EP1709138A1 - Abrasifs pourvus d'un revetement - Google Patents

Abrasifs pourvus d'un revetement

Info

Publication number
EP1709138A1
EP1709138A1 EP05702231A EP05702231A EP1709138A1 EP 1709138 A1 EP1709138 A1 EP 1709138A1 EP 05702231 A EP05702231 A EP 05702231A EP 05702231 A EP05702231 A EP 05702231A EP 1709138 A1 EP1709138 A1 EP 1709138A1
Authority
EP
European Patent Office
Prior art keywords
hard abrasive
metals
super
metal
coated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05702231A
Other languages
German (de)
English (en)
Inventor
David Patrick Egan
Johannes Alexander Engels
Michael Lester Fish
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Element Six Ltd
Original Assignee
Element Six Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Element Six Ltd filed Critical Element Six Ltd
Publication of EP1709138A1 publication Critical patent/EP1709138A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1436—Composite particles, e.g. coated particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
    • B24D11/001—Manufacture of flexible abrasive materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4584—Coating or impregnating of particulate or fibrous ceramic material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1436—Composite particles, e.g. coated particles
    • C09K3/1445—Composite particles, e.g. coated particles the coating consisting exclusively of metals

Definitions

  • This invention relates to coated abrasives, a process for their production, and to coated abrasives for use in abrasive-containing tools.
  • Abrasive particles such as diamond and cubic boron nitride are commonly used in cutting, grinding, drilling, sawing and polishing applications. In such applications, abrasive particles are mixed with metal powder mixes, then sintered at high temperatures to form bonded cutting elements.
  • Typical bond matrices contain iron, cobalt, copper, nickel and/or alloys thereof.
  • Titanium carbide is an example of a material that has been proposed as a coating for abrasive particles, because of its good adhesion to diamond.
  • Chromium carbide is a similar coating material that can be used.
  • a problem with the use of titanium carbide coatings is that in order for the coating to protect the diamond particles, it has to form a barrier between the bond matrix and the particles.
  • a coating may initially be dense and impermeable, but during the sintering process, a phase change may occur due to alloying with the bond matrix, for example, which results in the formation of a less dense alloy, or perhaps a porous coating, which allows passage of the bond matrix components through the coating to the particle surface. Titanium carbide coatings often do not form good barriers, particularly in aggressive sintering conditions.
  • a coated super-hard abrasive comprising a core of super-hard abrasive material, an inner layer of a metal carbide, nitride, boride, carbonitride or boronitride chemically bonded to an outer surface of the super-hard abrasive material and an outer layer of a metal, metal alloy or a combination of metals or metal alloys deposited on the inner layer.
  • the outer layer is preferably applied by physical vapour deposition, in particular by PVD sputter coating.
  • the super-hard abrasive material may be diamond or cBN based, and may include diamond or cBN grit, PCD substrates, PcBN substrates, thermally stable PCD (TSPCD) substrates, CVD diamond film, single crystal diamond substrates.
  • TPCD thermally stable PCD
  • the inner layer is formed from an element capable of forming (singly or in combination) carbides, nitrides or borides to the surface(s) of the abrasive material when applied as an inner layer using a hot coating process.
  • these elements come from groups IVa, Va, Via, lllb and IVb of the periodic table and include examples such as Ti, Cr, Zr, Mo, Ta, W, Al, B and Si.
  • the inner layer is preferably a titanium or chromium carbide coating in the case of a diamond abrasive core, or a titanium or chromium nitride, boride or boronitride coating in the case of a cBN abrasive core.
  • the properties of the metal layer may be tailored for better compatibility with the inner layer or for better bonding with metal bond matrices.
  • Ti in the form of titanium carbide or titanium nitrides, borides and boronitrides have been shown to be useful coating materials for diamond and cBN substrates, respectively. They are particularly useful because of their ability to bind chemically to the substrate and to protect the substrate. However, as has been mentioned previously, they are not suitable in some applications, particularly where they are sintered in aggressive sintering conditions. They are also prone to problems with bonding properly with the bond matrix.
  • titanium coatings can be extended to other applications where an outer metal coating is applied over the titanium coating layer. This is particularly the case where the titanium coating is prone to deterioration and where there is poor bonding with the metal matrix.
  • diamond impregnated tools such as segments for saw blades, drills, beads for diamond wires especially where high amounts of bronze or copper limit the usefulness of titanium carbide coatings
  • brazed diamond layer tools such as brazed diamond wire beads
  • diamond containing metal matrix composites brazing of diamond materials such as affixing TSPCD, PCD and diamond drillstones to a drill body, affixing CVD, monocrystal, TSPCD and PCD to a saw blade, tool post, drill body and the like.
  • coated diamond impregnated tools yield improved performance, such as longer tool life and higher productivity.
  • Coated diamond particles or substrates of the invention for brazing applications allow the use of simple brazes that work in air as opposed to active brazes containing Ti which require the exclusion of oxygen.
  • the coated abrasive particles are preferably formed -using a hot coating process for applying the inner layer and a low temperature CVD or PVD process for applying the outer layer.
  • the diamond grit particles are those used conventionally in the manufacturing of metal bonded tools. They are generally uniformly sized, typically 0.1 to 10 mm. Examples of such diamond grit particles include: Micron grit 0.1 to 60 micron, wheel grit 40 micron to 200 micron, saw grit 180 micron to 2 millimeter, mono crystal 1 millimeter to 10 millimeter, CVD inserts of a few square millimeter to discs up to 200 millimeter diameter, PCD inserts of a few square millimeter to discs 104 millimeter diameter, cBN grit in micron range 0.1 to 60 micron, in wheel grit range 40 micron to 200 micron, PCBN inserts of a few mm to discs up to 104 mm diameter.
  • the diamond particles are first coated in a hot coating process to provide an inner layer, which may be a metal layer or a metal carbide, nitride or carbonitride layer.
  • an inner layer which may be a metal layer or a metal carbide, nitride or carbonitride layer.
  • such inner coating would typically be a metal nitride or boride or boronitride layer.
  • the metal-based coat is applied to the diamond substrate under suitable hot conditions for such bonding to take place.
  • Typical hot coating technologies that can be used include processes involving deposition from a metal halide gas phase, CVD processes, or thermodiffusion vacuum coating or metal vapour deposition processes, for example. Deposition from a metal halide gas phase and CVD processes are preferred.
  • the particles to be coated are exposed to a metal-halide containing the metal to be coated (e.g. titanium) in an appropriate gaseous environment (e.g. non- oxidising environments containing one or more of the following: inert gas, hydrogen, hydrocarbon, reduced pressure).
  • a metal-halide containing the metal to be coated e.g. titanium
  • an appropriate gaseous environment e.g. non- oxidising environments containing one or more of the following: inert gas, hydrogen, hydrocarbon, reduced pressure.
  • the metal halide may be generated from a metal as part of the process.
  • the mixture is subjected to a heat cycle during which the metal-halide transports the titanium to the surfaces of the particles where it is released and is chemically bonded to the particles.
  • the outer layer of metal, metal alloy or combination of metals or metal alloys is deposited using a cold coating technique such as low temperature CVD or PVD, which is preferred. It is a low temperature process in that insufficient heat is generated to cause significant carbide formation. Hence, if used alone, it would result in poor adhesion to the diamond particles.
  • a PVD process for applying the outer coating is PVD sputtering.
  • the metals, metal alloys or multiple layers of metal are deposited on the inner layer.
  • the sputtering can take place from different positions, using more than one metal/metal alloy. This allows for the production of metallic outer layers that bond better with the bond matrix. They can also be tailored to provide for improved chemical resistance, tailored melt point, and improved resistance to diffusion reactions and the tendency to alloy with the bond matrix.
  • coated abrasives of the invention include:
  • Titanium carbide coating applied by a hot coating process such as the commercially available SDBTCH, with an outer coating of: t i) titanium, which improves oxidation resistance, ii) tungsten, which provides for improved chemical resistance.
  • Diamond grit from Element Six, 40/45 US mesh size was coated in a CVD process to produce TiC coated diamond according to general methods commonly known in the art. The CVD TiC coated diamond was then used as the substrate for the second coating step.
  • this coating appeared a dark coppery colour. This colouring appeared evenly distributed over each particle and each particle appeared identical. The coating looked uniform and without any uncoated areas. Observation on the SEM again showed an even coating with a rough morphology composed of agglomerated particles. Fractured particles were also observed on the SEM. A two-layer structure was not easily distinguishable, the complete layer having a thickness of about 0.8 microns. This particular coating resulted in an assay of 2.7%. The TiC coating in this size used for this batch typically has an assay of 0.77%. The rest of the 2.7% is therefore attributable to the PVD TiC and Ti/Cu metal layer on top of the CVD TiC. When analysed using XRD, TiC and Cu metal were found. XRF analysis showed 23% Ti and 77% Cu.
  • CVD TiC coated diamond produced in accordance with Example 1 was used as the substrate for the second coating step.
  • 1 ,000 carats of this TiC coated diamond, 40/45 US mesh size, was placed in a magnetron sputter coater with a rotating barrel.
  • Two small targets of titanium and tungsten were used with two small independent magnetrons.
  • the coating chamber was evacuated, argon was admitted and the power turned on to form plasma.
  • Sputtering power was increased to 2kW (420V) on the titanium target while rotating the barrel to ensure an even coating on all the diamond particles at 20sccm argon pressure.
  • Titanium was coated for 45 minutes while oscillating the barrel.
  • Tungsten was simultaneously coated at 100W purely to prevent contaminating the tungsten target.
  • Power to the titanium target was ramped down from 2kW to 100W and at the same time power to the tungsten target was ramped up from 100W to 2kW, over 30 minutes.
  • Tungsten was coated at 2kW (450V) for 60 minutes. Titanium was simultaneously coated at 100W purely to prevent contaminating the titanium target. The total coating time was 135 minutes.
  • this coating appeared a dark silvery grey metallic colour. This colouring appeared evenly distributed over each particle and each particle appeared identical. The coating looked uniform and without any uncoated areas. Observation on the SEM again showed an even coating with a slightly rough morphology composed of small agglomerated particles. Fractured particles were also observed on the SEM. A two-layer structure was seen in most instances, the Ti-W layer having a thickness of about 0.2 microns. This particular coating resulted in an assay of 2%. The TiC coating in this size used for this batch typically has an assay of 0.77%. The rest of the 2% is therefore attributable to the PVD TiC and Ti/W metal layer on top of the CVD TiC. When analysed using XRD, diamond, TiC and W metal were found. XRF analysis showed 32% Ti and 68% W.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Abstract

Abrasifs revêtus super-durs composés d'un noyau de matériau abrasif super-dur, par exemple, diamant ou matériau à base cBN, d'une couche intérieure de carbure, nitrure, borure, carbonitrure ou boronitrure métallique liée chimiquement à une surface extérieure du matériau abrasif super-dur et d'une couche extérieure d'un métal, alliage de métal ou d'une combinaison de métaux ou d'alliage de métaux déposée sur la couche intérieure. Des exemples de métaux ou d'alliage de métaux pouvant être appliqués en tant que couche extérieure, consistent en des métaux du groupe IVa, Va, VI des métaux de transition, y compris tungstène, titane, chrome, molybdène et zirconium, et en des métaux de métaux de transition de première rangée (Ti à Cu), en particulier, les métaux non magnétiques ou les alliages de métaux pouvant être soumis à une pulvérisation au magnétron, ainsi qu'en des éléments des groupes IlIb et IVb de la table périodique, tels que B, Al, Si.
EP05702231A 2004-01-15 2005-01-13 Abrasifs pourvus d'un revetement Withdrawn EP1709138A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IE20040023 2004-01-15
PCT/IB2005/000061 WO2005078044A1 (fr) 2004-01-15 2005-01-13 Abrasifs pourvus d'un revetement

Publications (1)

Publication Number Publication Date
EP1709138A1 true EP1709138A1 (fr) 2006-10-11

Family

ID=34856838

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05702231A Withdrawn EP1709138A1 (fr) 2004-01-15 2005-01-13 Abrasifs pourvus d'un revetement

Country Status (4)

Country Link
US (1) US20070214727A1 (fr)
EP (1) EP1709138A1 (fr)
WO (1) WO2005078044A1 (fr)
ZA (1) ZA200606184B (fr)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1709136B1 (fr) * 2004-01-15 2008-03-26 Element Six Limited Abrasifs revetus
US8069936B2 (en) * 2007-02-23 2011-12-06 Baker Hughes Incorporated Encapsulated diamond particles, materials and impregnated diamond earth-boring bits including such particles, and methods of forming such particles, materials, and bits
CN101652210A (zh) * 2007-02-28 2010-02-17 六号元素（产品）（控股）公司 对工件进行机械加工的方法
KR20100022072A (ko) 2007-05-22 2010-02-26 엘리먼트 씩스 리미티드 코팅된 ｃｂｎ
WO2009013714A1 (fr) * 2007-07-23 2009-01-29 Element Six Limited Matière pouvant être brasée à l'air
US8815329B2 (en) * 2008-12-05 2014-08-26 Advanced Energy Industries, Inc. Delivered energy compensation during plasma processing
GB201215469D0 (en) * 2012-08-30 2012-10-17 Element Six Ltd Diamond constructions, tools comprising same and method for making same
FR2998464B1 (fr) * 2012-11-26 2015-05-22 Seb Sa Dispositif de cuisson comportant une surface de cuisson facile a nettoyer et resistant a la rayure

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ZA781390B (en) * 1978-03-09 1979-04-25 De Beers Ind Diamond The metal coating of abrasive particles
US5062865A (en) * 1987-12-04 1991-11-05 Norton Company Chemically bonded superabrasive grit
US5024680A (en) * 1988-11-07 1991-06-18 Norton Company Multiple metal coated superabrasive grit and methods for their manufacture
HUT62831A (en) * 1991-09-12 1993-06-28 Gen Electric Method for producing covered cubed leather-nitride abrasive grain, abrasive grain and grinding tool by using the same
US5143523A (en) * 1991-09-20 1992-09-01 General Electric Company Dual-coated diamond pellets and saw blade semgents made therewith
JP3309897B2 (ja) * 1995-11-15 2002-07-29 住友電気工業株式会社 超硬質複合部材およびその製造方法

Non-Patent Citations (1)

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Title
See references of WO2005078044A1 *

Also Published As

Publication number Publication date
US20070214727A1 (en) 2007-09-20
ZA200606184B (en) 2007-11-28
WO2005078044A1 (fr) 2005-08-25

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