an oxide. In yet another embodiment, the potassium-containing compound can include potassium oxide. In one embodiment, the silicon may comprise a silicon-containing compound. In another aspect, the silicon-containing compound may include an oxide. In yet another embodiment, the silicon-containing compound may comprise silicon dioxide. In one aspect, the potassium/silicon percentage is at least 0.01%, or at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.1%, or at least 3.2%, or at least 3.4%, or at least 3.6%, or at least 3.8%. In yet other embodiments, the potassium/silicon percentage is no greater than 40%, or no greater than 39%, or no greater than 38%, or no greater than 37%, or no greater than 36%, or no greater than 35%, or no greater than 34%, or no greater than 33%, or no greater than 32%, or no greater than 31%, or no greater than 30%, or no greater than 29%, or no greater than 28%, or no greater than 27%, or no greater than 26%, or no greater than 25%, or no greater than 24%, or no greater than 23%, or no greater than 22%, or no greater than 21%, or no greater than 20%, or no greater than 19%, no greater than 18%, or no greater than 17%, or no greater than 16%, or no greater than 15%, or no greater than 14%, or no greater than 13%, or no greater than 12%, or no greater than 11%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%. In yet another example, the coating may have a potassium/silicon percentage within a range including any of the minimum and maximum values mentioned herein. It should be understood that all of the above ratios apply to the elements potassium and silicon and their compounds, including for example oxides. For example, the coating may have a potassium oxide/silicon oxide (SiOx) percentage within a range including any of the minimum and maximum values described above for the potassium/silicon percentages. The potassium/silicon percentage is calculated by dividing the weight percent of potassium in the coating by the weight percent of silicon in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% potassium and 90wt% silicon will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% potassium/silicon percent.

In another embodiment, the coating may have a specific content of silicon, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the silicon content is at least 50wt%, at least 55wt%, at least 60wt%, at least 65wt%, at least 70wt%, at least 75wt%, at least 80wt%, at least 85wt%, at least 90wt%, at least 92wt%, at least 95wt% of the total weight of the coating (e.g., the first portion 202 of the coating). In yet other non-limiting embodiments, the silicon content can be no greater than 99wt%, no greater than 98wt%, no greater than 97wt%, or no greater than 96wt%, or no greater than 95wt%, or no greater than 93wt%, or no greater than 90wt%, or no greater than 88wt%, or no greater than 85wt%, or no greater than 83wt%, or no greater than 80wt%, or no greater than 77wt%, based on the total weight of the coating. In yet another example, the coating may have a silicon content within a range including any of the minima and maxima mentioned herein. As will be appreciated, the weight percent of silicon is calculated according to ICP analysis techniques as described herein.

In another embodiment, the coating may have a specific content of potassium, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the potassium content is at least 0.01wt%, or at least 0.02wt%, at least 0.03wt%, at least 0.04wt%, at least 0.05wt%, at least 0.06wt%, at least 0.07wt%, at least 0.08wt%, or at least 0.09wt%, or at least 1wt%, at least 2wt%, at least 3wt%, at least 4wt%, at least 5wt%, at least 6wt%, at least 7wt%, at least 8wt%, at least 9wt%, or at least 10wt%, based on the total weight of the coating. In yet other embodiments, the potassium content is no greater than 30wt%, no greater than 29wt%, or no greater than 28wt%, or no greater than 27wt%, or no greater than 26wt%, or no greater than 25wt%, or no greater than 24wt%, or no greater than 23wt%, or no greater than 22wt%, or no greater than 21wt%, or no greater than 20wt%, or no greater than 19wt%, or no greater than 18wt%, or no greater than 17wt%, or no greater than 16wt%, or no greater than 15wt%, or no greater than 14wt%, or no greater than 13wt%, or no greater than 12wt%, or no greater than 11wt%, or no greater than 10wt%, or no greater than 9wt%, or no greater than 8wt%, or no greater than 7wt% of the total weight of the coating. In yet another example, the coating can have a potassium content within a range including any of the minimum and maximum values mentioned herein. As will be appreciated, the weight percent of potassium is calculated according to ICP analysis techniques as described herein.

In yet another embodiment, the coating may have a specific percentage of sodium content to silicon content, which may promote improved formation and properties of the abrasive particles 200. In one embodiment, the sodium may comprise a sodium-containing compound. In another aspect, the sodium-containing compound may include an oxide. In yet another embodiment, the sodium-containing compound may include sodium oxide. In one embodiment, the silicon may comprise a silicon-containing compound. In another aspect, the silicon-containing compound may include an oxide. In yet another embodiment, the silicon-containing compound may comprise silicon dioxide. In one aspect, the sodium/silicon percentage is at least 0.01%, or at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 4.2%, or at least 4.4%, or at least 4.6%, or at least 4.8%, or at least 5.0%, or at least 5.5%. In yet other embodiments, the sodium/silicon percentage is no greater than 40%, or no greater than 39%, or no greater than 38%, or no greater than 37%, or no greater than 36%, or no greater than 35%, or no greater than 34%, or no greater than 33%, or no greater than 32%, or no greater than 31%, or no greater than 30%, or no greater than 29%, or no greater than 28%, or no greater than 27%, or no greater than 26%, or no greater than 25%, or no greater than 24%, or no greater than 23%, or no greater than 22%, or no greater than 21%, or no greater than 20%, or no greater than 19%, no greater than 18%, or no greater than 17%, or no greater than 16%, or no greater than 15%, or no greater than 14%, or no greater than 13%, or no greater than 12%, or no greater than 11%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%, or no greater than 3%, or no greater than 1%, or no greater than 5%, or no greater than 0.0%, or no greater than 5%. In yet another example, the coating may have a sodium/silicon percentage within a range including any of the minimum and maximum values mentioned herein. It should be understood that all of the above ratios apply to sodium and silicon elements and their compounds, including for example oxides. For example, the coating may have a percentage of sodium oxide/silicon oxide (SiOx) within a range including any of the minimum and maximum values described above for the percentage of sodium/silicon. The sodium/silicon percentage is calculated by dividing the weight percent of sodium in the coating by the weight percent of silicon in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% sodium and 90wt% silicon will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% sodium/silicon percentage.

In another embodiment, the coating may have a specific content of sodium, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the sodium content is at least 1wt%, or at least 1.5wt%, or at least 2wt%, at least 3wt%, at least 4wt%, at least 5wt%, at least 6wt%, at least 7wt%, at least 8wt%, at least 9wt%, or at least 10wt%, based on the total weight of the coating. In still other embodiments, the sodium content is no greater than 20wt%, or no greater than 19wt%, or no greater than 18wt%, or no greater than 17wt%, or no greater than 16wt%, or no greater than 15wt%, or no greater than 14wt%, or no greater than 13wt%, or no greater than 12wt%, or no greater than 11wt%, based on the total weight of the coating. In yet another example, the coating may have a sodium content within a range including any of the minima and maxima mentioned herein. As will be appreciated, the weight percent of sodium is calculated according to ICP analysis techniques as described herein.

According to another non-limiting embodiment, the coating may have a specific percentage of sodium content to lithium content, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the sodium/lithium percentage is at least 0.01%, or at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.2%, or at least 3.4%, or at least 3.6%, or at least 3.8%, or at least 4.0%. In still other embodiments, the sodium/lithium percentage is no greater than 100%, or no greater than 90%, or no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%, or no greater than 20%, or no greater than 15%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%. In yet another example, the coating may have a sodium/silicon percentage within a range including any of the minimum and maximum values mentioned herein. The sodium/lithium percentage is calculated by dividing the weight percent of sodium in the coating by the weight percent of lithium in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% sodium and 90wt% lithium will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% sodium/lithium percentage.

According to another non-limiting embodiment, the coating may have a specific percentage of sodium content to potassium content, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the sodium/potassium percentage is at least 0.01%, or at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.4.0%, or at least 5.0%, or at least 8.0%, or at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80% of the other embodiments, the sodium/potassium percentage is no greater than 200%, or no greater than 190%, or no greater than 180%, or no greater than 170%, or no greater than 60%, or no greater than 150%, or no greater than 140%, or no greater than 130%, or no greater than 120%, or no greater than 110%, or no greater than 100%, or no greater than 90%, or no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%, or no greater than 20%, or no greater than 15%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%. In yet another example, the coating may have a sodium/potassium percentage within a range including any of the minimum and maximum values mentioned herein. The sodium/potassium percentage is calculated by dividing the weight percent of sodium in the coating by the weight percent of potassium in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% sodium and 90wt% potassium will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% sodium/potassium percentage.

According to another non-limiting embodiment, the coating may have a specific percentage of potassium content to lithium content, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the potassium/lithium percentage is at least 0.01%, or at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.4%, or at least 5.0%, or at least 8.0%, or at least 10%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60%, or at least 80%. In still other embodiments, the potassium/lithium percentage is no greater than 200%, or no greater than 190%, or no greater than 180%, or no greater than 170%, or no greater than 60%, or no greater than 150%, or no greater than 140%, or no greater than 130%, or no greater than 120%, or no greater than 110%, or no greater than 100%, or no greater than 90%, or no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%, or no greater than 20%, or no greater than 15%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%. In yet another example, the coating may have a potassium/lithium percentage within a range including any of the minimum and maximum values mentioned herein. The potassium/lithium percentage is calculated by dividing the weight percent of potassium in the coating by the weight percent of lithium in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% potassium and 90wt% lithium will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% potassium/lithium percentage.

In still other embodiments, the coating may have a specific content of sodium compared to the lithium content, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the coating comprises a sodium content of not greater than 10 times the lithium content, or wherein the coating comprises a sodium content of not greater than 8 times the lithium content, or wherein the coating comprises a sodium content of not greater than 6 times the lithium content, or wherein the coating comprises a sodium content of not greater than 4 times the lithium content, or wherein the coating comprises a sodium content of not greater than 3 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2.8 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2.5 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2.2 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2 times the lithium content, or wherein the coating comprises a sodium content of not greater than 1.8 times the lithium content, or wherein the coating comprises a sodium content of not greater than 1.5 times the lithium content, or wherein the coating comprises a sodium content of not greater than 1.3 times the lithium content, or wherein the coating comprises a sodium content of not greater than 0.9 times the lithium content, or wherein the coating comprises a sodium content of not greater than 0.0.05 times the lithium content, or wherein the coating comprises a sodium content of not greater than 0.0.0 times the lithium content or wherein the sodium content of not greater than 0.0.0.01 times the lithium content.

In still other embodiments, the coating may have a specific content of sodium compared to the potassium content, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the coating comprises a sodium content of not greater than 10 times the potassium content, or wherein the coating comprises a sodium content of not greater than 8 times the potassium content, or wherein the coating comprises a sodium content of not greater than 6 times the potassium content, or wherein the coating comprises a sodium content of not greater than 4 times the potassium content, or wherein the coating comprises a sodium content of not greater than 3 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2.8 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2.5 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2.2 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2 times the potassium content, or wherein the coating comprises a sodium content of not greater than 1.8 times the potassium content, or wherein the coating comprises a sodium content of not greater than 1.5 times the potassium content, or wherein the coating comprises a sodium content of not greater than 1.3 times the potassium content, or wherein the coating comprises a sodium content of not greater than 0.9 times the potassium content, or wherein the coating comprises a sodium content of not greater than 0.05 times the potassium content of not greater than 0.0, or wherein the sodium content of not greater than 0.0.0 times the potassium content of not greater than 0.0.2 times the potassium content.

In one embodiment, the coating may have a specific content of silicate-containing compounds, which may promote improved formation and properties of the abrasive particles 200. In a particular embodiment, the silicate-containing compound may include potassium silicate, sodium silicate, lithium silicate, or a combination thereof. In one aspect, the silicate-containing compound content is at least 1 wt.%, or at least 5wt.%, or at least 10wt.%, or at least 15wt.%, or at least 20wt.%, or at least 30wt.%, or at least 40wt.%, or at least 50wt.%, or at least 60wt.%, or at least 70wt.%, or at least 80wt.%, or at least 90 wt.% of the total weight of the coating. In still other embodiments, the silicate-containing compound is present in an amount of no greater than 99wt%, or no greater than 95wt%, or no greater than 90wt%, or no greater than 80wt%, or no greater than 70wt%, or no greater than 60wt%, or no greater than 50wt%, or no greater than 40wt%, or no greater than 30wt%, or no greater than 20wt%, or no greater than 10wt%, based on the total weight of the coating. In yet another example, the coating may have a silicate-containing compound content within a range including any of the minimum and maximum values mentioned herein. As will be appreciated, the weight percent of silicate-containing compound is calculated according to ICP analysis techniques as described herein.

In another embodiment, the coating may have a specific content of silica-containing compounds, which may promote improved formation and properties of the abrasive particles 200. In a particular embodiment, the silica-containing compound can include silicon dioxide or a combination thereof. In one aspect, the silica-containing compound is present in an amount of at least 1 wt.%, or at least 5wt.%, or at least 10wt.%, or at least 15wt.%, or at least 20wt.%, or at least 30wt.%, or at least 40wt.%, or at least 50wt.%, or at least 60wt.%, or at least 70wt.%, or at least 80wt.%, or at least 90 wt.% based on the total weight of the coating. In still other embodiments, the silica-containing compound is present in an amount of no greater than 99wt%, or no greater than 95wt%, or no greater than 90wt%, or no greater than 80wt%, or no greater than 70wt%, or no greater than 60wt%, or no greater than 50wt%, or no greater than 40wt%, or no greater than 30wt%, or no greater than 20wt%, or no greater than 10wt%, based on the total weight of the coating. In yet another example, the coating may have a silica-containing compound content within a range including any of the minimum and maximum values mentioned herein. As will be appreciated, the weight percent of the silica-containing compound is calculated according to the ICP analysis technique as described herein.

According to another non-limiting embodiment, the coating may have a specific silicate content to silica content percentage, which may promote improved formation and properties of the abrasive particles 200. In one aspect, the silicate/silica percentage is at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 100%. In yet other embodiments, the silicate/silica percentage is no greater than 1000%, or no greater than 900%, or no greater than 800%, or no greater than 700%, or no greater than 600%, or no greater than 500%, or no greater than 400%, or no greater than 300%200%, or no greater than 190%, or no greater than 180%, or no greater than 170%, or no greater than 60%, or no greater than 150%, or no greater than 140%, or no greater than 130%, or no greater than 120%, or no greater than 110%, or no greater than 100%, or no greater than 90%, or no greater than 80%, or no greater than 70%, or no greater than 60%, or no greater than 50%, or no greater than 40%, or no greater than 30%, or no greater than 20%, or no greater than 15%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%. In yet another example, the coating may have a silicate/silica percentage within a range including any of the minima and maxima mentioned herein. The silicate/silica percentage is calculated by dividing the weight percent of silicate-containing compound in the coating by the weight percent of silica-containing compound in the coating and then multiplying the calculated number by 100%. Weight percentages are those obtained by ICP analysis of the coatings provided herein. For example, a coating comprising 0.9wt% silicate-containing compound and 90wt% silica-containing compound will have [ (0.9 wt%/90 wt%) x 100%) ] = 1% silicate/silica percentage. In an embodiment, the abrasive particles 200 may have an average coating coverage of the surface of the core 201, which may promote improved properties and performance of the abrasive particles. In one aspect, the average coating coverage may be at least 50% of the entire surface of the core, at least 55%, at least 57%, at least 59%, at least 61%, at least 63%, at least 65%, at least 68%, at least 70%, at least 72%, at least 75%, at least 76%, at least 77%, at least 79%, at least 80%, at least 82%, at least 84%, at least 85%, at least 87%, at least 88%, at least 90%, at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least 97%, and at least 98%, at least 99% and not greater than 100% of the entire surface of the core 201.

Coating coverage may be determined by Energy Dispersive Spectroscopy (EDS) analysis. Image acquisition of abrasive particles can be accomplished by using Merlin from Zeiss with appropriate imaging parameters ^TM Field Emission Scanning Electron Microscopy (FESEM) and Fast Acquisition in Bmker software. For example, imaging can be performed using parameters of 7kV, 300pA and up to 10mm WD. The abrasive particles may be coated with Au/Pd for 30 seconds prior to image acquisition. Using EDS, the elements of the abrasive particles can be quantified and used as an indication of whether the points of the core are covered by the first portion. 1% Si can be used as a threshold of 1% Si, and quantitative chemical analysis for each point can be reduced to binomial (covered or uncovered). The amounts of Au/Pd coating and C element were not considered in the analysis. The 95% confidence interval (95% ci) may be used in a binomial distribution calculator, such as binomial probability confidence interval calculator (version 4.0) provided on www.dianelsoper.com, to calculate the reported confidence interval. For example, whenWhen 53 points out of the 60 points indicate Si greater than 1%, the number of tests input to the calculator was 60 and the success number was 53. At 95% ci, coverage is 77% to 95%.

In another embodiment, the coating 202 may have a substantially uniform thickness. In one embodiment, the thickness of the coating 202 may vary along the surface of the core 201.

In another embodiment, the abrasive particles 200 can include an average thickness of the coating 202, which can facilitate improved formation and properties of the abrasive particles. For example, the average thickness of the coating 202 can be at least 10nm, at least 12nm, at least 15nm, at least 18nm, at least 20nm, at least 25nm, at least 28nm, at least 30nm, at least 32nm, at least 35nm, at least 38nm, at least 40nm, at least 43nm, at least 45nm, at least 48nm, at least 50nm, at least 52nm, at least 55nm, at least 58nm, at least 60nm, at least 63nm, at least 68nm, at least 70nm, at least 74nm, at least 76nm, at least 80nm, at least 83nm, at least 86nm, at least 90nm. In another example, the average thickness of the coating 202 of the abrasive particles 200 can be no greater than 150nm, no greater than 140nm, no greater than 130nm, no greater than 120nm, no greater than 110nm, no greater than 100nm. Further, the average thickness of the coating 202 of the abrasive particles 200 can be within a range including any of the minimum and maximum values mentioned herein. For example, the abrasive particles can include an average thickness of the coating 202 in the range of 10nm to 150nm or in the range of 80nm to 100nm.

In yet another embodiment, the abrasive particles 200 can include a specific thickness standard deviation of the coating 202, which can promote improved formation of abrasive particles and improved performance of abrasive particles. In one aspect, the absolute value of the standard deviation of thickness can be no greater than 200% of the average thickness, no greater than 150%, no greater than 100%, no greater than 80%, no greater than 50%, no greater than 49%, no greater than 47%, no greater than 44%, no greater than 42%, no greater than 40%, no greater than 38%, no greater than 36%, no greater than 34%, no greater than 33%, no greater than 31%, no greater than 30%, no greater than 29%, no greater than 27%, no greater than 25%, no greater than 23%, no greater than 21%, no greater than 20%, no greater than 19%, no greater than 18%, no greater than 17%, no greater than 16%, no greater than 14%, no greater than 12%, no greater than 11%, no greater than 10%, no greater than 9%, no greater than 8%, no greater than 7%, no greater than 6%, no greater than 5%, no greater than 4%, no greater than 3%, no greater than 2%, no greater than 1%, no greater than 0.8%, no greater than 0.7%, or no greater than 0.5%. In another aspect, the abrasive particles can include an absolute value of a standard deviation of thickness that is at least 0.001% of an average thickness, at least 0.05%, at least 0.08%, at least 0.1%, at least 0.2%, at least 0.3%, at least 0.4%, at least 0.5%, at least 0.7%, at least 0.8%, at least 0.9%, at least 1%, at least 1.2%, at least 1.5%, at least 1.8%, at least 2%, at least 2.2%, at least 2.5%, at least 2.8%, at least 3%, at least 4%, or at least 5% of an average thickness of the coating. Furthermore, the abrasive particles can include a thickness standard deviation of the coating having an absolute value within a range including any of the minimum and maximum values mentioned herein.

In another aspect, the abrasive particles can include a standard deviation of the thickness of the coating 202 that is at least 1nm, at least 3nm, at least 5nm, at least 7nm, at least 9nm, at least 10nm, at least 13nm, at least 15nm, at least 17nm, at least 19nm, at least 21nm, at least 23nm, at least 25nm, at least 28nm, at least 30nm, at least 32nm, at least 34nm, at least 36nm, at least 39nm, at least 41nm, at least 45nm, at least 46nm, at least 48nm, or at least 50nm, at least 60nm, at least 70nm, at least 80nm, at least 100nm, at least 110nm, at least 120nm, at least 130nm, at least 140nm, at least 150nm, at least 160nm, at least 170nm, at least 180nm, at least 190nm, at least 210nm, at least 220nm, or at least 230nm, at least 240nm, at least 250nm, at least 260nm, at least 270nm, or at least 280nm. In another aspect, the standard deviation of thickness can be no greater than 500nm, no greater than 480nm, no greater than 460nm, no greater than 420nm, no greater than 400nm, no greater than 350nm, no greater than 320nm, no greater than 310nm, no greater than 300nm, no greater than 280nm, no greater than 260nm, no greater than 230nm, no greater than 210nm, no greater than 190nm, no greater than 170nm, no greater than 150nm, no greater than 130nm, no greater than 120nm, no greater than 110nm, no greater than 100nm, no greater than 90nm, no greater than 80nm, no greater than 70nm, no greater than 60nm, no greater than 50nm, no greater than 40nm, no greater than 30nm, no greater than 20nm, no greater than 18nm, no greater than 15nm, no greater than 12nm, no greater than 10nm, or no greater than 5nm. Furthermore, the standard deviation of the thickness of the coating may be within a range including any of the minimum and maximum values mentioned herein. In a particular example, the thickness standard deviation of the coating may be in the range of 10nm to 400nm, or in the range of 30nm to 300nm, or in the range of 50nm to 200 nm.

In an embodiment, the coating 202 may include an amorphous phase including silicon dioxide. In another particular aspect, the coating 202 can include a particular amount of amorphous phase, which can promote improved formation and properties of the abrasive particles 210 and abrasive articles including the abrasive particles 210. For example, at least 90vol% or at least 95vol% of the coating 202 may be amorphous. In another particular aspect, the coating 202 consists essentially of an amorphous phase.

In another aspect, the coating 202 can comprise silica in both amorphous and crystalline phases. In another particular aspect, the coating 202 can include an amorphous phase consisting essentially of silica and a crystalline phase consisting essentially of silica.

In one aspect, the coating, and in particular the first portion 202 of the coating, can have a particular crystalline content that can improve the manufacture and/or performance of the abrasive particles and/or the fixed abrasive article comprising such abrasive particles. For example, the coating may have a particular crystalline content (i.e., single crystal or polycrystalline), including, for example, but not limited to, a crystalline content of at least 1vol% of the total volume of the first portion 202, such as at least 3vol%, or at least 5vol%, or at least 7vol%, or at least 10vol%, or at least 12vol%, or at least 15vo1% of the total volume of the coating (particularly the first portion 202). In a non-limiting embodiment, the total crystal content of the coating (e.g., first portion 202) may be limited due to the lack of high temperature sintering. For example, in one non-limiting embodiment, the coating (e.g., first portion 202) can have a total crystal content of no greater than 99vol% of the total volume of the coating or first portion 202 of the coating, such as no greater than 97vol%, or no greater than 90vol%, or no greater than 80vol%, or no greater than 70vol%, or no greater than 60vol%, or no greater than 50vol%, or no greater than 40vol%, or no greater than 30vol%, or no greater than 20vol%, or no greater than 10vol%, or no greater than 8vol%, or no greater than 5vol%, or no greater than 3vol%, or no greater than 2vol%, of the total volume of the coating or first portion 202 of the coating, can have no greater than 1vol% of the total volume of the coating. Furthermore, the coating 202 may include a crystalline content within a range including any of the minimum and maximum percentages mentioned herein. In a particular embodiment, the first portion 202 of the coating may be substantially free of crystalline phases.

In another particular embodiment, the coating, e.g., the first portion 202 of the coating, can comprise a predominant amount of amorphous phase, such as at least 55vol% amorphous phase, based on the total volume of the first portion 202, such as at least 60vol%, or at least 70vol%, or at least 80vol%, or at least 90vol%, or at least 95vol% amorphous content, based on the total volume of the first portion 202 of the coating of abrasive particles. In one particular example, the first portion 202 can consist essentially of an amorphous phase material. For example, in one particular embodiment, the first portion 202 may comprise a mixture of amorphous silica and amorphous silicate.

Crystallinity can be determined by X-ray diffraction (also referred to as "XRD" in this disclosure) analysis of a powder sample of coating 202 prepared as follows. The first material may be placed in an alumina crucible and heated in a furnace for 30 minutes at the sintering temperature mentioned in the examples herein. The crucible can then be removed from the furnace and cooled at ambient temperature (i.e., 20 ℃ to 25 ℃). The solids may be recovered from the crucible and manually ground, such as using a mortar and pestle, to obtain a powder sample of the coating 202. XRD may be obtained in a bragg-brentuno configuration (standard for powder XRD) using a copper X-ray source with a Cu ka wavelength of 1.54 angstroms. The identification of the crystalline phase may be performed using EVA Bruker AXS software or other equivalent software and the ICDD-PDF4+ database (2020 edition). Crystallinity can be achieved using TOPAS 4.2 software from Bruker or following Corindon Al ₂ O ₃ Other equivalent software of the standard is determined by Rietveld refinement.

In an embodiment, the first portion of the coating may include domains having a particular average domain size, which may promote improved formation and performance of the abrasive particles.

Fig. 3 includes an atomic force microscopy (also referred to as "AFM" in this disclosure) phase diagram of abrasive particles. Fig. 3 includes an image of a core 301 that includes grains 310.

In an embodiment, the abrasive particles can comprise an average domain size of at least 50nm, at least 55nm, at least 60nm, at least 65nm, at least 70nm, at least 75nm, at least 80nm, at least 90nm, at least 100nm, at least 200nm, at least 300nm, at least 400nm, at least 500nm, or at least 600. In another aspect, the abrasive particles can comprise an average domain size of the coating greater than nm or greater than 26 nm. In a particular aspect, the abrasive particles can comprise an average domain size of no greater than 3mm, no greater than 2mm, no greater than 1mm, no greater than 0.5mm, no greater than 0.1mm, no greater than 0.01mm, or no greater than 0.001 mm. Furthermore, the abrasive particles may comprise an average domain size within a range including any of the minimum and maximum values mentioned above. As used herein, average domain size is intended to mean the average of the largest dimensions of at least 20 identifiable domains in the phase diagram of a randomly selected abrasive particle. The domain size of the abrasive particles was measured by Scanning Electron Microscopy (SEM) of the polished portion of the abrasive particles. The sample was hot etched at 100 ℃ for 5 minutes using a magnification of 50,000 x. The domain size is obtained by the intercept method without statistical correction.

In one embodiment, the abrasive particles may include a particular standard deviation of domain size, which may facilitate improved formation and performance of the abrasive particles. In one aspect of the present invention, the standard deviation of the domain sizes may have a mean domain size of no greater than 50%, no greater than 49%, no greater than 48%, no greater than 47%, no greater than 46%, no greater than 45%, no greater than 44%, no greater than 43%, no greater than 42%, no greater than 41%, no greater than 40%, no greater than 39%, no greater than 38%, no greater than 37%, no greater than 36%, no greater than 35%, no greater than 33%, no greater than 31%, no greater than 30%, no greater than 29%, no greater than 27%, no greater than 25%, no greater than 23%, no greater than 21%, no greater than 20%, no greater than 19%, no greater than no greater than 17%, no greater than 16%, no greater than 15%, no greater than 49%, no greater than 48%, no greater than 47%, no greater than 46%, no greater than 45%, no greater than 43%, no greater than 42%, no greater than 41%, no greater than 40%, no greater than 39%, no greater than 37%, no greater than 35%, no greater than 33%, no greater than 30%, no greater than 28%, no greater than 26%, no greater than 24%, no greater than 21%, no greater than 19%, no greater than 17%, no greater than 15%, no greater than 13%, no greater than 11%, no greater than 10%, no greater than 9%, no greater than 8%, no greater than 7%, or no greater than 5% absolute value. In another aspect, the abrasive particles can comprise a standard deviation of the domain size having an absolute value of at least 0.001% of the domain size of the coating, at least 0.01% of the domain size of the coating, at least 0.1%, at least 1%, at least 2%, at least 4%, at least 3%, or at least 5%. Furthermore, the abrasive particles can comprise standard deviations having absolute values within a range including any of the minimum and maximum values mentioned herein.

In another embodiment, the abrasive particles can comprise a standard deviation having an absolute value of no greater than 65nm, no greater than 63nm, no greater than 61nm, no greater than 60nm, no greater than 58nm, no greater than 55nm, no greater than 53nm, no greater than 51nm, no greater than 50nm, no greater than 49nm, no greater than 47nm, no greater than 45nm, no greater than 43nm, no greater than 41nm, no greater than 40nm, no greater than 38nm, no greater than 36nm, no greater than 32nm, no greater than 30nm, no greater than 28nm, no greater than 25nm, no greater than 23nm, no greater than 22nm, no greater than 20nm, no greater than 19nm, no greater than 17nm, no greater than 16nm, no greater than 15nm, no greater than 14nm, no greater than 13nm, or no greater than 12 nm. In another aspect, the abrasive particles can comprise a standard deviation of domain size having an absolute value of at least 0.1nm, at least 0.3nm, at least 0.5nm, at least 1nm, at least 2nm, at least 3nm, at least 4nm, at least 5nm, at least 6nm, at least 7nm, at least 8nm, at least 9nm, at least 10nm, at least 11nm, at least 12nm, at least 13nm, at least 14nm, at least 15nm, at least 16nm, or at least 17 nm. Furthermore, the standard deviation may have an absolute value within a range that includes any of the minimum and maximum values mentioned herein.

Referring to fig. 1, the process may continue to block 104 to form a second portion of the coating overlying at least a portion of the core. Forming the second portion may include treating the core with a second coating. In an embodiment, the second coating may comprise a coupling agent, for example, a silicon-containing compound, such as silane or another organosilicon compound. In particular, the second coating may comprise a silicone coupling agent, which may provide improved bonding between the surface having-OH functional groups and the organic polymeric material. For example, the second coating may comprise an organosilane having amino, alkoxy, alkylalkoxy, alkyltrialkoxy, vinyl, propenyl, methylpropenyl, mercapto, or other functional groups, or any combination thereof. Specific examples of silanes may include aminosilanes including, for example, bisaminosilane, aminoalkyl trialkoxysilane, aminoethyl triethoxysilane, aminopropyl triethoxysilane, phenylaminoalkyl trialkoxysilane, or any combination thereof. Further examples of organosilicon compounds may include siloxanes, silicone fluids, silsesquioxanes, and the like, or any combination thereof.

In an exemplary embodiment, the core may be wetted with a solution comprising silane in a solvent such as water or ethanol. The concentration of silane may be in the range of, for example, 2vol% to 6 vol%. In other embodiments, in situ spray coating or other methods known in the art may be used to coat the core with the second coating.

Forming the second portion of the coating may further include drying the wet or otherwise coated core. For the second part of the coating, it may be dried at a temperature of 20 ℃ to 180 ℃ for 10 minutes up to 36 hours.

According to one embodiment, after the second portion 203 is applied, the finally-formed abrasive particles may contain a specific content of a silane-containing compound, including, for example, but not limited to, at least 0.02wt% of the silane-containing compound based on the total weight of the coating. In another embodiment, the coating may comprise at least 0.5wt%, such as at least 1wt%, or at least 2wt%, or at least 3wt%, or at least 4wt%, or at least 5wt%, or at least 6wt%, or at least 7wt%, or at least 8wt%, or at least 9wt%, or at least 10wt% of the silane-containing compound, based on the total weight of the coating. Additionally, in another non-limiting embodiment, the coating may comprise no more than 25wt% of the total weight of the coating, such as no more than 20wt%, or no more than 18wt%, or no more than 16wt%, or no more than 14wt%, or no more than 12wt%, or no more than 10wt% of the silane-containing compound, based on the total weight of the coating. It will be appreciated that the coating may comprise a silane-containing compound content within a range including any of the minimum and maximum values described above.

Referring to fig. 2B, a cross section of an abrasive particle 210 is provided and represents an abrasive particle according to an alternative embodiment. In one embodiment, the abrasive particles 210 can comprise a core 201 and a coating 205 overlying the core 201. The coating 205 may comprise a first portion 202 overlying the core 201 and a second portion 203 overlying the first portion 202 and the core 201. The first portion 202 may be located between the surface of the core 201 and the second portion 203. In one non-limiting embodiment, the abrasive particles 210 can be formed by: the abrasive particles as provided in fig. 2A are first formed by using steps 101, 102 and 103, and second, as provided in step 104, the second portion 203 is formed overlying the first portion of the core.

In one non-limiting embodiment, the second portion 203 may be in direct contact with the first portion 202. In an embodiment, the second portion 203 may cover the entire surface of the core 201, the entire first portion 202, or both. In one embodiment, the second portion 203 may overlie a majority of the first portion 202. For example, a portion of the first portion 202 may not be covered by the second portion 203. In one embodiment, a portion of the core surface may be in direct contact with the second portion 203. In yet another embodiment, the second portion 203 may be bonded to the first portion 202 and to the core 201.

In an embodiment, the second portion 203 of the coating 205 may include silane or a silane reaction product. The silane reaction product is intended to mean a silane derivative which can be formed during the formation of the coating. For example, one suitable silane or silane reaction product may include 3-aminopropyl triethoxysilane.

In an embodiment, the abrasive particles 210 or 201 may comprise an average content of at least 0.01wt.% of the coating 205 or 202, such as at least 0.02wt.%, at least 0.03wt.%, at least 0.04wt.%, at least 0.05wt.%, at least 0.06wt.%, at least 0.07wt.%, at least 0.08wt.%, at least 0.09wt.%, at least 0.1wt.%, at least 0.15wt.%, at least 0.16wt.%, at least 0.17wt.%, at least 0.18wt.%, at least 0.19wt.%, at least 0.2wt.%, at least 0.25wt.%, at least 0.26wt.%, at least 0.27wt.%, at least 0.28wt.%, at least 0.29wt.%, or at least 0.3wt.% of the weight of the core 201. As used herein, the average content of the coating 205 or 202 may be an average of the coating content of at least 5 abrasive particles 210 or 201. In another example, the abrasive particles 210 or 201 may include an average content of the coating 205 or 202 of no greater than 1wt.% based on the weight of the core 201, such as no greater than 0.9wt.%, no greater than 0.8wt.%, no greater than 0.7wt.%, no greater than 0.6wt.%, no greater than 0.55wt.%, no greater than 0.5wt.%, no greater than 0.48wt.%, no greater than 0.46wt.%, no greater than 0.45wt.%, no greater than 0.43wt.%, no greater than 0.42wt.%, no greater than 0.41wt.%, no greater than 0.4wt.%, no greater than 0.38wt.%, no greater than 0.37wt.%, no greater than 0.36wt.%, no greater than 0.35wt.%, or no greater than 0.34wt.% based on the weight of the core 201. Furthermore, the abrasive particles 210 can comprise an average content of the coating 205 within a range including any of the minimum and maximum percentages mentioned herein.

In an embodiment, the abrasive particles 210 may include a particular average thickness of the coating 205, which may facilitate improved formation and properties of the abrasive particles 210. For example, the abrasive particles 210 can include an average thickness of the coating 205 of no greater than 10 microns, no greater than 9 microns, no greater than 8 microns, no greater than 7 microns, no greater than 6 microns, no greater than 5 microns, no greater than 4 microns, no greater than 3 microns, no greater than 2 microns, no greater than 1 micron, no greater than 0.9 microns, no greater than 0.8 microns, no greater than 0.7 microns, no greater than 0.6 microns, no greater than 0.5 microns, no greater than 0.4 microns, no greater than 0.3 microns, or no greater than 0.2 microns. In another example, the abrasive particles 210 can include an average thickness of the coating 205 of at least 0.05 microns, at least 0.06 microns, at least 0.07 microns, at least 0.08 microns, at least 0.09 microns, at least 0.1 microns, at least 0.11 microns, at least 0.12 microns, at least 0.13 microns, at least 0.14 microns, at least 0.15 microns, at least 0.16 microns, at least 0.17 microns, at least 0.18 microns, at least 0.19 microns, at least 0.20 microns, at least 0.21 microns, at least 0.22 microns, at least 0.24 microns, at least 0.26 microns, at least 0.28 microns, at least 0.29 microns, at least 0.30 microns, or at least 0.31 microns. Furthermore, the abrasive particles 210 can comprise an average thickness of the coating 205 within a range including any of the minimum and maximum percentages mentioned herein. As used herein, the average thickness of the coating 205 may refer to the average of the thicknesses of the coating 205 of at least 5 abrasive particles 210.

In an embodiment, the abrasive particles 210 or 201 may comprise a particular ratio of the average thickness of the coating 205 or 202, respectively, to the average particle size of the core 201, which may facilitate improved formation and properties of the abrasive particles 210. For example, the ratio may be less than 1, such as not greater than 0.9, not greater than 0.7, not greater than 0.5, not greater than 0.4, not greater than 0.2, not greater than 0.1, not greater than 0.08, not greater than 0.06, not greater than 0.05, not greater than 0.03, not greater than 0.02, not greater than 0.01, not greater than 0.009, not greater than 0.008, not greater than 0.007, not greater than 0.006, not greater than 0.005, not greater than 0.004, not greater than 0.003, not greater than 0.002, or not greater than 0.1. In another example, the ratio of the average thickness of the coating 205 or 202 to the average particle size of the core 201 can be at least 0.0005, at least 0.0007, at least 0.0009, at least 0.001, at least 0.002, at least 0.003, at least 0.004, at least 0.005, at least 0.006, at least 0.007, at least 0.008, at least 0.009, at least 0.01, at least 0.02, or at least 0.03. Furthermore, the ratio of the average thickness of the coating 205 or 202 to the average particle size of the core 201 may be within a range that includes any of the minimum and maximum percentages mentioned herein. As used herein, the average particle size of the core 201 is intended to refer to D of the core 201 ₅₀ 。

In one embodimentIn embodiments, abrasive particles 210 and 201 can include an average particle size (i.e., D) of at least 10 microns, at least 30 microns, at least 40 microns, at least 50 microns, at least 60 microns, at least 70 microns, at least 80 microns, at least 90 microns, at least 100 microns, at least 120 microns, at least 140 microns, at least 150 microns, at least 170 microns, at least 180 microns, at least 200 microns, at least 210 microns, at least 230 microns, at least 250 microns, at least 260 microns, at least 270 microns, at least 290 microns, at least 300 microns, at least 320 microns, at least 340 microns, at least 350 microns, at least 360 microns, at least 380 microns, at least 400 microns, at least 420 microns, at least 430 microns, at least 440 microns, at least 450 microns, at least 460 microns, at least 470 microns, at least 490 microns, or at least 500 microns ₅₀ ). In another embodiment, the abrasive particles 210 and 201 can include an average particle size of no greater than 3mm, such as no greater than 2mm, no greater than 1.8mm, no greater than 1.6mm, no greater than 1.5mm, no greater than 1.2mm, no greater than 1mm, no greater than 900 microns, no greater than 850 microns, no greater than 830 microns, no greater than 800 microns, no greater than 750 microns, no greater than 700 microns, no greater than 650 microns, no greater than 600 microns, no greater than 550 microns, no greater than 500 microns, no greater than 450 microns, or no greater than 400 microns. Furthermore, the abrasive particles 210 and 201 can comprise an average particle size within a range including any of the minimum and maximum values mentioned herein.

Notably, the abrasive particles of the embodiments herein may have improved characteristics, properties, and/or performance as compared to corresponding conventional abrasive particles. As used herein, the corresponding conventional abrasive particles are intended to refer to abrasive particles having the same core and coating as the abrasive particles of the embodiments herein, except that the coating of the conventional abrasive particles is formed using a different process than the abrasive particles of the embodiments herein. Such improved characteristics of the abrasive particles may include morphology, coating coverage, average thickness of the coating, uniformity of thickness of the coating, such as standard deviation of thickness of the coating, average domain size of the coating, standard deviation of domain size of the coating, or any combination thereof. In particular, the abrasive particles of the embodiments herein have statistically relevant sample sizes, and improved characteristics, properties, and performance are described with respect to all samples of abrasive particles. For example, the abrasive particles can be at least 1kg abrasive particles, at least 2kg abrasive particles, at least 4kg abrasive particles, at least 5kg abrasive particles, at least 7kg abrasive particles, at least 8kg abrasive particles, at least 10kg abrasive particles, at least 20kg abrasive particles, at least 30kg abrasive particles, at least 50kg abrasive particles, at least 100kg abrasive particles, at least 250kg, at least 500kg, or at least 1 ton abrasive particles. In another example, the abrasive particles may constitute a significant percentage of abrasive particles from the fixed abrasive article. In yet another example, at least 100 abrasive particles, at least 500 abrasive particles, at least 1000 abrasive particles, at least 2000 abrasive particles, at least 5000 abrasive particles, at least 8000 abrasive particles, at least 10000 abrasive particles, or at least 500000 abrasive particles.

It is also worth noting that the variables and parameters of the processes of the embodiments herein are controlled and/or adapted to facilitate the formation of improved coating properties and abrasive particles having improved characteristics, properties and performance. The processes of the embodiments herein may facilitate formation of abrasive particles having improved quality compared to corresponding conventional abrasive particles. For example, drying conditions, silica concentration, mixing conditions, and/or other process features as described in the embodiments herein may help reduce the formation of abrasive particle agglomerates and prevent degradation of the core material, as well as form improved coatings. The abrasive particles may comprise a conformal and uniform coating.

In yet another embodiment, the abrasive particle 201 or 210 can comprise at least 5% better than a plurality of corresponding conventional abrasive particles, at least 8% better than a plurality of corresponding conventional abrasive particles, at least 10% better than a plurality of conventional abrasive particles, at least 12% better than a plurality of conventional abrasive particles, at least 15% better than a plurality of conventional abrasive particles, at least 18% better than a plurality of conventional abrasive particles, at least 20% better than a plurality of conventional abrasive particles, at least 24% better than a plurality of conventional abrasive particles, at least 25% better than a plurality of conventional abrasive particles, at least 28% better than a plurality of conventional abrasive particles, at least 30% better than a plurality of conventional abrasive particles, at least 32% better than a plurality of conventional abrasive particles, at least 35% better than a plurality of conventional abrasive particles.

In an embodiment, the coating 202 or 205 can have a particular hardness, which can promote improved performance and/or properties of the abrasive particles and abrasive article. In one aspect, the hardness may be greater than 1GPa, such as at least 1.5GPa, at least 1.8GPa, at least 2GPa, at least 2.2GPa, at least 2.5GPa, at least 2.8GPa, or at least 3GPa. In another aspect, the hardness may be less than 10GPa, such as less than 8GPa, at most 7GPa, at most 6GPa, at most 5GPa, at most 4GPa, at most 3.8GPa, at most 3.5GPa, at most 3.3GPa, at most 3.2GPa, or at most 3GPa. In yet another aspect, the coating 202 or 205 can have a hardness within a range including any of the minimums and maximums mentioned herein. The hardness can be determined as follows. The prepared suspension may be deposited by dip coating on a flat alumina substrate (purity 99.5%). The coated substrate may be dried as described in the examples herein. Nanoindentation may be performed on the coated sheet. 20 impressions can be made to determine the hardness of the coating.

Fig. 4 includes a cross-sectional view of a consolidated abrasive article 400 comprising a body 401 that includes abrasive particles 210 contained within a bond material 403. In at least one embodiment, the bonding material 403 defines an interconnected and continuous phase throughout the volume of the body 401. In another embodiment, the bonding material 403 may form a three-dimensional matrix. In another embodiment, the abrasive particles 201 may be used alone or in combination with the abrasive particles 210 to form the abrasive article 400.

In an embodiment, the abrasive particles 210 may be bonded to the bond material 403. In yet another embodiment, a portion of the coating 203 may be crosslinked to the bonding material 403. For example, silane or silane derivatives may be crosslinked to the bonding material during formation of the body 401.

In an embodiment, the bonding material 403 may include an organic material, an inorganic material, a ceramic material, a vitreous material, a metal, or a metal alloy material. In a particular embodiment, the bonding material 403 may include an organic material, such as one or more natural organic materials, synthetic organic materials, or a combination thereof. In certain examples, the organic material may be made of a resin, which may include thermosets, thermoplastics, and combinations thereof. For example, some suitable resins may include phenolic resins, epoxy resins, polyesters, cyanate esters, shellac, polyurethanes, polybenzoxazines, polydimaleimides, polyimides, rubbers, and combinations thereof.

The phenolic resin may be modified with a curing or cross-linking agent, such as hexamethylenetetramine. Some examples of hexamethylenetetramine may form crosslinks at temperatures exceeding about 90 ℃ to form methylene and dimethylamino bridges that aid in curing the resin. Hexamethylenetetramine can be uniformly dispersed in the resin. More specifically, hexamethylenetetramine may be uniformly dispersed in the resin region as a crosslinking agent. Even more particularly, the phenolic resin may comprise regions of resin having crosslinked domains of submicron average size.

In an embodiment, the body 401 may include a certain amount of bonding material 403, which may facilitate improved formation of the abrasive article. In an example, the body 401 may contain no greater than 98vol%, or no greater than 95vol%, or no greater than 90vol%, or no greater than 85vol%, or no greater than 80vol%, or no greater than 75vol%, or no greater than 70vol%, or no greater than 65vol%, or no greater than 60vol%, or no greater than 55vol%, or no greater than 50vol%, or no greater than 45vol%, or no greater than 40vol%, or no greater than 35vol%, or no greater than 30vol%, or no greater than 25vol% of the bonding material 403 of the total volume of the body. In another example, the body 401 may include at least 1vol%, or at least 2vol%, or at least 5vol%, or at least 10vol%, or at least 20vol%, or at least 30vol%, or at least 35vol%, or at least 40vol%, or at least 45vol% of the bonding material 403 of the total volume of the body. Further, the body 401 may include a bonding material 403 in an amount including any minimum and maximum percentages mentioned herein.

In an embodiment, the body 401 may include a certain content of abrasive particles 210 and/or 201, which may facilitate improved properties and performance of the abrasive article. In an example, the body 401 can include no greater than 65vol% abrasive particles 210, such as no greater than 64vol%, or no greater than 62vol%, or no greater than 60vol%, or no greater than 58vol%, or no greater than 56vol%, or no greater than 54vol%, or no greater than 52vol%, or no greater than 50vol%, or no greater than 48vol%, or no greater than 46vol%, or no greater than 44vol%, or no greater than 42vo1%, or no greater than 40vol%, or no greater than 38vol%, or no greater than 36vol%, or no greater than 34vol%, or no greater than 32vol%, or no greater than 30vol%, or no greater than 28vol%, or no greater than 26vol%, or no greater than 24vol%, or no greater than 22vol%, or no greater than 20vol%, of the total volume of the body 401. In another example, the body 901 can comprise at least 1vol% abrasive particles 210 and/or 201 of the total volume of the body 401, such as at least 2vol%, or at least about 4vol%, or at least 6vol%, or at least 8vol%, or at least 10vol%, or at least 12vol%, or at least 14vol%, or at least 16vol%, or at least 18vol%, or at least 20vol%, or at least 25vol%, or at least 30vol%, or at least 35vol% abrasive particles 210 and/or 201 of the total volume of the body 401. Further, the body 401 may comprise a content of abrasive particles 210 and/or 201 within a range including any of the minimum and maximum percentages mentioned herein.

In at least one embodiment, the body 401 can comprise abrasive particles comprising a core 201 having at least one different characteristic, including composition, shape, hardness, grain size, brittleness, toughness, grain size, or any combination thereof. For example, the core 201 may include shaped abrasive particles and non-shaped particles or abrasive particles having different shapes. In yet another example, the core 201 may include a first type of abrasive particles including premium abrasive particles (e.g., fused alumina, alumina-zirconia, seeded sol gel alumina, shaped abrasive particles, etc.) and a second type of abrasive particles including diluent abrasive particles.

Referring to fig. 4, the body 401 further includes a central opening 430 and an axial axis 931 extending axially through the central opening 430, which may be perpendicular to a radial axis extending in a direction defining a diameter (d) of the body. It should be appreciated that any other filler and/or phase (e.g., porosity) of the body may be included within the bonding material 403.

In an embodiment, the body 401 may include a porosity type selected from the group consisting of: closed porosity, open porosity, and combinations thereof. In one aspect, the majority of the porosity may be closed porosity defined by discrete pores, and in a particular aspect, the porosity may consist essentially of closed porosity. In another aspect, the majority of the porosity may be open, defining a network of interconnected channels extending through at least a portion of the body, and in a particular aspect, substantially all of the porosity may be open porosity. In yet another aspect, the porosity may comprise a combination of open porosity and closed porosity.

In an embodiment, the body 401 may include a particular porosity that may facilitate improved properties and performance of the abrasive article. In an example, the body 401 may comprise a porosity of at least 1vol%, or at least 2vol%, or at least 4vol%, or at least 6vol%, or at least 8vol%, or at least 10vol%, or at least 12vol%, or at least 14vol%, or at least 16vol%, or at least 18vol%, or at least 20vol%, or at least 25vol%, or at least 30vol%, or at least 40vol%, or at least 45vol%, or at least 50vol%, or at least 55vol% of the total volume of the body. In another example, the body 401 may contain a porosity of no greater than 80vol%, or no greater than 75vol%, or no greater than 70vol%, or no greater than 65vol%, or no greater than 60vol%, or no greater than 55vol%, or no greater than 50vol%, or no greater than 45vol%, or no greater than 40vol%, or no greater than 35vol%, or no greater than 30vol%, or no greater than 25vol%, or no greater than 20vol%, or no greater than 15vol%, or no greater than 10vol%, or no greater than 5vol%, or no greater than 2vol% of the total volume of the body. It should be appreciated that the body 401 may include a porosity within a range including any of the minimum and maximum percentages mentioned herein. The porosity of the body 401 was measured using a mercury porosimeter (Mercury Porosimetry) (Micromeritics AutoPore IV 9520) to quantify the porosity in the body. A1 cm by 1cm sample was cut from the body and measured at low pressure (50 μm Hg) and high pressure (equilibration time 10 seconds) to obtain bulk and apparent densities of the body. The porosity is then calculated by the following equation: (porosity= [100- (bulk density/apparent density) ].

In an embodiment, the body 401 may contain a filler. For example, the body 401 may contain no more than 40vol% filler based on the total volume of the body. In a particular example, body 401 can have no greater than 35vol%, such as no greater than 30vol%, or no greater than 25vol%, or no greater than 20vol%, or no greater than 15vol%, or no greater than 10vol%, or no greater than 8vol%, or no greater than 5vol%, or no greater than 4vol%, or even no greater than 3vol% filler. For at least one embodiment, the body 401 may be free of filler. According to one non-limiting embodiment, the body 401 may have at least 0.05vol% filler, such as at least 0.5vol%, or at least 1vol%, or at least 2vol%, or at least 3vol%, or at least 5vol%, or at least 10vol%, or at least 15vol%, or at least 20vol%, or even at least 30vol% filler, of the total volume of the body 401. Furthermore, the filler within the body 401 may be in a range between any minimum and maximum percentages mentioned above, including for example, but not limited to, a content in a range of at least 0.5vol% and not greater than 30 vol%.

The filler may comprise a material selected from the group consisting of powders, granules, spheres, fibers, and combinations thereof. Further, in particular examples, the filler may include inorganic materials, organic materials, fibers, woven materials, nonwoven materials, particles, minerals, nuts, shells, oxides, alumina, carbides, nitrides, borides, polymeric materials, naturally occurring materials, and combinations thereof. In one embodiment, the filler may include materials such as sand, alumina hollow spheres, chromite, magnesite, dolomite, mullite hollow spheres, boride, titanium dioxide, carbon products (e.g., carbon black, coke, or graphite), silicon carbide, wood flour, clay, talc, hexagonal boron nitride, molybdenum disulfide, feldspar, nepheline syenite, glass spheres, glass fibers, caF ₂ 、KBF ₄ Cryolite (Na) ₃ AlF ₆ ) Elpasolite (K) ₃ AlF ₆ ) Pyrite, znS, copper sulfide, mineral oil,Fluoride, carbonate, calcium carbonate, wollastonite, mullite, steel, iron, copper, brass, bronze, tin, aluminum, kyanite, andalusite, garnet, quartz, fluoride, mica, nepheline syenite, sulfate (e.g., barium sulfate), carbonate (e.g., calcium carbonate), titanate (e.g., potassium titanate fibers), rock wool, clay, sepiolite, iron sulfide (e.g., fe) ₂ S ₃ 、FeS ₂ Or a combination thereof), potassium fluoroborate (KBF) ₄ ) Zinc borate, borax, boric acid, fine corundum powder, P15A, cork, glass spheres, silica microspheres (Z-light), silver, saran resin, P-dichlorobenzene, oxalic acid, alkali halides, organic halides, attapulgite or any combination thereof.

In at least one embodiment, the filler may comprise a material selected from the group consisting of: antistatic agents, lubricants, porosity inducers, colorants and combinations thereof. In particular examples where the filler is a particulate material, the filler may be different from the abrasive particles, with an average particle size significantly smaller than the abrasive particles.

The cross-section of the body 401 is shown as having a generally rectangular shape, which may represent a wheel shape or disk shape with a central opening 430 such that it is a ring. It should be appreciated that the abrasive articles of embodiments herein may have bodies that may be honing, cones, cups, flange shapes, cylinders, wheels, rings, and combinations thereof.

The body 401 may have a generally circular shape as viewed from above. It should be appreciated that in three dimensions, the body 401 may have a thickness (t) such that the body 401 has a disk-like or cylindrical shape. As shown, the body 401 may have an outer diameter (d) that extends through the center of the body 401. The central opening 430 may extend through the entire thickness (t) of the body 401 such that the abrasive article 400 may be mounted on a spindle or other machine for rotating the abrasive article 400 during operation. According to one embodiment, the body 401 may have a particular relationship between thickness (t) and diameter (d) such that the aspect ratio (d: t) of the body is at least 10:1, such as at least 20:1, or at least 30:1, or at least 40:1, or at least 50:1, or at least 60:1, or at least 70:1, or at least 80:1, or at least 90:1, or at least 100:1. Furthermore, in one non-limiting embodiment, the aspect ratio (d: t) may be no greater than 1000:1, or no greater than 500:1. It should be appreciated that the aspect ratio (d: t) may be within a range including any of the minimum and maximum values mentioned above.

In one aspect, a consolidated abrasive article 400 according to an embodiment may have a moisture retention value, where the moisture retention value is measured by dividing the wet MOR value of the consolidated abrasive article by the dry MOR value of the consolidated abrasive article and multiplying by 100. In a particular embodiment, the consolidated abrasive article can have a moisture retention value of at least 70%, such as at least 71%, or at least 72%, or at least 73%, or at least 74%, or at least 75%, or at least 76%, or at least 77%, or at least 78%, or at least 79%, or at least 80%, or at least 81%, or at least 82%, or at least 83%, or at least 84%, or even at least 85%. Additionally, in one non-limiting embodiment, the moisture retention value may be no greater than 99.9%, or no greater than 99.5%, or no greater than 99%, or no greater than 98%, or no greater than 96%, or no greater than 94%, or no greater than 92%, or no greater than 90%. It should be appreciated that the moisturizing value may be within any range including the minimum and maximum values described above. MOR of the abrasive article 400 is determined by The 3-point bend test on the universal tester was measured using the following parameters: the test speed was 1.27mm/min, the support span was 50.8mm, and the load cell was 10kN. A 3-point bend test was performed on a strip sample representing an abrasive article 400 having dimensions of 4.0 x 1.0 x 0.5 inches. At least three samples were tested to obtain the maximum flexural stress (i.e., modulus of rupture (MOR)) of the abrasive article.

Fig. 5 includes an illustration of a process of forming an abrasive article including a body. At block 601, the process may include forming a mixture including a bond material and/or bond precursor material and abrasive particles.

According to one embodiment, the bonding material and/or bonding precursor material may comprise a material selected from the group consisting of organic materials, organic precursor materials, inorganic precursor materials, natural materials, and combinations thereof. In a particular example, the bonding material may include a metal or metal alloy (such as a powder metal material, or a precursor of a metal material) that is suitable for forming a metal bonding matrix material during further processing.

According to another embodiment, the mixture may comprise a vitreous material or a precursor of a vitreous material suitable for forming a vitreous binding material during further processing. For example, the mixture may comprise a vitreous material in powder form, including, for example, an oxygen-containing material, an oxide or oxide composite, a frit, and any combination thereof.

In yet another embodiment, the mixture may comprise a ceramic material or a precursor of a ceramic material suitable for forming a ceramic bond material during further processing. For example, the mixture may comprise a ceramic material in powder form, including, for example, an oxygen-containing material, an oxide, or an oxide composite, and any combination thereof.

According to another embodiment, the mixture may comprise an organic material or a precursor of an organic material, which is suitable for forming an organic binding material during further processing. Such organic materials may include one or more natural organic materials, synthetic organic materials, and combinations thereof. In certain examples, the organic material may be made of a resin, which may include thermosets, thermoplastics, and combinations thereof. For example, some suitable resins may include phenolic resins, epoxy resins, polyesters, cyanate esters, shellac, polyurethanes, polybenzoxazines, polydimaleimides, polyimides, rubbers, and combinations thereof. In a particular embodiment, the mixture includes an uncured resin material configured to form a phenolic resin bond material by further processing.

Other materials, such as fillers, may be included in the mixture. The filler may or may not be present in the final shaped abrasive article. After forming the mixture, the method of forming the abrasive article may further include forming a green body comprising abrasive particles contained in a bond material. The green body is a green body that may be further processed prior to forming the final shaped abrasive article. The formation of the green body may include techniques such as pressing, molding, casting, printing, spraying, and combinations thereof. In a particular embodiment, forming the green body may include pressing the mixture into a particular shape, including, for example, performing a pressing operation to form the green body in the form of a grinding wheel.

It should also be appreciated that one or more reinforcing materials may be included within the mixture, or between portions of the mixture, to form a composite that includes one or more abrasive segments (i.e., abrasive particles contained within the bond material, as well as porosity, filler, etc.) and reinforcing segments made of the reinforcing material. Some suitable examples of reinforcing materials include woven materials, nonwoven materials, fiberglass, fibers, natural materials, synthetic materials, inorganic materials, organic materials, or any combination thereof. As used herein, terms such as "reinforced" or "reinforcing" refer to discrete layers or portions of reinforcing material that are different from the bond material and abrasive material used to make the abrasive portion. Terms such as "internally enhanced" or "internally enhanced" and the like mean that these components are within or embedded within the body of the abrasive article. In a cutting wheel, the inner reinforcing component may be, for example, in the shape of a disc with a central opening to accommodate the spindle bore of the wheel. In some wheels, the reinforcing material extends from the spindle bore to the periphery of the body. In other cases, the reinforcing material may extend from the periphery of the body to a point just below the flange for securing the body. Some abrasive articles may be "zone reinforced" in which the (inner) fiber reinforcement component is around the spindle bore and flange region of the body (about 50% of the body diameter).

After forming the mixture of the desired components and applying the mixture to the desired processing equipment, the method may continue by treating the mixture to form the finally-formed abrasive article. Some examples of suitable treatments may include curing, heating, sintering, crystallization, polymerization, pressing, and combinations thereof. In one example, the process may include binder formulation, mixing abrasive particles with a binder or binder precursor material, filling a mold, pressing and heating or curing the mixture.

After the treatment process is completed, an abrasive article, such as abrasive article 400, is formed, including abrasive particles and any other additives contained in the bond material.

Fig. 6 includes a cross-sectional view of a coated abrasive article 600 that includes a substrate 601, a make layer 602 overlying the substrate 601, and abrasive particles 210. The coated abrasive article 600 may optionally include fillers, additives, or any combination thereof. A size layer 603 covers and bonds to the abrasive particles 210 and the make layer 602. In another embodiment, the abrasive particles 200 may be used or combined with the abrasive particles 210 to form a coated abrasive article 600.

In an embodiment, the substrate 601 may include organic materials, inorganic materials, and combinations thereof. In certain examples, the substrate 601 can comprise a woven material. However, the substrate 601 may be made of a nonwoven material. Particularly suitable substrate materials may include organic materials including polymers, especially polyesters, polyurethanes, polypropylenes, polyimides such as KAPTON of DuPont, paper, or any combination thereof. Some suitable inorganic materials may include metals, metal alloys, especially foils of copper, aluminum, steel, and combinations thereof.

The make coat 602 may be applied to the surface of the substrate 601 in a single process, or alternatively, the abrasive particles 210 may be material bonded to the make coat 602 and the combination of the make coat 602 and abrasive particles 210 may be applied to the surface of the substrate 601 as a mixture. In some examples, by separating the process of applying the make coat 602 from the process of depositing the abrasive particles 210 in the make coat 602, the controlled deposition or placement of the abrasive particles 210 in the make coat 602 may be better suited. In addition, it is contemplated that such processes may be combined. Suitable primer layer 602 materials may include organic materials, particularly polymeric materials, including, for example, polyesters, epoxies, polychloroetsters, polyamides, polyacrylates, polymethacrylates, polyvinylchloride, polyethylene, polysiloxanes, silicones, cellulose acetate, nitrocellulose, natural rubber, starches, shellac, and mixtures thereof. In one embodiment, primer layer 602 may comprise a polyester resin. The coated substrate may then be heated to cure the resin and bonded abrasive particles 210 to the substrate 601. Typically, during this curing process, the coated substrate 601 may be heated to a temperature of about 100 ℃ to less than about 250 ℃.

After the make coat 602 having the abrasive particles 210 contained therein is sufficiently formed, a make coat 603 may be formed overlying the bonded abrasive particles 210 and bonding the bonded abrasive particles to the make coat 602 and substrate 601. The size coat 603 may comprise an organic material and may be made substantially of a polymeric material, and notably polyesters, epoxies, polyurethanes, polyamides, polyacrylates, polymethacrylates, polyvinylchloride, polyethylene, polysiloxanes, silicones, cellulose acetate, nitrocellulose, natural rubber, starch, shellac, and mixtures thereof may be used.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. Those skilled in the art will appreciate after reading this specification that those aspects and embodiments are merely illustrative and do not limit the scope of the invention. Embodiments may be in accordance with any one or more of the embodiments listed below.

Examples

Example 1. An abrasive particle comprising:

a body, the body comprising:

a core body, and

a coating overlying at least a portion of the core, wherein the coating comprises at least one of:

a) A lithium/silicon percentage in the range of at least 0.01% to no more than 25%;

b) A potassium/silicon percentage in the range of at least 0.01% to not more than 40%;

c) A sodium/silicon percentage in the range of at least 0.01% to no more than 40%; or (b)

d) Any combination thereof.

Embodiment 2. The abrasive particles of embodiment 1, wherein the lithium/silicon percentage is at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.2%, or at least 3.4%, or at least 3.6%, or at least 3.8%.

Embodiment 3. The abrasive particles of embodiment 1 wherein the lithium/silicon percentage is no greater than 24%, or no greater than 23%, or no greater than 22%, or no greater than 21%, or no greater than 20%, or no greater than 19%, or no greater than 18%, or no greater than 17%, or no greater than 16%, or no greater than 15%, or no greater than 14%, or no greater than 13%, or no greater than 12%, or no greater than 11%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%, or no greater than 3%.

Embodiment 4. The abrasive particles of embodiment 1, wherein the coating comprises at least 0.01wt%, or at least 0.02wt%, at least 0.03wt%, at least 0.04wt%, at least 0.05wt%, at least 0.06wt%, at least 0.07wt%, at least 0.08wt%, or at least 0.09wt%, or at least 0.1wt%, or at least 0.15wt%, or at least 0.2wt%, or at least 0.25wt%, or at least 0.3wt%, or at least 0.35wt%, or at least 0.4wt%, or at least 0.5wt%, or at least 0.6wt%, or at least 0.7wt%, or at least 0.8wt%, or at least 0.9wt%, or at least 1.0wt%, or at least 1.1wt%, or at least 1.2wt%, or at least 1.3wt%, or at least 1.4wt%, or at least 1.5wt%, or at least 1.6wt%, or at least 1.7wt%, or at least 1.8wt%, or at least 1.9wt%, or at least 2.2wt%, or at least 2.2.3 wt%, or at least 2.2wt%, lithium content.

Embodiment 5. The abrasive particle of embodiment 1, wherein the coating comprises a lithium content of no greater than 20wt%, or no greater than 19wt%, or no greater than 18wt%, or no greater than 17wt%, or no greater than 16wt%, or no greater than 15wt%, or no greater than 14wt%, or no greater than 13wt%, or no greater than 12wt%, or no greater than 11wt%, or no greater than 10wt%, or no greater than 9wt%, or no greater than 8wt%, or no greater than 7wt%, or no greater than 6wt%, or no greater than 5wt%, or no greater than 4wt%, or no greater than 3wt%, or no greater than 2 wt%.

Embodiment 6. The abrasive particle of embodiment 1, wherein the coating comprises a silicon content of at least 80wt%, at least 81wt%, at least 82wt%, at least 83wt%, at least 84wt%, at least 85wt%, at least 86wt%, at least 87wt%, at least 88wt%, at least 89wt%, at least 90wt%, at least 91wt%, at least 92wt%, at least 93wt%, at least 94wt%, or at least 95 wt%.

Embodiment 7. The abrasive particle of embodiment 1 wherein the coating comprises a silicon content of not greater than 99wt%, not greater than 98wt%, not greater than 97wt%, or not greater than 96 wt%.

Embodiment 8. The abrasive particles of embodiment 1, wherein the potassium/silicon percentage is at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.1%, or at least 3.2%, or at least 3.4%, or at least 3.8%.

Embodiment 9. The abrasive particle of embodiment 1, wherein the potassium/silicon percentage is not greater than 39%, or not greater than 38%, or not greater than 37%, or not greater than 36%, or not greater than 35%, or not greater than 34%, or not greater than 33%, or not greater than 32%, or not greater than 31%, or not greater than 30%, or not greater than 29%, or not greater than 28%, or not greater than 27%, or not greater than 26%, or not greater than 25%, or not greater than 24%, or not greater than 23%, or not greater than 22%, or not greater than 21%, or not greater than 20%, or not greater than 19%, or not greater than 18%, or not greater than 17%, or not greater than 16%, or not greater than 15%, or not greater than 14%, or not greater than 13%, or not greater than 12%, or not greater than 11%, or not greater than 10%, or not greater than 9%, or not greater than 8%, or not greater than 7%, or not greater than 6%, or not greater than 5%, or not greater than 4%.

Embodiment 10. The abrasive particle of embodiment 1, wherein the coating comprises a potassium content of at least 0.01wt%, or at least 0.02wt%, at least 0.03wt%, at least 0.04wt%, at least 0.05wt%, at least 0.06wt%, at least 0.07wt%, at least 0.08wt%, or at least 0.09wt%, or at least 1wt%, at least 2wt%, at least 3wt%, at least 4wt%, at least 5wt%, at least 6wt%, at least 7wt%, at least 8wt%, at least 9wt%, or at least 10 wt%.

Embodiment 11. The abrasive particle of embodiment 1, wherein the coating comprises a potassium content of not greater than 30wt%, not greater than 29wt%, or not greater than 28wt%, or not greater than 27wt%, or not greater than 26wt%, or not greater than 25wt%, or not greater than 24wt%, or not greater than 23wt%, or not greater than 22wt%, or not greater than 21wt%, or not greater than 20wt%, or not greater than 19wt%, or not greater than 18wt%, or not greater than 17wt%, or not greater than 16wt%, or not greater than 15wt%, or not greater than 14wt%, or not greater than 13wt%, or not greater than 12wt%, or not greater than 11wt%, or not greater than 10wt%, or not greater than 9wt%, or not greater than 8wt%, or not greater than 7 wt%.

Embodiment 12. The abrasive particle of embodiment 1, wherein the coating comprises no greater than 39%, or no greater than 38%, or no greater than 37%, or no greater than 36%, or no greater than 35%, or no greater than 34%, or no greater than 33%, or no greater than 32%, or no greater than 31%, or no greater than 30%, or no greater than 29%, or no greater than 28%, or no greater than 27%, or no greater than 26%, or no greater than 25%, or no greater than 24%, or no greater than 23%, or no greater than 22%, or no greater than 21%, or no greater than 20%, or no greater than 19%, or no greater than 18%, or no greater than 17%, or no greater than 16%, or no greater than 15%, or no greater than 14%, or no greater than 13%, or no greater than 12%, or no greater than 11%, or no greater than 10%, or no greater than 9%, or no greater than 8%, or no greater than 7%, or no greater than 6%, or no greater than 5%, or no greater than 4%, or no greater than 3%, or no greater than 2.0% of sodium, or no greater than 1% of silicon.

Embodiment 13. The abrasive particle of embodiment 1, wherein the coating comprises at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, or at least 0.1%, or at least 0.2%, or at least 0.3%, or at least 0.4%, or at least 0.5%, or at least 0.6%, or at least 0.7%, or at least 0.8%, or at least 0.9%, or at least 1.0%, or at least 1.2%, or at least 1.4%, or at least 1.6%, or at least 1.8%, or at least 2.0%, or at least 2.2%, or at least 2.4%, or at least 2.6%, or at least 2.8%, or at least 3.0%, or at least 3.4.4%, or at least 4.6%, or at least 4.8%, or at least 5.0%, or at least 5.5% sodium.

Embodiment 14. The abrasive particle of embodiment 1, wherein the coating comprises a sodium content of not greater than 30wt%, not greater than 29wt%, or not greater than 28wt%, or not greater than 27wt%, or not greater than 26wt%, or not greater than 25wt%, or not greater than 24wt%, or not greater than 23wt%, or not greater than 22wt%, or not greater than 21wt%, or not greater than 20wt%, or not greater than 19wt%, or not greater than 18wt%, or not greater than 17wt%, or not greater than 16wt%, or not greater than 15wt%, or not greater than 14wt%, or not greater than 13wt%, or not greater than 12wt%, or not greater than 11wt%, or not greater than 10wt%, or not greater than 9wt%, or not greater than 8wt%, or not greater than 7wt%, or not greater than 6wt%, or not greater than 5wt%, or not greater than 4wt%, or not greater than 3wt%, or not greater than 2 wt%.

Embodiment 15. The abrasive particle of embodiment 1, wherein the coating comprises a sodium content of at least 0.01wt%, or at least 0.05wt%, or at least 0.1wt%, or at least 0.2wt%, or at least 0.3wt%, or at least 0.5wt%, or at least 1.0wt%, or at least 1.5wt%, or at least 2.0 wt%.

Embodiment 16. The abrasive particle of embodiment 1, wherein the coating comprises a sodium content of not greater than 10 times the lithium content, or wherein the coating comprises a sodium content of not greater than 8 times the lithium content, or wherein the coating comprises a sodium content of not greater than 6 times the lithium content, or wherein the coating comprises a sodium content of not greater than 4 times the lithium content, or wherein the coating comprises a sodium content of not greater than 3 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2.8 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2.5 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2.2 times the lithium content, or wherein the coating comprises a sodium content of not greater than 2 times the lithium content, or wherein the coating comprises a sodium content of not greater than 1.8 times the lithium content, or wherein the coating comprises a sodium content of not greater than 1.5 times the lithium content, or wherein the coating comprises a sodium content of not greater than 1.3 times the lithium content, or wherein the coating comprises a sodium content of not greater than 0.9 times the lithium content, or wherein the coating comprises a sodium content of not greater than 0.0.05 times the lithium content, or wherein the coating comprises a sodium content of not greater than 0.0.0 times the lithium content or wherein the sodium content of not greater than 0.0.0 times the lithium content of the sodium content of not greater than 0.0.0.

Embodiment 17. The abrasive particle of embodiment 1, wherein the coating comprises a sodium content of not greater than 10 times the potassium content, or wherein the coating comprises a sodium content of not greater than 8 times the potassium content, or wherein the coating comprises a sodium content of not greater than 6 times the potassium content, or wherein the coating comprises a sodium content of not greater than 4 times the potassium content, or wherein the coating comprises a sodium content of not greater than 3 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2.8 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2.5 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2.2 times the potassium content, or wherein the coating comprises a sodium content of not greater than 2 times the potassium content, or wherein the coating comprises a sodium content of not greater than 1.8 times the potassium content, or wherein the coating comprises a sodium content of not greater than 1.5 times the potassium content, or wherein the coating comprises a sodium content of not greater than 1.3 times the potassium content, or wherein the coating comprises a sodium content of not greater than 0.9 times the potassium content of not greater than 0.5 times the potassium content, or wherein the coating comprises a sodium content of not greater than 0.0.0 times the potassium content, or wherein the coating comprises a sodium content of not greater than 0.0.0.0 times the potassium content of not greater than 0.0.

Embodiment 18. The abrasive particles of embodiment 1 wherein the lithium comprises a lithium-containing compound.

Embodiment 19. The abrasive particles of embodiment 18 wherein the lithium-containing compound comprises an oxide.

Embodiment 20. The abrasive particles of embodiment 18 wherein the lithium-containing compound comprises lithium oxide.

Embodiment 21. The abrasive particles of embodiment 1 wherein the silicon comprises a silicon-containing compound.

Embodiment 22. The abrasive particles of embodiment 21 wherein the silicon-containing compound comprises an oxide.

Embodiment 23. The abrasive particles of embodiment 21 wherein the silicon-containing compound comprises silica.

Embodiment 24. The abrasive particles of embodiment 1 wherein the potassium comprises a potassium-containing compound.

Embodiment 25. The abrasive particles of embodiment 24 wherein the potassium-containing compound comprises an oxide.

Embodiment 26. The abrasive particles of embodiment 24 wherein the potassium-containing compound comprises potassium oxide.

Embodiment 27. The abrasive particles of embodiment 1 wherein the sodium comprises a sodium-containing compound.

Embodiment 28. The abrasive particles of embodiment 27 wherein the sodium-containing compound comprises an oxide.

Embodiment 29. The abrasive particles of embodiment 27 wherein the sodium-containing compound comprises sodium oxide.

Embodiment 30. The abrasive particle of embodiment 1 wherein the core comprises a ceramic material.

Embodiment 31. The abrasive particles of embodiment 1, wherein the core comprises an oxide, carbide, nitride, superabrasive, boride, oxycarbide, oxynitride, carbon-based material, agglomerates, aggregates, shaped abrasive particles, microcrystalline material, nanocrystalline material, or any combination thereof.

Embodiment 32. The abrasive particle of embodiment 1, wherein the core comprises an oxide selected from the group consisting of: alumina, silica, zirconia, or any combination thereof.

Embodiment 33. The abrasive particles of embodiment 1, wherein the core comprises fused alumina, sol-gel alumina, nanocrystalline alumina, brown fused alumina, or any combination thereof.

Embodiment 34. The abrasive particle of embodiment 1, wherein the core comprises a polycrystalline material made from a plurality of crystalline particles, wherein the crystalline particles have an average crystalline domain size of at least 50nm and not greater than 3 mm.

Embodiment 35. The abrasive particle of embodiment 1, wherein the core comprises at least one of: a single crystalline phase, a polycrystalline phase, an amorphous phase, or any combination thereof.

Embodiment 36. The abrasive particle of embodiment 1, wherein the coating comprises a total crystal content of not greater than 99vol%, or not greater than 97vol%, or not greater than 90vol%, or not greater than 80vol%, or not greater than 70vol%, or not greater than 60vol%, or not greater than 50vol%, or not greater than 40vol%, or not greater than 30vol%, or not greater than 20vol%, or not greater than 10vol%, or not greater than 8vol%, or not greater than 5vol%, or not greater than 3vol%, or not greater than 2vol%, or not greater than 1vol% of the total volume of the coating.

Embodiment 37. The abrasive particle of embodiment 1, wherein the core comprises a density of at least 2.10g/cm3, at least 2.20g/cm3, 2.30g/cm3, at least 2.40g/cm3, at least 2.50g/cm3, at least 2.60g/cm3, at least 2.70g/cm3, 2.80g/cm3, at least 2.90g/cm3, at least 3.00g/cm3, at least 3.10g/cm3, at least 3.20g/cm3, at least 3.30g/cm3, at least 3.40g/cm3, 3.50g/cm3, at least 3.55g/cm3, at least 3.60g/cm3, at least 3.65g/cm3, at least 3.70g/cm3, at least 3.75g/cm3, at least 3.80g/cm3, at least 3.85g/cm3, at least 3.90g/cm3, or at least 3.95g/cm 3.

Embodiment 38. The abrasive particle of embodiment 1, wherein the core comprises no greater than 5.80g/cm3, no greater than 5.70g/cm3, no greater than 5.60g/cm3, no greater than 5.50g/cm3, no greater than 5.40g/cm3, no greater than 5.30g/cm3, no greater than 5.20g/cm3, no greater than 5.10g/cm3, no greater than 5.00g/cm3, no greater than 4.90g/cm3, no greater than 4.80g/cm3, no greater than 4.70g/cm3, no greater than 4.60g/cm3, no greater than 4.50g/cm3, no greater than 4.40g/cm3, no greater than 4.30g/cm3, no greater than 4.20g/cm3, no greater than 4.10g/cm3, no greater than 4.00g/cm3, or no greater than 97g/cm 3.

Embodiment 39 the abrasive particle of embodiment 1, wherein the core comprises a density of at least 80% of its theoretical density, at least 85% of its theoretical density, at least 88%, at least 90%, at least 92%, at least 95%, or at least 98%.

Embodiment 40. The abrasive particle of embodiment 1, wherein the core comprises a porosity of not greater than 10vol% of the total volume of the core, not greater than 9vol% of the total volume of the core, not greater than 8vol%, not greater than 7vol%, not greater than 6vol%, not greater than 5vol%, not greater than 4vol%, not greater than 3vol%, not greater than 2vol%, or not greater than 1 vol%.

Embodiment 41. The abrasive particle of embodiment 1, wherein the core comprises substantially no voids.

Embodiment 42. The abrasive particles of embodiment 1 wherein the coating comprises a dry material.

Embodiment 43. The abrasive particles of embodiment 1 wherein the coating comprises an unsintered material.

Embodiment 44. The abrasive particle of embodiment 1, wherein the coating comprises an average coating thickness of at least 10nm, at least 12nm, at least 15nm, at least 18nm, at least 20nm, at least 25nm, at least 28nm, at least 30nm, at least 32nm, at least 35nm, at least 38nm, at least 40nm, at least 43nm, at least 45nm, at least 48nm, at least 50nm, at least 52nm, at least 55nm, at least 58nm, at least 60nm, at least 63nm, at least 68nm, at least 70nm, at least 74nm, at least 76nm, at least 80nm, at least 83nm, at least 86nm, at least 90 nm.

Embodiment 45. The abrasive particle of embodiment 1, wherein the coating comprises an average coating thickness of no greater than 150nm, no greater than 140nm, no greater than 130nm, no greater than 120nm, no greater than 110nm, no greater than 100 nm.

Embodiment 46. The abrasive particle of embodiment 1, the coating comprises an average thickness of not greater than 200%, not greater than 150%, not greater than 100%, not greater than 80%, not greater than 50%, not greater than 49%, not greater than 47%, not greater than 44%, not greater than 42%, not greater than 40%, not greater than 38%, not greater than 36%, not greater than 34%, not greater than 33%, not greater than 31%, not greater than 30%, not greater than 29%, not greater than 27%, not greater than 25%, not greater than 23%, not greater than 21%, not greater than 20%, not greater than 19%, not greater than 18%, not greater than 17%, not greater than 16%, not greater than 14%, not greater than 12%, not greater than 11%, not greater than 10%, not greater than 9%, not greater than 8%, not greater than 7%, not greater than 6%, not greater than 5%, not greater than 4%, not greater than 3%, not greater than 2%, not greater than 1%, not greater than 0.8%, not greater than 0.7%, not greater than 0.5%, or a standard deviation of the thickness of the coating of not greater than 0.5%.

Embodiment 47. The abrasive particle of embodiment 1, the coating comprises a thickness standard deviation of at least 0.001% of the average thickness of the coating, at least 0.05%, at least 0.08%, at least 0.1%, at least 0.2%, at least 0.3%, at least 0.4%, at least 0.5%, at least 0.7%, at least 0.8%, at least 0.9%, at least 1%, at least 1.2%, at least 1.5%, at least 1.8%, at least 2%, at least 2.2%, at least 2.5%, at least 2.8%, at least 3%, at least 4%, or at least 5% of the average thickness of the coating.

Embodiment 48. The abrasive particle of embodiment 1 wherein the coating comprises an amorphous phase content in the range of at least 90wt% of the total weight of the coating.

Embodiment 49 the abrasive particle of embodiment 1 wherein the coating consists essentially of an amorphous phase.

Example 50. The abrasive particle of example 1, further comprising a coating content of at least 0.01wt.%, at least 0.02wt.%, at least 0.03wt.%, at least 0.04wt.%, at least 0.05wt.%, at least 0.06wt.%, at least 0.07wt.%, at least 0.08wt.%, at least 0.09wt.%, at least 0.1wt.%, at least 0.15wt.%, at least 0.16wt.%, at least 0.17wt.%, at least 0.18wt.%, at least 0.19wt.%, at least 0.2wt.%, at least 0.25wt.%, at least 0.26wt.%, at least 0.27wt.%, at least 0.28wt.%, at least 0.29wt.%, or at least 0.3wt.% of the total weight of the core.

Example 51. The abrasive particle of example 1, further comprising a coating content of not greater than 1wt.%, not greater than 0.9wt.%, not greater than 0.8wt.%, not greater than 0.7wt.%, not greater than 0.6wt.%, not greater than 0.55wt.%, not greater than 0.5wt.%, not greater than 0.48wt.%, not greater than 0.46wt.%, not greater than 0.45wt.%, not greater than 0.43wt.%, not greater than 0.42wt.%, not greater than 0.41wt.%, not greater than 0.4wt.%, not greater than 0.38wt.%, not greater than 0.37wt.%, not greater than 0.36wt.%, not greater than 0.35wt.%, or not greater than 0.34wt.% of the total weight of the core.

Example 52. The abrasive particle of example 1, further comprising a ratio of average coating thickness to average particle size of the core, wherein the ratio is less than 1, no greater than 0.9, no greater than 0.7, no greater than 0.5, no greater than 0.4, no greater than 0.2, no greater than 0.1, no greater than 0.08, no greater than 0.06, no greater than 0.05, no greater than 0.03, no greater than 0.02, no greater than 0.01, no greater than 0.009, no greater than 0.008, no greater than 0.007, no greater than 0.006, no greater than 0.005, no greater than 0.004, no greater than 0.003, no greater than 0.002, or no greater than 0.1.

Embodiment 53 the abrasive particle of embodiment 1, further comprising a ratio of average coating thickness to average particle size of the core, wherein the ratio is at least 0.0005, at least 0.0007, at least 0.0009, at least 0.001, at least 0.002, at least 0.003, at least 0.004, at least 0.005, at least 0.006, at least 0.007, at least 0.008, at least 0.009, at least 0.01, at least 0.02, or at least 0.03.

Embodiment 54. The abrasive particle of embodiment 1, wherein the coating further comprises at least one silane-containing composition.

Embodiment 55. The abrasive particle of embodiment 54, wherein the coating comprises at least 0.02wt%, or at least 0.5wt%, or at least 1wt%, or at least 2wt%, or at least 3wt%, or at least 4wt%, or at least 5wt%, or at least 6wt%, or at least 7wt%, or at least 8wt%, or at least 9wt%, or at least 10wt% of the silane-containing composition, or further wherein the coating comprises no more than 25wt%, such as no more than 20wt%, or no more than 18wt%, or no more than 16wt%, or no more than 14wt%, or no more than 12wt%, or no more than 10wt% of the silane-containing compound, based on the total weight of the coating.

Embodiment 56. The abrasive particles of embodiment 1, wherein the abrasive particles have an average particle size of at least 10 microns, at least 30 microns, at least 40 microns, at least 50 microns, at least 60 microns, at least 70 microns, at least 80 microns, at least 90 microns, at least 100 microns, at least 120 microns, at least 140 microns, at least 150 microns, at least 170 microns, at least 180 microns, at least 200 microns, at least 210 microns, at least 230 microns, at least 250 microns, at least 260 microns, at least 270 microns, at least 290 microns, at least 300 microns, at least 320 microns, at least 340 microns, at least 350 microns, at least 360 microns, at least 380 microns, at least 400 microns, at least 420 microns, at least 430 microns, at least 440 microns, at least 450 microns, at least 460 microns, at least 470 microns, at least 490 microns, or at least 500 microns.

Embodiment 57. The abrasive particles of embodiment 1, having an average particle size of no greater than 3mm, such as no greater than 2mm, no greater than 1.8mm, no greater than 1.6mm, no greater than 1.5mm, no greater than 1.2mm, no greater than 1mm, no greater than 900 microns, no greater than 850 microns, no greater than 830 microns, no greater than 800 microns, no greater than 750 microns, no greater than 700 microns, no greater than 650 microns, no greater than 600 microns, no greater than 550 microns, no greater than 500 microns, no greater than 450 microns, or no greater than 400 microns.

Example 58A fixed abrasive article comprising abrasive particles according to example 1.

Embodiment 59. The fixed abrasive article of embodiment 58, wherein the abrasive article has a moisture retention value of at least 70%, such as at least 71%, or at least 72%, or at least 73%, or at least 74%, or at least 75%, or at least 76%, or at least 77%, or at least 78%, or at least 79%, or at least 80%, or at least 81%, or at least 82%, or at least 83%, or at least 84%, or even at least 85%.

Example 60. An abrasive particle batch comprising abrasive particles according to example 1.

Embodiment 61. The batch of abrasive particles of embodiment 60, wherein the batch comprises at least 10wt%, or at least 20wt%, or at least 30wt%, or at least 40wt%, or at least 50wt%, or at least 60wt%, or at least 70wt%, or at least 80wt%, or at least 90wt% of the abrasive particles of embodiment 1, based on the total weight of abrasive particles in the batch.

Embodiment 62. The batch of abrasive particles according to embodiment 60, wherein the batch consists essentially of abrasive particles according to embodiment 1.

Embodiment 63. The batch of abrasive particles of embodiment 60, wherein the abrasive particles comprise any one or more combinations of features of the embodiment section or any of the embodiments described herein.

Embodiment 64 a method for forming an abrasive particle or a plurality of abrasive particles, comprising:

a) Providing a core; and

b) Forming a coating over at least a portion of the core; wherein the coating comprises any one or more features of any one of the embodiments described in the examples section or herein.

Embodiment 65. The method of embodiment 64, wherein forming comprises heating the coating at a temperature of no greater than 800 ℃, or no greater than 700 ℃, or no greater than 600 ℃, or no greater than 500 ℃, or no greater than 400 ℃, or no greater than 300 ℃, or no greater than 250 ℃.

Embodiment 66. The method of embodiment 64, wherein forming comprises heating the coating at a temperature of at least 20 ℃, or at least 30 ℃, or at least 40 ℃, or at least 50 ℃, or at least 60 ℃, or at least 70 ℃, or at least 80 ℃, or at least 90 ℃, or at least 100 ℃, or at least 110 ℃, or at least 120 ℃, or at least 130 ℃, or at least 140 ℃, or at least 150 ℃.

Embodiment 67. The method of embodiment 64, further comprising providing a silane-containing material, a silanol-containing material, or a combination thereof overlying the coating.

Embodiment 68 the method of embodiment 64, further comprising disposing the abrasive particle or particles in a fixed abrasive article.

Embodiment 69 the method of embodiment 64, further comprising disposing the abrasive particle or particles in a consolidated abrasive article.

Embodiment 70 the method of embodiment 64, further comprising disposing the abrasive particle or particles in a consolidated abrasive article comprising an organic bond material.

Embodiment 71. The method of embodiment 70 wherein the organic bonding material comprises at least one of phenolic resin, epoxy resin, polyester, cyanate ester, shellac, polyurethane, polybenzoxazine, polydimaleimide, polyimide, rubber, or a combination thereof.

Example 72. An abrasive particle comprising:

a body, the body comprising:

core body

A coating overlying at least a portion of the core, wherein the coating comprises a total crystalline content of no more than 60vol% of the total volume of the coating,

Wherein the coating comprises at least one silicate-containing compound and at least one silica-containing compound; and wherein the coating comprises a silicate/silica percentage of at least 10% and not more than 1000%.

Embodiment 73. The abrasive particle of embodiment 72, wherein the coating comprises a total crystal content of not greater than 50vol%, or not greater than 40vol%, or not greater than 30vol%, or not greater than 20vol%, or not greater than 10vol%, or not greater than 8vol%, or not greater than 5vol%, or not greater than 3vol%, or not greater than 2vol%, or not greater than 1 vol%.

Embodiment 74. The abrasive particle of embodiment 72, wherein the one silicate-containing compound comprises at least one of sodium silicate, potassium silicate, lithium silicate, or a combination thereof.

Embodiment 75. The abrasive particles of embodiment 72 wherein the silica-containing compound comprises silica.

Embodiment 76. The abrasive particle of embodiment 72, wherein the coating comprises a silica-containing compound content of at least 1 wt.%, at least 5wt.%, or at least 10wt.%, or at least 15wt.%, or at least 20wt.%, or at least 30wt.%, or at least 40wt.%, or at least 50wt.%, or at least 60wt.%, or at least 70wt.%, or at least 80wt.%, or at least 90 wt.%, based on the total weight of the coating.

Embodiment 77. The abrasive particle of embodiment 72, wherein the coating comprises a silica-containing compound content of not greater than 99wt%, not greater than 95wt%, or not greater than 90wt%, or not greater than 80wt%, or not greater than 70wt%, or not greater than 60wt%, or not greater than 50wt%, or not greater than 40wt%, or not greater than 30wt%, or not greater than 20wt%, or not greater than 10wt%, based on the total weight of the coating.

Embodiment 78. The abrasive particle of embodiment 72, wherein the coating comprises a silicate-containing compound content of at least 1 wt.%, at least 5wt.%, or at least 10wt.%, or at least 15wt.%, or at least 20wt.%, or at least 30wt.%, or at least 40wt.%, or at least 50wt.%, or at least 60wt.%, or at least 70wt.%, or at least 80wt.%, or at least 90 wt.%, based on the total weight of the coating.

Embodiment 79. The abrasive particles of embodiment 72, wherein the coating comprises a silicate-containing compound content of not greater than 99wt%, or not greater than 95wt%, or not greater than 90wt%, or not greater than 80wt%, or not greater than 70wt%, or not greater than 60wt%, or not greater than 50wt%, or not greater than 40wt%, or not greater than 30wt%, or not greater than 20wt%, or not greater than 10wt%, based on the total weight of the coating.

Embodiment 80. The abrasive particles of embodiment 72 wherein the silicate/silica percentage is at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 90%, or at least 100%.

Embodiment 81. The abrasive particles of embodiment 72, wherein the silicate/silica percentage is not greater than 1000%, or not greater than 900%, or not greater than 800%, or not greater than 700%, or not greater than 600%, or not greater than 500%, or not greater than 400%, or not greater than 300%200%, or not greater than 190%, or not greater than 180%, or not greater than 170%, or not greater than 60%, or not greater than 150%, or not greater than 140%, or not greater than 130%, or not greater than 120%, or not greater than 110%, or not greater than 100%, or not greater than 90%, or not greater than 80%, or not greater than 70%, or not greater than 60%, or not greater than 50%, or not greater than 40%, or not greater than 30%, or not greater than 20%, or not greater than 15%, or not greater than 10%, or not greater than 9%, or not greater than 8%, or not greater than 7%, or not greater than 6%, or not greater than 5%, or not greater than 4%.

Examples

Example 1

A representative sample of abrasive particles was formed by: first, a coating mixture was prepared, which comprised 7.01 grams of DS-13 silica available from singdao proso co., ltd.) and 2.65 grams of Lith available from dongguan pine chemical company (Dongguan Songshi Chemical co., ltd.)Lithium silicate and 20.34 grams deionized water. The proportions of the components in the mixture were 72wt% colloidal silica solution and 28wt% lithium silicate solution, which had the properties listed in table 1. White alumina 38A (white fused alumina (. Alpha. -a) ₁₂ O ₃ ) The particles are used as core particles by mixing 1000.0 g of molten alumina particles with 13.0 g of a coating mixture using a mixer for 1 to 5 minutes, and coating the core particles with the coating mixture. The wet and coated abrasive particles were dried in standard atmosphere at 150 ℃ for 14 hours to form coated abrasive particles (i.e., sample S1). The particles were unsintered and had a total crystal content of 0vol% based on the total volume of the coating.

TABLE 1

ICP analysis techniques. The following are ICP analysis techniques used herein to evaluate the composition of the coating, in particular the inorganic materials in the coating. ICP analysis was performed on the coating of sample 1. The analysis results are shown in Table 3. Sample 1 has a lithium/silicon percentage of 2.9% and a sodium/silicon ratio of 5.9%. Analysis was performed as follows: first, 20.0 g of sample S1 was weighed out and 2mL of hydrochloric acid, 0.5mL of nitric acid and 10mL of hydrofluoric acid were added. The samples were then sealed in a digestion tank at 100 ℃ for 1 hour. The samples were then filtered and the filtrate was measured by ICP-OES using the machine parameters provided in table 2.

TABLE 2

Table 3: ICP of coating

Composition of the composition	wt％
		Li ₂ O	2.69％
SiO ₂	91.89％
		Na ₂ O	5.42％

Example 2

A second representative example S2 of coated particles was prepared following the same procedure as S1 of example 1, except that the coating mixture of abrasive particles was a 72wt% colloidal silica solution and a 28wt% potassium silicate solution, available from the chen platform ocean chemical company (Xingtai Dayang Chemical co., ltd.) at DY-4.0, having the properties listed in table 4. The particles were unsintered and had a total crystal content of 0vol% based on the total volume of the coating.

TABLE 4 Table 4

ICP analysis was performed on the coating of S2. The analytical results are shown in Table 5. Sample 2 had a potassium/silicon percentage of about 3.2 to 7.7% and a sodium/silicon ratio of about 2.1% to 5.5%.

Table 5: ICP of coating S2

Composition of the composition	wt％
		K ₂ O	3-7％
SiO ₂	91-95％
		Na ₂ O	2-5％

Example 3

A third representative example S3 of coated particles was prepared following the same procedure as S1 of example 1, except that the coating mixture of abrasive particles was an 80wt% colloidal silica solution and a 20wt% sodium silicate solution, available from the chen platform ocean chemical company (Xingtai Dayang Chemical co., ltd.) as TPY-2.8, having the properties listed in table 6. The particles were unsintered and had a total crystal content of 0vol% based on the total volume of the coating.

TABLE 6

ICP analysis was performed on the coating of S3. The analytical results are shown in Table 7. Sample 3 has a sodium/silicon percentage of about 5.3 to 17.6%.

Table 7: ICP of coating S2

Composition of the composition	wt％
		Na ₂ O	5-15％
SiO ₂	85-95％

Example 4

Comparative coated particles CS1 were prepared by: the white alumina 38A particles were mixed with DS-13 silica available from the peninsula Hibiscus limited for 3 to 5 minutes at a silica content of 0.1wt.% based on the total weight of the alumina particles. A portion of the wetted particles were sintered at 850 ℃ for 15 minutes to form a coated particle sample CS1 and had a total crystal content of 63vol% of the total volume of the coating.

Example 5

The second comparative coated particles CS2 were prepared by: the white alumina 38A particles were mixed with DS-13 silica available from the peninsula Hibiscus limited for 3 to 5 minutes at a silica content of 0.1wt.% based on the total weight of the alumina particles. A portion of the wetted particles were dried at 150 ℃ for 14 hours to form coated abrasive particles and had a total crystalline content of 0vol% of the total volume of the coating.

Example 6

The third comparative coated particle CS3 was prepared by: first of all a coating mixture is prepared, the mixture contained 2.88 g of DY-4.0 potassium silicate solution available from Chemicals, inc. of Dain Chemie, inc. of Dongguan and 10.38 g of Lith available from Toguan pine, inc A48 lithium silicate and 16.74 grams deionized water. The proportions of the components in the mixture were 78wt% lithium silicate solution and 22wt% potassium silicate solution, which had the properties listed in table 8. White alumina 38A (white fused alumina (. Alpha. -a) _l2 O ₃ ) The particles are used as core particles by mixing 1000.0 g of molten alumina particles with 13.0 g of a coating mixture using a mixer for 1 to 5 minutes, and coating the core particles with the coating mixture. The wet and coated abrasive particles were dried at 150 ℃ for 14 hours to form coated abrasive particles (i.e., sample CS 3). The particles were unsintered and had a total crystal content of 0vol% based on the total volume of the coating.

TABLE 8

Composition of the composition	Chemical composition of the coating mixture	Proportioning of
			Potassium silicate solution	K in water ₂ O·nSiO ₂ (n=4.0); (concentration of 20% SiO) ₂ )	22wt％
Lithium silicate solution	Li in water ₂ O·nSiO ₂ (n=4.8); (concentration of 20% SiO) ₂ )	78wt％

Example 7

The fourth comparative coated particle CS4 was prepared by: a coating mixture was first prepared comprising 8.76 grams of a TPY-2.8 sodium silicate solution available from chen ocean chemical company, ltd, and 21.24 grams of deionized water. The component in the mixture was 100wt% sodium silicate, which has the properties listed in table 9. White alumina 38A (white fused alumina (. Alpha. -a) _l2 O ₃ ) The particles are used as core particles by mixing 1000.0 g of molten alumina particles with 13.0 g of a coating mixture using a mixer for 1 to 5 minutes, and coating the core particles with the coating mixture. The wet and coated abrasive particles were dried at 150 ℃ for 14 hours to form coated abrasive particles (i.e., sample CS 4). The particles were unsintered and had a total crystal content of 0vol% based on the total volume of the coating. Particles of CS4 cannot be used due to significant agglomeration of the particles, which is believed to be due to the coating composition. See fig. 7 for agglomeration of particles.

TABLE 9

Example 8

The fifth comparative coated particle CS5 was prepared by: a coating mixture was first prepared that contained 13.27g of DY-4.0 potassium silicate solution available from chen ocean chemicals limited and 16.73 g of deionized water. MixingThe component in the composition was 100wt% potassium silicate, which has the properties listed in table 10. White alumina 38A (white fused alumina (. Alpha. -a) _l2 O ₃ ) The particles are used as core particles by mixing 1000.0 g of molten alumina particles with 13.0 g of a coating mixture using a mixer for 1 to 5 minutes, and coating the core particles with the coating mixture. The wet and coated abrasive particles were dried at 150 ℃ for 14 hours to form coated abrasive particles (i.e., sample CS 5). The particles were unsintered and had a total crystal content of 0vol% based on the total volume of the coating.

Table 10

Composition of the composition	Chemical composition of the coating mixture	Proportioning of
			Potassium silicate solution	K in water ₂ O·nSiO ₂ (n=4.0); (concentration of 20% SiO) ₂ )	100wt％

Example 9

The coated alumina particles of samples S1, S2, S3, CS1, CS2, CS3, CS4 and CS5 were further treated with 3-aminopropyl triethoxysilane and dried at 150℃for 14 hours to form abrasive particles.

Example 10

The coated alumina particles of example 3 were used to form grinding wheel S1, grinding wheel S2, grinding wheel S3, grinding wheel CS1, grinding wheel CS2, and grinding wheel CS4, respectively, using their corresponding abrasive particle samples.

The grinding wheel S1 is prepared by: 74.3 grams of sample S1 abrasive particles were mixed with the bond mixture comprising phenolic resin for 2 to 7 minutes until all of the sample S1 abrasive particles were coated with the bond mixture to form an abrasive mixture. The abrasive mixture was then molded at room temperature under a 300 ton press and cold pressed to the desired dimensions to make a green grinding wheel. The green grinding wheel was removed from the mold and cured in an oven at 160 ℃ for 15 hours.

All other grinding wheels (including grinding wheel S2, grinding wheel S3, grinding wheel CS1, grinding wheel CS2, and grinding wheel CS 4) were formed using the same bond mixture composition as grinding wheel S1 and were prepared according to the same process as grinding wheel S1, except that each grinding wheel was made using the corresponding abrasive particles listed above (i.e., grinding wheel S2 contained S2 particles instead of S1 abrasive particles, grinding wheel S3 contained S3 abrasive particles instead of S1 abrasive particles, etc.). All of the grinding wheels were formed to have the same grinding wheel structure as grinding wheel S1, including the pore content, abrasive grain content, and bond mixture content.

All grinding wheels were tested for dry and wet flexural strength (i.e., mor). To measure wet MOR, the samples were immersed in boiling water for 2.5 hours prior to measurement. Table 11 summarizes the dry and wet MoR. The moisture retention was measured by dividing the wet MOR by the dry MOR and multiplying by 100. MOR is measured according to the disclosed three point bend test.

TABLE 11

Surprisingly, it was noted that the grinding wheel with the dry coating (i.e., S2, and S3) was statistically equivalent in terms of its performance when compared to the grinding wheel CS1 comprising abrasive particles with a sintered coating. Abrasive particles produced by low temperature processes may be beneficial in both sustainability and manufacturing.

The above-described embodiments represent a difference from the prior art. Embodiments relate to abrasive particles including a coating overlying a core. In particular, the abrasive particles may comprise a thin conformal coating having improved average thickness and uniformity, which may facilitate improved performance of the abrasive particles in the fixed abrasive, such as reduced friction associated with their use in material removal operations, anti-aging, and chemical and mechanical bonding of the conformal layer to the surface of the abrasive particles (i.e., core particles). Furthermore, the abrasive particles may have improved bond strength and reduced hygroscopicity and/or permeability, and are particularly suitable for use in coated abrasives and thin wheels.

Abrasive articles formed with representative abrasive particles further exhibit improved performance and properties, such as wet MoR, grinding ratio, and MMR, as compared to abrasive articles comprising abrasive particles having a dry coating. Without wishing to be bound by any theory, the improved properties and performance of the abrasive article may be facilitated by one or more characteristics of the abrasive particles.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. The benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as a critical, required, or essential feature or features of any or all the claims. References herein to a material comprising one or more components may be construed as including at least one embodiment in which the material consists essentially of the specified one or more components. The term "consisting essentially of should be interpreted to include ingredients that include those materials specified, and exclude all other materials except minor amounts (e.g., impurity levels) of the materials that do not significantly alter the properties of the materials. Additionally or alternatively, in certain non-limiting embodiments, any of the compositions specified herein may be substantially free of materials not explicitly disclosed. The examples herein include ranges for the content of certain components within a material, and it is understood that the content of components within a given material totals 100%.

The description and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The description and illustrations are not intended to serve as an exhaustive and complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Individual embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, references to values expressed as ranges include each and every value within the range. Many other embodiments will be apparent to the skilled artisan only after reading this specification. Other embodiments may be utilized and derived from the disclosure, such that structural, logical substitutions, or other changes may be made without departing from the scope of the disclosure. Accordingly, the present disclosure should be considered as illustrative and not restrictive.

Claims

1. An abrasive particle comprising:

a body, the body comprising:

a core body, and

d) Any combination thereof.

2. The abrasive particle of claim 1, wherein the lithium comprises lithium oxide.

3. The abrasive particle of claim 1, wherein the silicon comprises silica.

4. The abrasive particle of claim 1, wherein the potassium comprises potassium oxide.

5. The abrasive particle of claim 1, wherein the sodium comprises sodium oxide.

6. The abrasive particle of claim 1, wherein the coating comprises a total crystalline content of no greater than 1vol% of the total volume of the coating.

7. The abrasive particle of claim 1, wherein the coating further comprises at least one silane-containing composition.

8. A fixed abrasive article comprising the abrasive particles of claim 1.

9. The fixed abrasive article of claim 8, wherein the abrasive article has a moisture retention value of at least 70%, such as at least 71%, or at least 72%, or at least 73%, or at least 74%, or at least 75%, or at least 76%, or at least 77%, or at least 78%, or at least 79%, or at least 80%, or at least 81%, or at least 82%, or at least 83%, or at least 84%, or even at least 85%.

10. An abrasive particle comprising:

a body, the body comprising:

a core body, and

wherein the coating comprises at least one silicate-containing compound and at least one silica-containing compound; and is also provided with

Wherein the coating comprises a silicate/silica percentage of at least 10% and not more than 1000%.