EP3089850B1 - Verbundkörper und verfahren zur herstellung davon - Google Patents

Verbundkörper und verfahren zur herstellung davon Download PDF

Info

Publication number
EP3089850B1
EP3089850B1 EP14875911.1A EP14875911A EP3089850B1 EP 3089850 B1 EP3089850 B1 EP 3089850B1 EP 14875911 A EP14875911 A EP 14875911A EP 3089850 B1 EP3089850 B1 EP 3089850B1
Authority
EP
European Patent Office
Prior art keywords
pore
composition
content
mixture
composite body
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.)
Active
Application number
EP14875911.1A
Other languages
English (en)
French (fr)
Other versions
EP3089850A4 (de
EP3089850A1 (de
Inventor
Susanne Liebelt
Thomas J. Tschernig
Cécile JOUSSEAUME
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.)
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
Original Assignee
Saint Gobain Abrasifs SA
Saint Gobain Abrasives Inc
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 Saint Gobain Abrasifs SA, Saint Gobain Abrasives Inc filed Critical Saint Gobain Abrasifs SA
Priority to PL14875911T priority Critical patent/PL3089850T3/pl
Publication of EP3089850A1 publication Critical patent/EP3089850A1/de
Publication of EP3089850A4 publication Critical patent/EP3089850A4/de
Application granted granted Critical
Publication of EP3089850B1 publication Critical patent/EP3089850B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/14—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic ceramic, i.e. vitrified bondings
    • B24D3/18—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic ceramic, i.e. vitrified bondings for porous or cellular structure

Definitions

  • the present disclosure is directed to composite bodies, and particularly directed to, composite bodies including a bond material and pores within the bond material.
  • Abrasives are generally utilized in various machining operations, ranging from fine polishing to bulk material removal and cutting.
  • free abrasives composed of loose particles are used in slurries for polishing applications such as, chemical mechanical polishing (CMP) in the semiconductor industry.
  • CMP chemical mechanical polishing
  • abrasives can be in the form of fixed abrasive articles such as, bonded and coated abrasives which can include devices such as, grinding wheels, belts, rolls, disks and the like.
  • Fixed abrasives generally differ from free abrasives in that fixed abrasives utilize abrasive grains or grit within a matrix of material that fixes the position of the abrasive grains relative to each other.
  • Common fixed abrasive grits can include alumina, silicon carbide, various minerals such as, garnet, as well as superabrasives such as, diamond and cubic boron nitride (cBN).
  • the abrasive grits are fixed in relation to each other in a bond material. While many different bond materials can be used, vitrified bond materials, such as, an amorphous phase glass materials are common.
  • Abrasive tools with abrasive grains embedded in a porous bond matrix are known from WO00/59684 , which forms the basis for the preamble of claim 1.
  • performance properties of conventional bonded abrasives having vitrified bonds are limited by the nature of the bond, the composition of the abrasive grains and the presence and composition of material surrounding pore within the bond.
  • the properties of pores within the bond i.e., pore size, porosity, pore size distribution, microstructure of material surrounding pores
  • a composite body is provided according to claim 1.
  • a composite body can include a bond material that may include a ceramic material and a pore within the ceramic material.
  • the bond material may include a peripheral region at a surface defining the pore.
  • the peripheral region may extend for a depth into the bond material.
  • the peripheral region may include a first pore defining composition distinct from a composition of the ceramic material.
  • the first pore defining composition may have a melting point not less than a melting point of the composition of the ceramic material.
  • a composite body can include a bond material that may include a ceramic material and a pore within the ceramic material.
  • the bond material may include a region at a surface of the pore.
  • the region at a surface of the pore may include a first pore defining composition distinct from a composition of the ceramic material.
  • the first pore defining composition may have a first melting point (Tml) and the composition of the ceramic material has a second melting point (Tm2).
  • Tml first melting point
  • Tm2 second melting point
  • the differential melting point between the first melting point and the second melting point may be defined as [Tm1-Tm2].
  • the differential melting point may be at least about 0.5°C and not greater than about 1000°C.
  • a composite body can include a bond material that may include a ceramic material and a pore with-in the ceramic material.
  • the bond material may include a region of the bond material at a surface of the pore.
  • the region at the surface of the pore may include a first pore defining composition distinct from a composition of the ceramic material.
  • the first pore defining composition may have a first hardness (H1) and the composition of the ceramic material may have a second hardness (H2).
  • the first hardness may be not less than the second hardness.
  • a method of forming a composite body according to claim 13 includes providing a composite body mixture that includes a bond material precursor powder and a pore former comprising a first pore former composition. The method further includes forming the composite body mixture into a composite body comprising a bond material including a ceramic material and a region surrounding a pore in the bond material.
  • the ceramic material includes a composition and the region surrounding the pore includes a first pore defining composition.
  • the first pore defining composition has a melting point not less than a melting point of a composition of the ceramic material.
  • the composite bodies may include more than one component, including for example, a bond material and a pore contained within the bond material.
  • the composite bodies may be utilized in various applications, including for example abrasives (e.g., fixed abrasives), medical industries, building and construction industries, aerospace industries, and a combination thereof.
  • the composite body may be a bonded abrasive body including abrasive particles contained within a bond material, and pores contained within the bond material.
  • FIG. 1 includes a flow chart illustrating a method of forming a composite body in accordance with an embodiment.
  • a process 100 can be initiated at step 101 by providing a composite body mixture that may include a bond material precursor powder and a pore former, which may include at least a first pore former composition.
  • the composite body mixture may be a dry mixture.
  • the composite body mixture may be a wet mixture, such as, in the form of a slurry, which may facilitate formation of a particular shape of the body.
  • the composite body mixture may include other components, including, for example, abrasive particles, additives or a combination thereof.
  • the bond material precursor powder may include one or more powder components configured to be treated and formed into a bond material of the composite body.
  • forming of the composite body from a composite body mixture may include changing the bond material precursor powder to a bond material, which may include a ceramic material.
  • the bond material precursor powder may generally include a glass (amorphous) powder, such that not less than about 80 wt% of the glass is amorphous phase.
  • the glass powder can include a greater content of amorphous phase, such as, not less than about 90 wt% or even not less than about 95 wt% amorphous phase.
  • a glass powder can be completed by mixing a suitable proportion of raw materials and melting the mixture of raw materials to form a glass at high temperatures. After sufficient melting and mixing of the glass, the glass can be cooled (quenched) and crushed to a powder. The glass powder may be further processed, such as, by a milling process, to provide a glass powder having a suitable particle size distribution.
  • the glass powder may have an average particle size of not greater than about 100 microns. In a particular embodiment, the glass powder has an average particle size of not greater than 75 microns, such as, not greater than about 50 microns or even not greater than about 10 microns. However, the average particle size of the glass powder can be within a range of between about 5.0 microns and about 75 microns.
  • the composition of the glass powder may be described using the equation aM 2 O-bMO-cM 2 O 3 -dMO 2 .
  • the glass powder can include more than one metal oxide, such that the oxides are present together as a compound oxide material.
  • the glass powder can include metal oxide compounds having monovalent cations (1+), such as, those metal oxide compounds represented by the generic formula M 2 O.
  • Suitable metal oxide compositions represented by M 2 O can include compounds, such as, Li 2 O, Na 2 O, K 2 O, and Cs 2 O.
  • the glass powder may include other metal oxide compounds.
  • the glass powder may include metal oxide compounds having divalent cations (2+), such as, those metal oxide compounds represented by the generic formula MO.
  • Suitable metal oxide compounds represented by MO can include compounds such as, MgO, CaO, SrO, BaO, and ZnO.
  • the glass powder may include metal oxide compounds having trivalent cations (3+), particularly those metal oxide compounds represented by the generic formula M 2 O 3 .
  • Suitable metal oxide compounds represented by M 2 O 3 can include compounds such as, Al 2 O 3 , B 2 O 3 , Y 2 O 3 , Fe 2 O 3 , Bi 2 O 3 , and La 2 O 3 .
  • the glass powder can include metal oxide compounds having cations of a 4+ valence state, as represented by MO 2 .
  • MO 2 metal oxide compounds having cations of a 4+ valence state
  • suitable MO 2 compounds may include SiO 2 , TiO 2 , and ZrO 2 .
  • coefficients (a, b, c, and d) may be provided to indicate the amount (mol fraction) of each of the different types of metal oxide compounds (M 2 O, MO, M 2 O 3 , and MO 2 ) that can be present within the glass powder.
  • coefficient "a” generally represents the total amount of the M 2 O metal oxide compounds within the glass powder.
  • the total amount of M 2 O metal oxide compounds within the glass powder may be generally within a range between about 0.30 and about 0.0. According to a particular embodiment, the total amount of M 2 O metal oxide compounds may be present within a range of about 0.15 and about 0.0, and more particularly, within a range of about 0.10 and about 0.0.
  • the total amount (mol fraction) of such compounds can be defined by the coefficient "b".
  • the total amount of MO metal oxide compounds within the glass powder may be within a range between about 0.60 and about 0.0.
  • the amount of MO metal oxide compounds may be within a range of between about 0.45 and about 0.0, and more particularly, within a range of between about 0.35 and about 0.15.
  • the amount of M 2 O 3 metal oxide compounds containing a trivalent cation species within the glass powder may be represented by the coefficient "c".
  • the total amount (mol fraction) of M 2 O 3 oxide compounds may be generally within a range of between about 0.60 and about 0.0.
  • the amount of M 2 O 3 metal oxide compounds within the glass powder may be within a range of between about 0.40 and about 0.0, and more particularly, within a range of between about 0.30 and about 0.10.
  • MO 2 metal oxide compounds containing a 4+ cation species as described in the general equation aM 2 O-bMO-cM 2 O 3 -dMO 2 may be represented by the coefficient "d".
  • the total amount (mol fraction) of MO 2 oxide compounds within the glass powder may be within a range of between about 0.80 and about 0.20.
  • the amount of MO 2 metal oxide compounds within the glass powder may be within a range of between about 0.75 and about 0.30, and more particularly, within a range of between about 0.60 and about 0.40.
  • particular embodiments may utilize a glass powder that can include silicon dioxide (SiO 2 ) such that the glass powder may be a silicate-based composition.
  • the glass powder may include not greater than about 80 mol% silicon dioxide.
  • the glass powder may include not greater than about 70 mol% or even not greater than about 60 mol% silicon dioxide.
  • the amount of silicon dioxide in the glass powder may be not less than about 20 mol%.
  • the amount of silicon dioxide in the glass powder may be generally within a range of between about 30 mol% and about 70 mol%, and particularly within a range between about 40 mol% and about 60 mol%.
  • certain compositions of the glass powder include aluminum oxide (Al 2 O 3 ) particularly in addition to silicon dioxide, such that the glass powder may be an aluminum silicate.
  • Al 2 O 3 aluminum oxide
  • the glass powder can include not greater than about 60 mol% Al 2 O 3 .
  • the glass powder can include aluminum oxide in lesser amounts, such as, not greater than about 50 mol% or even not greater than about 40 mol%.
  • the glass powder may incorporate aluminum oxide within a range between about 5.0 mol% to about 40 mol%, and particularly within a range between about 10 mol% and about 30 mol%.
  • the glass powder can include at least one of magnesium oxide and lithium oxide in addition to silicon dioxide, and more particularly, in addition to silicon dioxide and aluminum oxide.
  • the amount of magnesium oxide within the glass powder may be generally not greater than about 45 mol%, such as, not greater than 40 mol% or even, not greater than 35 mol%.
  • the glass powder compositions having magnesium oxide may utilize an amount within a range between about 5 mol% and about 40 mol%, and particularly within a range between about 15 mol% and about 35 mol%.
  • Magnesium-containing aluminum silicate glasses may be referred to as MAS glasses having a magnesium aluminum silicate composition.
  • the glass powder can include lithium oxide.
  • the amount of lithium oxide within the glass powder may be generally not greater than about 45 mol%, such as, not greater than 30 mol% or even, not greater than 20 mol%.
  • the glass powder compositions having lithium oxide may utilize an amount within a range between about 1.0 mol% and about 20 mol%, and particularly within a range between about 5.0 mol% and about 15 mol%.
  • Lithium-containing aluminum silicate glasses may be referred to as LAS glasses having a lithium aluminum silicate composition.
  • the glass powder can include barium oxide.
  • the amount of barium oxide within the glass powder may be generally not greater than about 45 mol%, such as, not greater than 30 mol% or even, not greater than 20 mol%.
  • the glass powder compositions having barium oxide may utilize an amount within a range between about 0.1 mol% and about 20 mol%, and more particularly, within a range between about 1.0 mol% and about 10 mol%.
  • Barium-containing aluminum silicate glasses may be referred to as BAS glasses having a barium aluminum silicate composition.
  • the glass powder can include calcium oxide.
  • the amount of calcium oxide within the glass powder may be generally not greater than about 45 mol%, such as, not greater than 30 mol% or even, not greater than 20 mol%.
  • the glass powder compositions having calcium oxide may utilize an amount within a range between about 0.5 mol% and about 20 mol%, and particularly within a range between about 1.0 mol% and about 10 mol%.
  • calcium oxide may be present in systems utilizing other metal oxide compounds mentioned above, notably in combination with the MAS or BAS glasses.
  • the calcium oxide can form a compound oxide, for example a calcium magnesium aluminum silicate (CMAS) or calcium barium magnesium aluminum silicate (CBAS).
  • CMAS calcium magnesium aluminum silicate
  • CBAS calcium barium magnesium aluminum silicate
  • the glass powder can include other metal oxide compounds.
  • the glass powder may include boron oxide.
  • the amount of boron oxide within the glass powder may be not greater than about 45 mol%, such as, not greater than 30 mol% or even, not greater than 20 mol%.
  • the glass powder having boron oxide may utilize an amount within a range between about 0.5 mol% and about 20 mol%, and particularly within a range between about 2.0 mol% and about 10 mol%.
  • the glass powder can include other metal oxides, as described above, such as, for example, Na 2 O, K 2 O, Cs 2 O, Y 2 O 3 , Fe 2 O 3 , Bi 2 O 3 , La 2 O 3 , SrO, ZnO, TiO 2 , P 2 O 5 , and ZrO 2 .
  • Such metal oxides can be added as modifiers to control the properties and processability of the glass powder and the resulting bond material.
  • Such modifiers may be present in the glass powder in an amount of not greater than about 20 mol%.
  • such modifiers may be present in the glass powder in an amount of not greater than about 15 mol%, such as, not greater than about 10 mol%.
  • Glass powder compositions with modifiers may utilize an amount within a range between about 1.0 mol% and about 20 mol%, and more particularly, within a range between about 2.0 mol % and about 15 mol%.
  • the composite body mixture may include a pore former.
  • the pore former may be a component configured to create porosity in the finally-formed composite body.
  • the pore former may have a particular size and shape, which may facilitate formation of a particular size and shape of porosity within the finally-formed composite body.
  • the pore former may be obtained from readily-available, commercial sources.
  • the pore former can be formed independent of the composite body.
  • the process of forming a pore former can include obtaining a precursor pore forming agent of a suitable size and shape.
  • the precursor pore former agent may be hollow spheres of organic material, including for example polymer bubbles.
  • the process of forming a pore former can further include coating the precursor pore forming agent with a particular composition.
  • the precursor pore forming agent may be coated with a slurry comprising at least a first pore forming composition precursor material, which may be configured, upon further treatment, to combine with and/or convert the precursor pore forming agent to form the first pore former composition.
  • the process can continue by treating the coated precursor pore forming agent to form the pore former, which can include the first pore former composition.
  • Certain exemplary processes for treating the coated precursor forming agent may include heating of the coated precursor pore forming agent to a suitable temperature to volatilize a polymer component of the precursor pore forming agent and solidify or densify the first pore forming composition precursor material.
  • the process of heating can facilitate volatilization of the polymer material and solidification of the first pore former composition precursor material to form hollow spheres, wherein the walls may be made of the first pore former composition.
  • the process of treating can include a heating process and a controlled cooling process to facilitate the formation of pore formers, wherein the wall of the pore formers may be made of a first pore former composition, which may include a polycrystalline material.
  • the first pore former composition may include a ceramic material.
  • a ceramic material may refer to inorganic compositions, including, for example, a combination of a metal element and non-metal element.
  • a ceramic material may include materials having an amorphous phase, crystalline phase, polycrystalline phase, and a combination thereof.
  • the first pore former composition of the pore former may include a content of amorphous phase material, such as, a glassy material.
  • the first pore former composition of the pore former may include a polycrystalline material. Still, it will be appreciated that in certain instances, the first pore former composition of the pore former can include a combination of amorphous phase material and polycrystalline phase material.
  • the first pore former composition of the pore former can include a polycrystalline material including a crystalline material selected from the group consisting of cordierite, indialite, enstatite, sapphirine, anorthite, celsian, diopside, spinel, beta-spodumene, and a combination thereof.
  • FIG. 2 includes a cross-sectional view of a pore former in accordance with an embodiment.
  • the pore former 200 can include a body 201.
  • the body can be in the form of a hollow object having a void 202 contained within the interior of the body 201.
  • the pore former 200 can be in the shape of a hollow spheroid, generally having a spherical-like three-dimensional shape.
  • the pore former 200 can be in the form of a hollow spheroid, wherein the body 201 includes a wall 205, which defines the interior space 202.
  • the wall 205 of the body 201 may include the first pore former composition.
  • the wall 205 may have a particular thickness 203, such as, a thickness of not greater than about 200 ⁇ m.
  • the thickness 203 of the wall can be not greater than about 180 ⁇ m, not greater than about 150 ⁇ m, not greater than about 130 ⁇ m, not greater than about 100 ⁇ m or even not greater than about 80 ⁇ m.
  • the thickness 203 of the wall can be at least about 1 ⁇ m, such as, at least 5 ⁇ m or even at least about 10 ⁇ m. It will be appreciated that the thickness 203 of the wall 205 can be any value within a range between any of the minimum and maximum values noted above.
  • the amount of the pore former provided in the mixture may be not greater than about 35 vol%.
  • the mixture can include not greater than about 30 vol% of the pore former, such as, not greater than about 20 vol% or even not greater than about 15 vol% of the pore former.
  • the mixture can include an amount of pore former in a range of between about 1.0 vol%, and about 35 vol%, and more particularly, within a range between about 5.0 vol % and about 25 vol%.
  • the composite body mixture may further include abrasive particles.
  • the composite body mixture may include not less than about 25 vol% abrasive particles.
  • the mixture can include not less than about 40 vol% abrasive particles, such as, not less than about 45 vol% or even not less than about 50 vol% abrasive particles.
  • the amount of abrasive particles may be limited such that the composite body mixture can include not greater than about 60 vol% abrasive particles.
  • the abrasive particles within the mixture may be generally present in an amount within a range between about 30 vol% and about 55 vol%.
  • the abrasive particles include hard, abrasive materials, and particularly include superabrasive materials.
  • the abrasive particles may be superabrasive particles, such that they may be either diamond or cubic boron nitride (cBN).
  • the abrasive particles include cubic boron nitride, and more particularly, the abrasive particles consist essentially of cubic boron nitride.
  • the abrasive particles may generally have an average grain size of not greater than about 500 microns, such as, not greater than about 400 microns, not greater than about 300 microns, not greater than about 250 microns, not greater than about 200 microns, not greater than about 180 microns, not greater than about 160 microns, not greater than about 140 microns, not greater than about 120 microns, not greater than about 100 microns, not greater than about 80 microns, not greater than about 60 microns, not greater than about 40 microns or even not greater than about 20 microns.
  • an average grain size of not greater than about 500 microns, such as, not greater than about 400 microns, not greater than about 300 microns, not greater than about 250 microns, not greater than about 200 microns, not greater than about 180 microns, not greater than about 160 microns, not greater than about 140 microns, not greater than about 120 microns, not greater than about 100 microns, not greater than about 80 microns,
  • the abrasive particles may have an average grain size of at least about 1.0 micron, such as, at least about 5 microns, at least about 10 microns, at least about 15 microns, at least about 20 microns, at least about 25 microns, at least about 30 microns, at least about 35 microns, at least about 40 microns, at least about 60 microns, at least about 80 microns or even at least about 100 microns. It will be appreciated that the abrasive particles may have an average grain size of any value within a range between any of the minimum and maximum values noted above.
  • the abrasive particles may have a major component of cubic boron nitride.
  • a certain percentage of the abrasive particles which generally may be otherwise cubic boron nitride can be replaced with substitute abrasive particles, such as, aluminum oxide, silicon carbide, boron carbide, tungsten carbide, and zirconium silicate.
  • the amount of substitute abrasive particles may be generally not greater than about 40 vol% of the total abrasive particles, such as, not greater than about 25 vol% or even not greater than about 10 vol% for the total volume of the abrasive particles.
  • the composite body mixture may include not less than about 10 vol% bond material precursor powder, such as, not less than about 15 vol% bond material precursor powder. Still, the amount of bond material precursor powder may be limited, such that the mixture can include not greater than about 60 vol% bond material precursor powder, such as, not greater than about 50 vol% bond material precursor powder or even not greater than about 40 vol% bond material precursor powder. In particular, the mixture generally can include an amount of bond material precursor powder within a range between about 10 vol% and about 30 vol%.
  • the composite body mixture can include other additives, such as, a binder.
  • the binder may be an organic material. Suitable binder materials can include organic materials containing glycol (e.g., polyethylene glycol), dextrin, resin, glue or alcohol (e.g., polyvinyl alcohol) or combinations thereof.
  • the mixture can include not greater than about 15 vol% of a binder, such as, not greater than about 10 vol%. According to one particular embodiment, the binder may be provided in the mixture within a range between about 2.0 vol% and about 10 vol%.
  • the process may continue at step 102 by forming the composite body mixture into a composite body including a bond material.
  • the bond material may include a ceramic material and at least one pore within the bond material wherein a region of the bond material at a surface of the pore may include a first pore defining composition distinct from the ceramic material.
  • the first pore defining composition may be substantially the same as the first pore former composition.
  • the process of forming may include any suitable process, such as, molding, pressing, depositing, casting, extruding, heating, cooling, crystallization, melting, and a combination thereof.
  • step 102 may include forming the composite body mixture into a green article.
  • Forming of the mixture into a green article may include forming processes that give the green article the desired final contour or substantially the desired final contour.
  • the term "green article" refers to a piece that may be not fully processed (e.g., heat treatment).
  • the forming process may be a molding process.
  • step 102 may further include a pre-firing step.
  • the pre-firing step can include heating the green article to facilitating evolving volatiles (e.g., water and/or organic materials or pore formers).
  • heating of the mixture generally can include heating to a temperature of greater than about room temperature (22°C).
  • the pre-firing process can include heating the green article to a temperature of not less than about 100°C, such as, not less than about 200°C or even not less than about 300°C.
  • heating may be completed at a temperature of at least about 22°C, such as at least about 50 °C, at least about 100 °C, at least about 150 °C, at least about 200 °C, at least about 250 °C, at least about 300 °C, at least about 400 °C, at least about 500 °C, at least about 600 °C, at least about 700 °C, at least about 800 °C or even at least about 900°C.
  • heating may be completed at a temperature of not greater than about 1000°C, such as, not greater than about 950 °C, not greater than about 900 °C, not greater than about 850 °C, not greater than about 800 °C, not greater than about 700 °C, not greater than about 600 °C, not greater than about 500 °C, not greater than about 400 °C, not greater than about 300 °C, not greater than about 200 °C. It will be appreciated that heating may occur at a temperature within a range between any of the minimum and maximum values noted above.
  • step 102 may further include heating the composite body mixture to a temperature sufficient to change the bond material precursor powder to a three-dimensional matrix of bond material.
  • a process may include treating of the mixture at a temperature sufficient to melt a significant portion of the bond material precursor powder.
  • the process of treating, more particularly, heating of the mixture at a temperature may be at a temperature sufficient to maintain a substantially solid state of the first pore former composition.
  • Such a heating process may further limit the dissociation of the first pore former composition into the bond material.
  • the process may include treating the mixture at a temperature, wherein the bond material precursor powder has a viscosity less than a viscosity of the first pore former composition. In such instances, the bond material precursor powder may be converted to a more liquid state to facilitate flowing of the material over other components of the mixture and facilitate formation of a composite body in accordance with an embodiment.
  • heating the composite body mixture may include heating the mixture to a temperature below a melting point of the first pore former composition. More particularly, the process of heating may include heating the mixture to a temperature that may be above a melting point of the bond material precursor powder.
  • heating the composite body mixture may include heating the green article to a temperature of at least about 600 °C, such as, at least about 630 °C, at least about 650 °C, at least about 680 °C, at least about 700 °C, at least about 730 °C, at least about 750 °C, at least about 780 °C, at least about 800 °C, at least about 830 °C, at least about 850 °C, at least about 880 °C, at least about 900 °C, at least about 930 °C, at least about 950 °C, at least about 980 °C, at least about 1000 °C, at least about 1030 °C, at least about 1050 °C, at least about 1080 °C, at least about 1100 °C, at least about 1130 °C, at least about 1150 °C, at least about 1180 °C, at least about 1200 °C, at least about 1230 °C, at
  • heating the composite body mixture may include heating the green article to a temperature of not greater than about 1600 °C, such as, not greater than about 1580 °C, not greater than about 1550 °C, not greater than about 1530 °C, not greater than about 1500 °C, not greater than about 1480 °C, not greater than about 1450 °C, not greater than about 1430 °C, not greater than about 1400 °C, not greater than about 1380 °C, not greater than about 1350 °C, not greater than about 1330 °C, not greater than about 1300 °C, not greater than about 1280 °C, not greater than about 1250 °C, not greater than about 1230 °C, not greater than about 1200 °C, not greater than about 1180 °C, not greater than about 1150 °C, not greater than about 1150 °C, not greater than about 1130 °C, not greater than about 1100 °C, not greater than about 1080 °C, not
  • a controlled atmosphere can include a non-oxidizing atmosphere.
  • a non-oxidizing atmosphere can include an inert atmosphere, such as, one using a noble gas.
  • the atmosphere consists of nitrogen, such as, not less than about 90 vol% nitrogen.
  • Other embodiments utilize a greater concentration of nitrogen, such as, not less than about 95 vol% or even not less than 99.99 vol% of the atmosphere may be nitrogen.
  • the process of heating in a nitrogen atmosphere may begin with an initial evacuation of the ambient atmosphere to a reduced pressure of not greater than about 0.05 bar. In a particular embodiment, this process may be repeated such that the heating chamber may be evacuated numerous times. After the evacuation, the heating chamber can be purged with oxygen-free nitrogen gas.
  • heating may be carried out for a particular duration. As such, heating may be generally carried out for a duration of not less than about 10 minutes, such as, not less than about 60 minutes or even not less than about 240 minutes at the heating temperature. Generally, heating may be carried out for a duration between about 20 minutes to about 4 hours, and particularly between about 30 minutes and about 2 hours.
  • step 102 may further include a controlled cooling and crystallization process.
  • the controlled cooling and crystallization process may be conducted after a heating process. More particularly, the controlled cooling and crystallization process may be conducted after melting at least a portion of the bond material precursor powder to form a three-dimensional matrix of bond material comprising a ceramic material.
  • the use of a controlled cooling and crystallization process may facilitate formation of at least one polycrystalline phase within the bond material.
  • a controlled cooling process may be utilized to facilitate formation of at least one crystalline or polycrystalline phase within the first pore defining composition.
  • the ramp rate from the heating temperature can be controlled to facilitate crystallization of the bond material.
  • the cooling rate from the heating temperature may be not greater than about 30 °C/hr, such as, not greater than about 25 °C/hr or even not greater than about 20 °C/min. According to a particular embodiment, cooling may be undertaken at a rate of not greater than about 15 °C/hr.
  • the controlled cooling and crystallization process can include a hold process wherein the composite body may be held at a crystallization temperature above the glass transition temperature (T g ) of the bond material.
  • the composite body can be cooled to a temperature of not less than about 100°C above T g , such as, not less than about 200°C above T g or even not less than about 300°C above T g .
  • the crystallization temperature may be not less than about 800°C, such as, not less than about 900°C or even not less than about 1000°C.
  • the crystallization temperature may be within a range between about 900°C to about 1300°C, and more particularly, within a range between about 950°C to about 1200°C.
  • the composite body may be generally held at the crystallization temperature for a duration of not less than about 10 min.
  • the composite body may be held at the crystallization temperature for not less than about 20 min, such as, not less than about 60 min or even not less than about 2 hours.
  • Typical durations for holding the bonded abrasive at the crystallization temperature may be within a range between about 30 min to about 4 hours, and particularly within a range of about 1 hour to about 2 hours.
  • the atmosphere during this optional cooling and crystallization process may be the same as the atmosphere during the heating process and accordingly can include a controlled atmosphere, particularly an oxygen-free, nitrogen-rich atmosphere.
  • the composite body generally can include a degree of porosity that may be not less than about 5.0 vol% of the total volume of the composite body.
  • the amount of porosity may be more, such that the porosity may be not less than about 10 vol%, such as, not less than about 15 vol%, about 20 vol% or even, not less than about 30 vol% of the total volume of the bonded abrasive.
  • the amount of porosity may be limited, such that the porosity may be not greater than about 70 vol%, such as, not greater than about 60 vol% or even not greater than about 50 vol%.
  • the porosity of the composite body may be within a range of between about 20 vol% and about 50 vol%.
  • Such porosity may be generally a combination of both open and closed porosity.
  • the composite body mixture may include "natural porosity" or the existence of bubbles or pores within the mass of the mixture of abrasive grains, bonded material precursor powder, and other additives. Accordingly, this natural porosity can be maintained in the final composite body depending upon the forming techniques.
  • the natural porosity within the mixture in addition to the pore former, may be utilized and maintained throughout the forming and heating process to form a final composite body having the desired amount of porosity.
  • the natural porosity of the mixture may be not greater than about 40 vol%.
  • the natural porosity within the mixture may be less, such as, not greater than about 25 vol% or not greater than about 15 vol%.
  • the amount of natural porosity within the mixture may be within a range between about 5.0 vol% and about 25 vol%.
  • the average pore size may be generally not greater than about 500 microns, such as, not greater than about 500 microns, such as, not greater than about 400 microns, not greater than about 300 microns, not greater than about 250 microns, not greater than about 200 microns, not greater than about 180 microns, not greater than about 160 microns, not greater than about 140 microns, not greater than about 120 microns, not greater than about 100 microns, not greater than about 80 microns, not greater than about 60 microns, not greater than about 40 microns or even not greater than about 20 microns.
  • the composite body may have an average pore size of at least about 1.0 micron, such as, at least about 5 microns, at least about 10 microns, at least about 15 microns, at least about 20 microns, at least about 25 microns, at least about 30 microns, at least about 35 microns, at least about 40 microns, at least about 60 microns, at least about 80 microns or even at least about 100 microns. It will be appreciated that the composite body may have an average pore size of any value within a range between any of the minimum and maximum values noted above.
  • FIG. 3 includes a cross-sectional view of a portion of a composite body in accordance with an embodiment, as illustrated, the composite body 300 can include a body 301 including bond material 302 in a three-dimensional matrix and abrasive particles 303 contained within the three-dimensional matrix of bond material 302. As further illustrated, the composite body 300 can include at least one pore 304. In particular embodiments, a plurality of pores 304 may be dispersed throughout the bond material 302. In accordance with an embodiment, the pore 304 can include an interior surface 305 defining the pore within the bond material 302. As further illustrated, the surface, in particular interior surface 305 of the pore 304 can define a first pore defining composition, which may be essentially the same as the first pore forming composition. The first pore defining composition may be distinct from the composition of the ceramic material defining the bond material 302.
  • the region of the bond material 302 at a surface 305 of the pore 304 can define a first pore defining composition having a melting point not less than a melting point of the composition of the ceramic material defining the bond material 302.
  • the first pore defining composition can have a first melting point (Tml) and the composition of the ceramic material defining the bond material 302 can have a second melting point (Tm2).
  • , can be within a range between at least about 0.5°C and not greater than about 200°C.
  • the differential melting point between the first melting point and the second melting point can be at least about 1°C, such as, at least about 2°C, at least about 3°C, at least about 4°C, at least about 5°C, at least about 6°C, at least about 7°C, at least about 8°C, at least about 9°C, at least about 10°C, at least about 12°C, at least about 15°C, at least about 18°C, at least about 20°C, at least about 25°C, at least about 30°C, at least about 35°C, at least about 40°C, at least about 45°C, at least about 50°C, at least about 55°C, at least about 100 °C, at least about 200 °C, at least about 300 °C, at least about 400 °C, at least about 500 °C, at least about 600 °C, at least about 700 °C, at least about 800 °C or even at least about 900 °C.
  • the differential melting point can be not greater than about 1000 °C, such as, not greater than about 900 °C, not greater than about 800 °C, not greater than about 700 °C, not greater than about 600 °C, not greater than about 500 °C, not greater than about 400 °C, not greater than about 300 °C, not greater than about 200, not greater than about 190°C, not greater than about 180°C, not greater than about 170°C, not great than about 160°C, not greater than about 150°C, not greater than about 140°C, not greater than about 130°C, not greater than about 120°C, not greater than about 110°C, not greater than about 100°C, not greater than about 90°C, not greater than about 80°C, not greater than about 70°C, not greater than about 60°C or even not greater than about 50°C. It will be appreciated that the differential melting point can be any value within a range between any of the minimum and maximum temperatures noted above.
  • the first pore defining composition can have a melting point (Tml) of at least about 1100°C. In still other embodiments, the first pore defining composition can have a melting point that may be greater, such as, at least about 1200°C, at least about 1300°C or even at least about 1350°C. Still, in another non-limiting embodiment, the first pore defining composition can have a melting point of not greater than about 1800°C, such as, not greater than about 1700°C or even not greater than about 1600°C. It will be appreciated that the first pore defining composition can have a melting point of any value within a range between any of the minimum and maximum values noted above.
  • the composition of the ceramic material can have a particular melting point.
  • the composition of the ceramic material can have a melting point of at least about 1000°C, such as, at least about 1100°C, at least about 1200°C or even at least about 1300°C.
  • the composition of the ceramic material can have a melting point of not greater than about 1700°C, such as, not greater than about 1600°C or even not greater than about 1500°C. It will be appreciated that the composition of the ceramic material can have a melting point within a range between any of the above minimum and maximum values.
  • the first pore defining composition can have a first melting point (Tml) and the composition of the ceramic material can have a second melting point (Tm2), and a percent difference between the first melting point and the second melting point may be defined as a differential melting point percentage defined by the equation [
  • the differential melting point percentage can be at least about 1%, such as, at least about 2%, at least about 3%, at least about 5%, at least about 8%, at least about 10%, at least about 12%, at least about 15%, at least about 18%, at least about 20%, at least about 22%, at least about 25%, at least about 28% or even at least about 30%.
  • the differential melting point percentage can be not greater than about 99%, such as, not greater than about 90%, not greater than about 80%, not greater than about 70%, not greater than about 60%, not greater than about 50%, not greater than about 45%, not greater than about 40%, not greater than about 35%, not greater than about 30%, not greater than about 25%, not greater than about 20%, not greater than about 18%, not greater than about 15%, not greater than about 12%, not greater than about 10% or even not greater than about 8%. It will be appreciated that the differential melting point percentage can be any value within a range between any of the minimum and maximum percentages noted above.
  • the bond material 302 can include a peripheral region 306 extending around at least a portion of the surface 305 defining the pore 304. Furthermore, the peripheral region 306 can define a depth between the surface 305 and a distance into the bond material defined by the first pore defining composition. Notably, the first pore defining composition can be distinct from the composition of the ceramic material making up the bond material 302. In accordance with an embodiment, the depth 307 of the peripheral region 306 may be not greater than a diameter 308 of the pore as defined by the greatest distance between the interior surface 305 as viewed in two-dimension (e.g. through SEM or other optical micrograph).
  • the depth 307 of the peripheral region 306 can be greater than a diameter 308 of the pore. In still another alternative embodiment, the depth 307 of the peripheral region 306 may be substantially related to a wall thickness of the pore former. In particular instances, the depth 307 of the peripheral region 306 may be not greater than about 200 ⁇ m, such as, not greater than about 180 ⁇ m, not greater than about 150 ⁇ m, not greater than about 100 ⁇ m or even not greater than about 80 ⁇ m. Still, in other non-limiting embodiments, the depth 307 of the peripheral region 306 can be at least about 1 ⁇ m, such as, at least about 3 ⁇ m, at least about 5 ⁇ m or even at least about 10 ⁇ m.
  • the depth 307 of the peripheral region 306 can be any value within a range between any of the minimum and maximum values noted above. Furthermore, it will be appreciated the depth 307 of the peripheral region 306 may be an average depth 307 measured from a suitable sampling of multiple pores within the composite body to create a statistically significant average value.
  • the first pore defining composition can have a particular hardness, including, for example, a first hardness (H1) and the composition of the ceramic material can have a second hardness (H2).
  • the first hardness can be not less than the second hardness. More particularly, the first hardness may be different from the second hardness by at least about 1% based on the equation [
  • the difference in hardness between the first hardness and the second hardness can be greater, such as, at least about 2%, at least about 3%, at least about 5%, at least about 8%, at least about 10%, at least about 12%, at least about 15%, at least about 18%, at least about 20%, at least about 22%, at least about 25%, at least about 28%, at least about 30%, at least about 40%, at least about 50% or even at least about 60%.
  • the difference between the first hardness and the second hardness may be not greater than about 99%, such as, not greater than about 90%, not greater than about 80%, not greater than about 70%, not greater than about 60%, not greater than about 50%, not greater than about 45%, not greater than about 40%, not greater than about 35%, not greater than about 30%, not greater than about 25%, not greater than about 20%, not greater than about 18%, not greater than about 15%, not greater than about 12%, not greater than about 10% or even not greater than about 8%. It will be appreciated that the difference between the first hardness and the second hardness may be any value within a range between any of the minimum and maximum percentages noted above.
  • the first hardness can be at least about 400 GPa, such as, at least about 430 GPa, at least about 450 GPa, at least about 480 GPa, at least about 500 GPa, at least about 530 GPa, at least about 550 GPa, at least about 580 GPa, at least about 600 GPa, at least about 630 GPa, at least about 650 GPa, at least about 680 GPa, at least about 700 GPa, at least about 730 GPa, at least about 750 GPa, at least about 780 GPa, at least about 800 GPa, at least about 830 GPa, at least about 850 GPa, at least about 880 GPa, at least about 900 GPa, at least about 930 GPa, at least about 950 GPa, at least about 980 GPa, at least about 1000 GPa, at least about 1030 GPa, at least about 1050 GPa, at least about
  • the first hardness may be not greater than about 1250 GPa, such as, not greater than about 1200 GPa, not greater than about 1150 GPa, not greater than about 1100 GPa, not greater than about 1000 GPa, not greater than about 900 GPa, not greater than about 800 GPa or even not greater than about 700 GPa. It will be appreciated that the first hardness can be within a range between any of the minimum and maximum values noted above.
  • the second hardness can be least about 400 GP, such as, at least about 430 GPa, at least about 450 GPa, at least about 480 GPa, at least about 500 GPa, at least about 530 GPa, at least about 550 GPa, at least about 580 GPa, at least about 600 GPa, at least about 630 GPa, at least about 650 GPa, at least about 680 GPa, at least about 700 GPa, at least about 730 GPa, at least about 750 GPa, at least about 780 GPa or even at least about 800 GPa.
  • the second hardness may be not greater than about 800 GPa, not greater than about 750 GPa, not greater than about 700 GPa, not greater than about 650 GPa, not greater than about 600 GPa or even not greater than about 500 GPa. It will be appreciated that the second hardness can be within a range between any of the minimum and maximum values noted above.
  • the composition of the ceramic material may include a content of amorphous phase material, polycrystalline phase material, and a combination thereof.
  • the composition of the ceramic material may include a greater content of polycrystalline material as compared to the content of amorphous phase material.
  • the content of amorphous material may be greater than the content of crystalline or polycrystalline material.
  • the ceramic material may include not less than about 50 vol% polycrystalline ceramic phase. According to a particular embodiment, the ceramic material can include not less than about 75 vol% polycrystalline ceramic phase, such as, not less than about 80 vol% or even not less than about 90 vol%. According to a particular embodiment, the ceramic material may be comprised essentially of a polycrystalline ceramic phase. The polycrystalline ceramic phase of the ceramic material may be present in an amount between about 60 vol% and about 100 vol%.
  • the polycrystalline ceramic phase can include a plurality of crystallites or crystalline grains which have an average size of not less than about 0.05 microns.
  • the average crystallite size may be not less than about 1.0 micron, such as, not less than about 10 microns or even not less than about 20 microns.
  • the average crystallite size may be generally not greater than about 100 microns, such that the average crystallite size may be within a range between about 1.0 micron and 100 microns.
  • the composition of the crystallites of the polycrystalline ceramic phase can include silicon dioxide, aluminum oxide or a combination of both.
  • the crystallites of the polycrystalline ceramic phase can include crystals such as, beta-quartz, which can incorporate other metal oxides incorporated in the initial glass powder, such as, for example, Li 2 O, K 2 O, MgO, ZnO, and Al 2 O 3 , in a solid solution.
  • the polycrystalline ceramic phase can include an aluminum silicate phase.
  • the crystallites of the polycrystalline ceramic phase can include compound oxide crystals, such as, for example, cordierite, enstatite, sapphirine, anorthite, celsian, diopside, spinel, and beta-spodumene, wherein the beta-spodumene in particular may be found in a solid solution.
  • compound oxide crystals such as, for example, cordierite, enstatite, sapphirine, anorthite, celsian, diopside, spinel, and beta-spodumene, wherein the beta-spodumene in particular may be found in a solid solution.
  • the ceramic material may also include an amorphous phase.
  • the amorphous phase like the polycrystalline ceramic phase, can include silicon dioxide and aluminum oxide and additional metal oxide species that may be present within the original glass powder.
  • the amorphous phase may be present in an amount not greater than about 50 vol% of the total volume of the bond material.
  • an amorphous phase may be generally present in a minority amount, such that it may be present in an amount not greater than about 40 vol%, such as, not greater than about 30 vol% or less, such as, not greater than about 15 vol%.
  • an amorphous phase may be present in an amount of between about 0 vol% to about 40 vol%, and more particularly, within a range between about 5.0 vol% and about 20 vol%.
  • the first pore defining composition may include a particular content of crystalline material, including, for example, a first crystalline content (C1) and the composition of the ceramic material may include a particular content of crystalline material defined as a second crystalline content (C2).
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first crystalline content may be different than the second crystalline content. For example, in certain instances the first crystalline content may be greater than the second crystalline content. In still other embodiments, the first crystalline content may be less than the second crystalline content.
  • the first crystalline content can be different than the second crystalline content by at least about 1% based the equation [
  • the difference in crystalline content between the first crystalline content and second crystalline content may be greater, such as, at least about 2%, at least about 3%, at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80% or even at least about 90%.
  • the difference in crystalline content between the first crystalline content and second crystalline content may be not greater than about 99%, such as, not greater than about 90%, not greater than about 80%, not greater than about 70%, not greater than about 60%, not greater than about 50%, not greater than about 40%, not greater than about 30%, not greater than about 20%, not greater than about 10% or even not greater than about 5%. It will be appreciated the difference between the first crystalline content and second crystalline content may be any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may include a particular content of amorphous phase material, defined as a first amorphous content and a composition of the ceramic material may include a particular content of amorphous phase material, defined as a second amorphous content.
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first amorphous content can be different than the second amorphous content.
  • the first amorphous content may be greater than the second amorphous content.
  • the first amorphous content can be less than the second amorphous content.
  • the first amorphous content can be different than the second amorphous content by at least about 1% based upon the equation [
  • the difference in amorphous content between the first amorphous content and second amorphous content may be greater, such as, at least about 2%, at least about 3%, at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80% or even at least about 90%.
  • the difference in amorphous content between the first amorphous content and second amorphous content may be not greater than about 99%, such as, not greater than about 90%, not greater than about 80%, not greater than about 70%, not greater than about 60%, not greater than about 50%, not greater than about 40%, not greater than about 30%, not greater than about 20%, not greater than about 10% or even not greater than about 5%. It will be appreciated the difference between the first amorphous content and second amorphous content may be any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may be formed from a mixture having a particular composition to facilitate forming of the composite body in accordance with an embodiment.
  • the first pore defining composition can be formed from a mixture including at least about 30 wt% silicon dioxide (SiO 2 ) for a total weight of the mixture.
  • the content of SiO 2 may be greater, such as, at least about 32 wt% or even at least about 34 wt%.
  • the first composition may be formed from a mixture having not greater than about 50 weight % SiO 2 , such as, not greater than about 48 wt% or even not greater than about 46 wt% SiO 2 for the total weight of the first mixture.
  • the first pore defining composition may have a content of SiO 2 that may be distinct from the content of SiO 2 in the composition of the ceramic material of the bond material 302.
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first composition can be formed from a mixture including a first content of SiO 2 and the composition of the ceramic material can include a second content of SiO 2 different than the first content. The first content may be less than the second content.
  • the first content (SI) can be less than the second content (S2) by at least about 1% based on of the equation [I(S1-S2)
  • the first content can be less than the second content by at least about 2%, such as, at least 3%, at least about 4% or even at least about 5%.
  • the first content can be less than the second content by not greater than about 40%, such as, not greater than about 35% or even not greater than about 30%. It will be appreciated the difference in first content of SiO 2 and the second content of SiO 2 can be within a range between any of the above minimum and maximum percentages.
  • the first pore defining composition can be formed from a mixture comprising a particular content of aluminum oxide (Al 3 O 2 ).
  • Al 3 O 2 aluminum oxide
  • the first pore defining composition can be formed from a mixture including at least about 20 wt% Al 3 O 2 for a total weight of the mixture.
  • the content of Al 3 O 2 may be greater, such as, at least about 22 wt% or even at least about 23 wt% for a total weight of the mixture.
  • the first pore defining composition may include a content of Al 3 O 2 of not greater than about 38 wt%, such as, not greater than about 36 wt% or even not greater than about 34 weight % for the total weight of the mixture. It will be appreciated that the first pore defining composition may be formed from a mixture including a content of Al 3 O 2 of any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition can be formed from a mixture having a first content of Al 3 O 2 and the composition of the ceramic material making up the bond material 302 may be formed from a mixture having a second content of Al 3 O 2 , which may be different than the first content.
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first content can be greater than the second content.
  • the first content may be greater than the second content by at least about 1% based upon the equation [
  • the first content may be greater than the second content by at least about 2%, such as, at least about 3%, at least about 4% or even at least about 5%. Still, in another embodiment, the first content may be greater than the second content by not greater than about 40%, such as, not greater than about 35% or even not greater than about 30%. It will be appreciated that the first content may be greater than the second content by a percentage within a range between any of the minimum percentages and maximum percentages noted above.
  • the first pore defining composition can be formed from a mixture having a particular content of titanium dioxide (TiO 2 ).
  • TiO 2 titanium dioxide
  • the first pore defining composition may have not greater than about 0.05 wt% TiO 2 for a total weight of the mixture.
  • the total content of TiO 2 may be less, such as, not greater than about 0.04 wt%, not greater than about 0.02 weigh% or in some instances the first pore defining composition may essentially free of TiO 2 .
  • the first pore defining composition may be formed from a mixture having a first content of TiO 2
  • the composition of the ceramic material may be formed from a mixture having a second content of TiO 2
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first content and second content may be different relative to each other.
  • the first content may be less than the second content. More particularly, the first content can be less than the second content by at least about 1% based upon the equation [
  • the first content of TiO 2 can be less than the second content of TiO 2 by at least about 2%, such as, at least about 3%, at least about 10%, at least about 50%, at least about 80% or even at least about 90%.
  • the first pore defining composition may include a particular content of calcium oxide (CaO).
  • the first pore defining composition may be formed from a mixture including at least about 2 wt% CaO for a total weight of the mixture.
  • the first pore defining composition may be formed from a mixture including at least about 3 wt%, at least about 5 wt%, at least about 7 wt% or even at least about 8 wt% CaO for a total weight of the mixture.
  • the first pore defining composition can be formed from a mixture including not greater than about 20 wt%, such as, not greater than about 18 wt% or even not greater than about 16 wt% CaO. It will be appreciated that the first pore defining composition can be formed from a mixture including a content of CaO within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may include a content of CaO and SiO 2 , and more particularly, the first pore defining composition may be formed from a mixture having a ratio of CaO and SiO 2 (CaO/SiO 2 ) of at least about 0.1.
  • the first pore defining composition can be formed from a mixture having a CaO/SiO 2 ratio of at least about 0.3, such as, at least about 0.15 or even at least about 0.17.
  • the first pore defining composition may be formed from mixture having CaO/SiO 2 ratio that may be not greater than about 0.7, such as, not greater than about 0.6, not greater than about 0.5 or even not greater than about 0.45. It will be appreciated the first pore defining composition can be formed from a mixture having a CaO/SiO 2 ratio of any value within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition may be formed from a mixture having a particular content of CaO, defined by a first content of CaO and the composition of the ceramic material including the bond material 302 can be formed from a mixture having a particular second content of CaO.
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first content of CaO may be different than the second content of CaO.
  • the first content may be greater than the second content. More particularly, the first content may be greater than the second content by at least about 1% based upon the equation [
  • the first content of CaO may be greater than the second content of CaO by at least about 2%, such as, at least about 3%, at least about 4%, at least about 5%, at least about 10% or even at least about 15%. Still, in other non-limiting embodiments, the first content of CaO may be greater than the second content of CaO by not greater than about 99%, such as, not greater than about 95%. It will be appreciated that the first content of CaO may be greater than the second content of CaO by a percent of any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may include a particular content of cesium oxide (Cs 2 O).
  • the first pore defining composition may be formed from a mixture including at least about 2 wt% Cs 2 O for a total weight of the mixture.
  • the first pore defining composition may be formed from a mixture including at least about 3 wt%, such as, at least 5 wt% or even at least about 7 wt% Cs 2 O for the total weight of the mixture.
  • the first pore defining composition may be formed from a mixture including not greater than about 22 wt%, such as, not greater than about 20 wt% or even not greater than about 18 wt% Cs 2 O for the total weight of the mixture. It will be appreciated that the first pore defining composition can be formed from a mixture having a content of Cs 2 O of any value within a range between any of minimum and maximum percentages noted above.
  • the first pore defining composition can be formed from a mixture having a Cs 2 O/SiO 2 ratio of at least about 0.1 based upon the wt% of the respective components in the mixture used to form the first pore defining composition.
  • the first pore defining composition can be formed from a mixture having a Cs 2 O/SiO 2 ratio of at least about 0.13, such as, at least about 0.15.
  • the composition may be formed from a mixture having a Cs 2 O/SiO 2 ratio of not greater than about 0.7, such as, not greater than about 0.6 or even not greater than about 0.55. It will be appreciated that the first pore defining composition can be formed from a mixture having a Cs 2 O/SiO 2 ratio of any value within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition can be formed from a mixture having a first content of Cs 2 O and the composition of the ceramic material can be formed from a mixture having a second content of Cs 2 O.
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first content of Cs 2 O can be different than the second content of Cs 2 O. More particularly, the first content may be greater than the second content.
  • the first content of Cs 2 O can be greater than the second content of Cs 2 O by at least about 1% based upon the equation [
  • the first content of Cs 2 O can be greater than the second of Cs 2 O by at least about 2%, such as, at least about 3%, at least about 4%, at least about 5%, at least about 10%, at least about 15% or even at least about 20%.
  • the first content may be greater than the second content by not greater than about 90% or even not greater than about 95%. It will be appreciated that the first content may be different than the second content by any value within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition may include a particular content of barium oxide (BaO).
  • the first pore defining composition may be formed from a mixture including at least about 2 wt%, such as, at least about 3 wt%, at least about 5 wt% or even at least about 7 wt% BaO for a total weight of the mixture.
  • the first pore defining composition can be formed from a mixture having not greater than about 26 wt%, such as, not greater than about 24 wt% or even not greater than about 22 wt% BaO for the total weight of the mixture. It will be appreciated that the first pore defining composition can be formed from a mixture having a content of BaO of any value within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition may be formed from a mixture having a particular ratio of BaO to SiO 2 , for example, a BaO/SiO 2 ratio of at least about 0.1.
  • the first pore defining composition may be formed from a mixture having a BaO/SiO 2 ratio of at least about 0.15, such as, at least about 0.2.
  • the first pore defining composition may be formed from a mixture having BaO/SiO 2 ratio of not greater than about 0.8, such as, not greater than about 0.7 or even not greater than about 0.68. It will be appreciated that the first pore defining composition can be formed from a mixture having a BaO/SiO 2 ratio of any value within a range between any of the minimum and maximum values noted about.
  • the first pore defining composition can include a first content of BaO and the composition of the ceramic material may be defined by a second content of BaO.
  • the second content of BaO may be different than the first content of BaO.
  • the first content of BaO can be greater than the second content of BaO.
  • the first content of BaO can be greater than the second content of BaO by at least about 1% based upon the equation [
  • the first content of BaO may be greater than the second content by at least about 2%, such as, at least about 3%, at least about 4%, at least about 5%, at least about 10% or even at least about 15%. Still, in one non-limiting embodiment the first content of BaO can be greater than the second content of BaO by not the greater than about 99%, such as, not greater than about 95. It will be appreciated that the first content of BaO can be different than the second content of BaO by any value within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition may be formed from a mixture including a particular content of magnesium oxide (MgO).
  • MgO magnesium oxide
  • the first pore defining composition may be formed from a mixture including at least about 2 wt%, such as, at least about 3 wt%, at least about 5 wt% or even at least about 7 wt% MgO for a total weight of the mixture.
  • the first pore defining composition may be formed from a mixture including not greater than about 20 wt%, such as, not greater than about 18 wt% or even not greater than about 16 wt% MgO for a total weight of the mixture.
  • the first pore defining composition can include a content of MgO within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition can be formed from a mixture having a MgO/SiO 2 ratio of at least about 0.1% wherein the content of MgO and SiO 2 may be measured in wt% for the total weight of the mixture.
  • the first pore defining composition may be formed from a mixture MgO/SiO 2 ratio of at least about 0.13, such as, at least about 0.15.
  • the first pore defining composition may be formed from a mixture having a MgO/SiO 2 ratio of not greater than about 0.7, such as, not greater than about 0.6, not greater than about 0.5 or even not greater than about 0.45. It will be appreciated the first pore defining composition may be formed from a mixture having a MgO/SiO 2 ratio within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition can include a particular content of additives, including for example oxide-based additives such as, MgO, CaO, BaO, ZrO 2 , Cs 2 O.
  • the first pore defining composition may include only one additive of the group MgO and CaO.
  • the first pore defining composition may be formed from a mixture including MgO or alternatively CaO.
  • the first pore defining composition may be formed from a mixture that does not include both MgO and CaO.
  • the first pore defining composition may be formed from a mixture that can include one of a first group of additives that can consist essentially of CaO and BaO.
  • the first pore defining composition can include a second group of additives including, and more particularly, consisting essentially of MgO.
  • the first pore defining composition may be formed from either the first group of additives or the second group of additives, in particularly need not necessarily include both the first group of additives and the second group of additives.
  • the first pore defining composition may include only one of a first group of additives including, more particularly, consisting essentially of CaO, BaO, and ZrO 2 .
  • the first pore defining composition may include only a second group of additives including, more particularly, consisting essentially of MgO and Cs 2 O.
  • the first pore defining composition may include only one of the first group of additives or the second group of additives, but not both the first group and second group of additives.
  • the additives may not necessarily include other oxide species such as, SiO 2 , AlO 2 and the like.
  • the first pore defining composition may be formed from a mixture including a particular content of boron oxide (B 2 O).
  • B 2 O boron oxide
  • the first pore defining composition may be formed from a mixture including not greater than about 7 wt%, such as, not greater than about 6 wt%, not greater than about 5 wt% or even not greater than about 4 wt% B 2 O for a total weight of the mixture.
  • the first pore defining composition may be formed from a mixture including at least about 0.05 wt% B 2 O. it will be appreciated that the first pore defining composition may be formed from a mixture including a content of B 2 O of any value within a range of any of the minimum and maximum percentages notes above.
  • the first pore defining composition may include a particular content of ZrO 2 .
  • the first pore defining composition may be formed from a mixture including at least about 1 wt%, such as, at least about 1.5 wt%, at least about 2 wt% or even at least about 3wt% ZrO 2 for a total weight of the mixture.
  • the first pore defining composition may be formed from a mixture including not greater than about 10 wt%, such as, not greater than about 8 wt% or even not greater than about 6 wt% ZrO 2 for a total weight of the mixture. It will be appreciated that the first pore defining composition may be formed from a mixture including a content of ZrO 2 of any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may be formed from a mixture including a first content of ZrO 2 and the composition of the ceramic material including the bond material 302 may be formed from a second content of ZrO 2 .
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first content of ZrO 2 and the second content of ZrO 2 may be different with respect to each other.
  • the content of ZrO 2 may be measured as the wt% of ZrO 2 .
  • the first content may be greater than the second content, and more particularly, the first content may be greater than the second content by at least about 1% based upon the equation [
  • the first content of ZrO 2 can be greater than the second content of ZrO 2 by at least about 2%, such as, at least about 3%, at least about 4%, at least about 5%, at least about 10% or even at least about 15%.
  • the first content of ZrO 2 can be greater than the second content of ZrO 2 by not greater than about 99%, such as, not greater than about 95%. It will be appreciated that in certain instances, the first content of ZrO 2 can be greater than the second content of ZrO 2 by any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may be formed from a mixture having a particular content of sodium oxide (Na 2 O).
  • the first pore defining composition may be formed from a mixture of having a first content of Na 2 O and the composition of the ceramic material making up the bond material may be formed from a mixture having a second content of Na 2 O.
  • the measure of content may be according to weight percent (wt%) or volume percent (vol%) based upon the total weight or volume of the composition within the composite body.
  • the first content and second content of Na 2 O may be different with respect to each other. More particularly, the first content of Na 2 O may be less than the second content of Na 2 O.
  • the first content of Na 2 O can be less than the second content of Na 2 O by at least 1% based on the equation [
  • the first content of Na 2 O can be less than the second content of Na 2 O by at least about 2%, such as, at least about 3%, at least about 4%, at least about 5%, at least about 10% or even at least about 15%.
  • the first content of Na 2 O can be less than the second content of Na 2 O by not greater than about 99% or even not greater than about 95%. It will be appreciated that the first content can be less than the second content of Na 2 O by any value within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition may be formed from a mixture having a particular content of Na 2 O.
  • the first pore defining composition may be formed from a mixture having a content of Na 2 O of not great than about 5 wt%, such as, not greater than about 4 wt%, not greater than about 2 wt% or even not greater than about 1 wt% for the total weight of the mixture.
  • the first pore defining composition may be formed from a mixture that may be essentially free of Na 2 O.
  • the first pore defining composition may be formed from a mixture having a particular content of lithium oxide (Li 2 O).
  • the first pore defining composition may be formed from a mixture having a first content of Li 2 O and the composition of the ceramic material making up the bond material 302 may be formed from a mixture having a second content of Li 2 O based upon wt% of the materials in the mixture.
  • the first content of Li 2 O can be different than the second content of Li 2 O. More particularly, the first content of Li 2 O may be less than the second content of Li 2 O.
  • the first content of Li 2 O can be less than the second content of Li 2 O by at least 1% based upon the equation [
  • the first content of Li 2 O can be less than the second content of Li 2 O by at least about 2%, such as, at least about 3%, at least about 4%, at least about 5%, at least about 10% or even at least about 15%.
  • the first content of the Li 2 O can be less than the second content of Li 2 O by not greater than about 99%, such as, not greater than about 95%. It will be appreciated that the first content of Li 2 O can be less than the second content of Li 2 O by any value within a range between any of the minimum and maximum values noted above.
  • the first pore defining composition can be formed from a mixture having a particular content of Li 2 O. In one particular embodiment, the first pore defining composition can be formed from a mixture that may be essentially free of Li 2 O.
  • the first pore defining composition may be formed from a mixture having a particular content of iron oxide (Fe 2 O 3 ).
  • the first pore defining composition may be formed from a mixture having a first content of Fe 2 O 3 and the composition of the ceramic material making up the bond material 302 may be formed from a mixture having a second content of Fe 2 O 3 based upon the wt% of Fe 2 O 3 in the mixture.
  • the first content of Fe 2 O 3 may be different than the second content of Fe 2 O 3 . More particularly, the first content of Fe 2 O 3 may be less than the second content of Fe 2 O 3 .
  • the first content of Fe 2 O 3 can be less than the second content of Fe 2 O 3 by at least about 1% based upon the equation [
  • the first content of Fe 2 O 3 can be less than the second content of Fe 2 O 3 by at least about 2%, such as, at least about 3% at least about 4%, at least about 5%, at least about 10% or even at least about 15%.
  • the first content of Fe 2 O 3 can be less than the second content of Fe 2 O 3 by not greater than about 99% or even not greater than about 95%. It will be appreciated that the first content of Fe 2 O 3 may be less than the second content of Fe 2 O 3 by a percentage within a range between any of the minimum and maximum percentages noted above.
  • the first pore defining composition can be formed from a mixture having a particular content of Fe 2 O 3 .
  • the first pore defining composition may be formed from a mixture that may be essentially free of Fe 2 O 3 .
  • the first pore defining composition may include a particular content of phosphorous oxide (P 2 O 3 ).
  • the first pore defining composition may be formed from a mixture having a first content of P 2 O 3 of not greater than about 5 wt%, such as, not greater than about 4 wt%, not greater than about 2 wt% or even not greater than about 1 wt% for a total weight of the mixture.
  • the first pore defining composition may be formed from a mixture that may be essentially free of P 2 O 3 .
  • the abrasive grains generally comprise not less than about 25 vol% of the total volume of the composite body. According to embodiments, the abrasive grains generally comprise not less than about 35 vol%, such as, not less than about 45 vol% or even not less than about 50 vol% of the total volume of the final formed composite body. According to one particular embodiment, the abrasive grains comprise between about 35 vol% and about 60 vol% of the total volume of the final formed abrasive article.
  • the bond material may be present in an amount of not greater than about 60 vol% of the total volume of the final formed composite body.
  • the bonded abrasive generally can include not greater than about 50 vol% bond material, such as, not greater than about 40 vol% or even not greater than about 30 vol%. Accordingly, the bond material may be generally present within an amount of between about 10 vol% and about 30 vol% of the total volume of the final formed composite body.
  • the bond material can include those compounds and particularly the ratio of the compounds within the initial bond material precursor powder and glass powder as described above. That is, the bond material comprises substantially the same composition as that of the bond material precursor power and glass powder, notably this can include metal oxide compounds, particularly complex metal oxide compounds, and more particularly, silicate-based compositions, such as, for example, an aluminum silicate, MAS, LAS, BAS, CMAS or CBAS composition.
  • the thermal expansion coefficient of the bond material may be low, such as, not greater than about 80 ⁇ 10 -7 /K -1 .
  • the bond material has a thermal expansion coefficient not greater than about 60 ⁇ 10 -7 /K -1 , such as, not greater than about 50 ⁇ 10 -7 /K -1 or even not greater than about 40 ⁇ 10 -7 /K -1 .
  • the thermal expansion coefficient of the bond material may be within a range of between about 10 ⁇ 10 -7 /K -1 and about 80 ⁇ 10 -7 /K -1 .
  • the post-heating polycrystalline bond material generally has a flexural strength of not less than about 80 MPa.
  • the flexural strength of the bond material may be greater, such as, not less than about 90 MPa, not less than about 100 MPa or in some instances, not less than about 110 MPa.
  • the flexural strength of the bond material may be within a range of between about 90 MPa and about 150 MPa.
  • the post-heating polycrystalline bond material generally has a toughness of not less than about 0.8 MPa m 1/2 .
  • the toughness of the bond material can be greater, such as, not less than about 1.5 MPa m 1/2 or even not less than about 2.0 MPa m 1/2 .
  • the formed composite body has a modulus of rupture (MOR) of not less than about 20 MPa.
  • MOR modulus of rupture
  • the MOR can be greater, such as, not less than about 30 MPa or not less than about 40 MPa, such as, not less than about 50 MPa or even not less than about 60 MPa.
  • the MOR of the composite body may be not less than about 70 MPa, and may be within a range of between about 50 MPa and about 150 MPa.
  • the abrasive articles have a modulus of elasticity (MOE) of not less than about 40 GPa.
  • MOE may be not less than about 80 GPa, such as, not less than about 100 GPa, and even not less than about 140 GPa.
  • the MOE of the composite body may be within a range of between about 40 GPa and about 200 GPa, and particularly within a range between about 60 GPa and about 140 GPa.
  • FIGS. 4A, 4B and 5 illustrate the difference in appearance between pore forming material in conventional composite bodies and composite bodies that include pore forming material as shown in embodiments described herein.
  • FIGS. 4A and 4B illustrate a composite body 400 having a bond material 403, pores 404 within the bond material, and a pore defining region 406 of the bond material 403 surrounding the pores 404.
  • Pore defining region 406 shows the remnants of the pore formers, which were combined in a mixture with the bond material during the formation process.
  • the pore defining region 406 of a conventional composite body does not maintain demarcation of the original shape of the pore former, but rather the pore defining region merges into the bond material 403.
  • FIG. 5 illustrates a composite body 500 having a bond material 503, pores 504 within the bond material 503 and a pore defining region 506 of the bond material 503 surrounding the pores 504.
  • Pore defining region 506 shows the remnants of the pore formers, which were combined in a mixture with the bond material during the formation process.
  • the pore defining region 506 shows clear demarcation of the remnants of the original shape of the pore former, with little, if no, infiltration or mixture into the bond material.
  • the composite bodies provided herein exhibit improved grinding performance, particularly, improved composite body wear, free grinding behavior, power draw and lower forces per grit.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)

Claims (15)

  1. Verbundkörper (300, 500), umfassend:
    ein Bindungsmaterial (302, 503), das ein keramisches Material umfasst; und
    mindestens eine Pore (304, 504) innerhalb des keramischen Materials, wobei die Pore eine Oberfläche (305), einen Innenraum (202) und einen peripheren Bereich (306, 506) des Bindungsmaterials (302, 503) aufweist, der die Oberfläche (305) der mindestens einen Pore (304, 504) umgibt,
    wobei der periphere Bereich eine Tiefe zwischen der Oberfläche (305) der Pore und
    einem Abstand in das Bindungsmaterial definiert, dadurch gekennzeichnet, dass die Oberfläche (305) und der periphere Bereich (306, 506) durch eine erste porendefinierende Zusammensetzung definiert sind;
    wobei sich die erste porendefinierende Zusammensetzung von einer Zusammensetzung des keramischen Materials unterscheidet und einen Schmelzpunkt von nicht weniger als einem Schmelzpunkt der Zusammensetzung des keramischen Materials (302) aufweist.
  2. Verbundkörper nach Anspruch 1, wobei der Bindungsmaterialvorläufer ein Glaspulver umfasst, das eine durch die allgemeine Gleichung aM2O-bMO-cM2O3-dMO2 beschriebene Metalloxidverbindung umfasst, wobei die Menge (Molanteil) der Metalloxidverbindungen 0,30 > a > 0, 0,60 > b > 0, 0,50 > c > 0 und 0,80 > d > 0,20 umfasst.
  3. Verbundkörper nach Anspruch 1, wobei das keramische Material ein Material umfasst, das ausgewählt ist aus der Gruppe, bestehend aus einer amorphen Phase, einer polykristallinen Phase und einer Kombination davon.
  4. Verbundkörper nach Anspruch 1, wobei die erste porendefinierende Zusammensetzung einen ersten kristallinen Inhalt (C1) umfasst und das keramische Material einen zweiten kristallinen Inhalt (C2) umfasst, wobei sich der erste kristalline Inhalt von dem zweiten kristallinen Inhalt unterscheidet
  5. Verbundkörper nach Anspruch 1, wobei die erste porendefinierende Zusammensetzung einen ersten amorphen Inhalt (A1) umfasst und das keramische Material einen zweiten amorphen Inhalt (A2) umfasst, wobei sich der erste amorphe Inhalt von dem zweiten amorphen Inhalt unterscheidet.
  6. Verbundkörper nach einem der Ansprüche 1, wobei die erste porendefinierende Zusammensetzung einen Schmelzpunkt von mindestens etwa 1100 °C und nicht mehr als etwa 1800 °C umfasst und wobei die Zusammensetzung des keramischen Materials einen Schmelzpunkt von mindestens etwa 1000 °C und nicht mehr als etwa 1700 °C umfasst.
  7. Verbundkörper nach Anspruch 1, wobei die Tiefe der ersten porenbildenden Zusammensetzung nicht größer als ein Durchmesser der Pore ist.
  8. Verbundkörper nach Anspruch 1, wobei die erste porendefinierende Zusammensetzung eine erste Härte (H1) aufweist und die Zusammensetzung des keramischen Materials eine zweite Härte (H2) aufweist und wobei die erste Härte nicht geringer als die zweite Härte ist.
  9. Verbundkörper nach Anspruch 8, wobei sich die erste Härte von der zweiten Härte auf der Gleichung [|(H1 - H2)|/(0,5 ∗ (H1 + H2))] ∗ 100 % um mindestens etwa 1 % unterscheidet.
  10. Verbundkörper nach Anspruch 1, wobei die erste porendefinierende Zusammensetzung eine kristalline Phase umfasst, die ausgewählt ist aus der Gruppe, bestehend aus Cordierit, Indialit, Enstatit, Saphir, Anorthit, Celsian, Diopsid, Spinell, Beta-Spodumen und einer Kombination davon.
  11. Verbundkörper nach Anspruch 1, wobei die erste porendefinierende Zusammensetzung aus einer Mischung gebildet ist, die mindestens etwa 30 Gew.-% und nicht mehr als etwa 50 Gew.-% Siliziumdioxid (SiO2) eines Gesamtgewichts der Mischung umfasst.
  12. Verbundkörper nach Anspruch 1, wobei die erste porendefinierende Zusammensetzung aus einer Mischung gebildet ist, die mindestens etwa 20 Gew.-% und nicht mehr als etwa 38 Gew.-% Aluminiumoxid (Al3O2) eines Gesamtgewichts der Mischung umfasst.
  13. Verfahren zum Bilden eines Verbundkörpers nach Anspruch 1, umfassend:
    Bereitstellen einer Mischung, umfassend:
    ein Bindematerialvorläufer-Pulver; und
    einen Porenbildner (200) einschließlich eines Körpers (201) in Form eines hohlen Sphäroids, das eine Wand (205) aufweist, die einen Innenraum (202) definiert, und wobei die Wand (205) eine erste Porenbildnerzusammensetzung umfasst;
    Bilden der Mischung zu einem Grünkörper, Erwärmen des Grünkörpers auf eine Temperatur unterhalb eines Schmelzpunktes der ersten Porenbildnerzusammensetzung von mindestens etwa 600 °C und nicht mehr als etwa 1600 °C, um einen Verbundkörper (300, 500) zu bilden. umfassend ein Bindungsmaterial (302, 503) einschließlich eines keramischen Materials und einen Bereich (306, 506), der eine Pore (304, 504) in dem Bindungsmaterial umgibt, wobei das keramische Bindungsmaterial (302, 503) eine Zusammensetzung umfasst und der die Pore (306, 506) umgebende Bereich eine erste porendefinierende Zusammensetzung umfasst und wobei die erste porendefinierende Zusammensetzung einen Schmelzpunkt von nicht weniger als einem Schmelzpunkt einer Zusammensetzung des keramischen Bindungsmaterials (302, 503) aufweist.
  14. Verfahren nach Anspruch 13, wobei die Wand eine durchschnittliche Dicke von nicht mehr als etwa 200 Mikrometern und mindestens etwa 1 Mikrometer aufweist.
  15. Verfahren nach Anspruch 13, wobei die erste Porenbildnerzusammensetzung eine erste Härte (H1) aufweist und die Zusammensetzung des keramischen Materials eine zweite Härte (H2) aufweist und wobei die erste Härte nicht geringer als die zweite Härte ist.
EP14875911.1A 2013-12-30 2014-12-17 Verbundkörper und verfahren zur herstellung davon Active EP3089850B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL14875911T PL3089850T3 (pl) 2013-12-30 2014-12-17 Elementy kompozytowe i sposoby ich formowania

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201361922036P 2013-12-30 2013-12-30
PCT/US2014/070955 WO2015102914A1 (en) 2013-12-30 2014-12-17 Composite bodies and methods of forming the same

Publications (3)

Publication Number Publication Date
EP3089850A1 EP3089850A1 (de) 2016-11-09
EP3089850A4 EP3089850A4 (de) 2017-09-13
EP3089850B1 true EP3089850B1 (de) 2021-12-08

Family

ID=53480742

Family Applications (1)

Application Number Title Priority Date Filing Date
EP14875911.1A Active EP3089850B1 (de) 2013-12-30 2014-12-17 Verbundkörper und verfahren zur herstellung davon

Country Status (6)

Country Link
US (1) US20150183087A1 (de)
EP (1) EP3089850B1 (de)
CN (1) CN106029300B (de)
PL (1) PL3089850T3 (de)
TW (1) TWI513781B (de)
WO (1) WO2015102914A1 (de)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6578036B1 (ja) * 2018-04-06 2019-09-18 株式会社ノリタケカンパニーリミテド 均質構造の高気孔率ｃｂｎビトリファイド砥石
JP2020069610A (ja) * 2018-10-31 2020-05-07 株式会社ノリタケカンパニーリミテド 細溝加工用ビトリファイド研削砥石
JP7232908B2 (ja) * 2018-11-16 2023-03-03 コーニング インコーポレイテッド コージエライト含有セラミック体、バッチ組成物混合物、及びコージエライト含有セラミック体の製造方法
CN110948403A (zh) * 2019-12-20 2020-04-03 江西冠亿研磨股份有限公司 一种低温烧成陶瓷结合剂砂轮及其制造方法

Family Cites Families (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1211312C (zh) * 1996-07-01 2005-07-20 宇部兴产株式会社 陶瓷复合材料和多孔陶瓷材料及其生产方法
WO2000059684A1 (de) 1999-04-01 2000-10-12 Meister Schleifmittelwerk Ag Selbstschmierende abrasive werkzeuge und verfahren zu ihrer herstellung
US6319108B1 (en) * 1999-07-09 2001-11-20 3M Innovative Properties Company Metal bond abrasive article comprising porous ceramic abrasive composites and method of using same to abrade a workpiece
JP2002331461A (ja) * 2001-05-08 2002-11-19 Mizuho:Kk 超仕上げ用砥石
JP2003053668A (ja) * 2001-08-20 2003-02-26 Noritake Super Abrasive:Kk ビトリファイドボンド砥石
US6679758B2 (en) * 2002-04-11 2004-01-20 Saint-Gobain Abrasives Technology Company Porous abrasive articles with agglomerated abrasives
US6988937B2 (en) * 2002-04-11 2006-01-24 Saint-Gobain Abrasives Technology Company Method of roll grinding
JP2004009164A (ja) * 2002-06-04 2004-01-15 Musashi Seimitsu Ind Co Ltd 砥石部材及びその製造方法
JP2004042176A (ja) * 2002-07-10 2004-02-12 Noritake Super Abrasive:Kk 研削加工用レジノイド砥石
CN1173898C (zh) * 2003-05-30 2004-11-03 武汉理工大学 有机泡沫微球作为成孔剂的热压铸多孔陶瓷的制备方法
DE10331049B4 (de) * 2003-07-09 2010-04-08 Saint-Gobain Industriekeramik Rödental GmbH Verfahren zur Herstellung eines porösen Keramikkörpers, danach hergestellter poröser Keramikkörper und dessen Verwendung
TW200538237A (en) * 2004-04-06 2005-12-01 Kure Norton Co Ltd Porous vitrified grinding wheel and method for production thereof
KR101233129B1 (ko) * 2007-03-14 2013-02-15 생-고벵 아브라시프 연마지석 제품 및 그의 제조방법
WO2010075091A2 (en) * 2008-12-15 2010-07-01 Saint-Gobain Abrasives, Inc. Bonded abrasive article and method of use
JP5316053B2 (ja) * 2009-02-12 2013-10-16 日立工機株式会社 有気孔ビトリファイドボンド砥石及びその製造方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

Also Published As

Publication number Publication date
EP3089850A4 (de) 2017-09-13
EP3089850A1 (de) 2016-11-09
CN106029300A (zh) 2016-10-12
CN106029300B (zh) 2019-06-28
TW201525089A (zh) 2015-07-01
US20150183087A1 (en) 2015-07-02
PL3089850T3 (pl) 2022-03-21
TWI513781B (zh) 2015-12-21
WO2015102914A1 (en) 2015-07-09

Similar Documents

Publication Publication Date Title
CA2680713C (en) Bonded abrasive article and method of making
EP2132002B1 (de) Gebundener schleifartikel und herstellungsverfahren dafür
CA2777403C (en) Bonded abrasive article and method of forming
EP3089850B1 (de) Verbundkörper und verfahren zur herstellung davon
KR101528151B1 (ko) 결합된 연마 물품 및 생성 방법
MXPA02009304A (es) Herramientas abrasivas con aglomerante vitrificado.
KR20150002836A (ko) 결합된 연마 물품 및 생성 방법
KR101602638B1 (ko) 고속 연삭 작업용 연마 물품
KR20200050472A (ko) 실리콘 카바이드를 포함하는 비응집된 연마제 입자 및 무기 결합 재료를 포함하는 연마제 물품
KR20170040378A (ko) 고속 연삭 작업용 연마 물품
WO2024050006A1 (en) Abrasive agglomerates having cubic boron nitride, abrasive article including abrasive agglomerates including cubic boron nitride and methods of forming
JP2509379C (de)
CA2878017A1 (en) Bonded abrasive article and method of forming

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 20160722

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

DAX Request for extension of the european patent (deleted)
A4 Supplementary search report drawn up and despatched

Effective date: 20170816

RIC1 Information provided on ipc code assigned before grant

Ipc: B24D 3/18 20060101ALI20170809BHEP

Ipc: B24D 3/00 20060101AFI20170809BHEP

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS

17Q First examination report despatched

Effective date: 20190405

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: GRANT OF PATENT IS INTENDED

INTG Intention to grant announced

Effective date: 20210630

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE PATENT HAS BEEN GRANTED

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

REG Reference to a national code

Ref country code: GB

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: AT

Ref legal event code: REF

Ref document number: 1453396

Country of ref document: AT

Kind code of ref document: T

Effective date: 20211215

Ref country code: CH

Ref legal event code: EP

REG Reference to a national code

Ref country code: DE

Ref legal event code: R096

Ref document number: 602014081684

Country of ref document: DE

REG Reference to a national code

Ref country code: IE

Ref legal event code: FG4D

REG Reference to a national code

Ref country code: LT

Ref legal event code: MG9D

REG Reference to a national code

Ref country code: NL

Ref legal event code: MP

Effective date: 20211208

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: RS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: LT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: FI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: BG

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20220308

REG Reference to a national code

Ref country code: AT

Ref legal event code: MK05

Ref document number: 1453396

Country of ref document: AT

Kind code of ref document: T

Effective date: 20211208

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: NO

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20220308

Ref country code: LV

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: HR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: GR

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20220309

Ref country code: ES

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: NL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SM

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: SK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: RO

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: PT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20220408

Ref country code: EE

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: CZ

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

REG Reference to a national code

Ref country code: CH

Ref legal event code: PL

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: AT

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

REG Reference to a national code

Ref country code: DE

Ref legal event code: R097

Ref document number: 602014081684

Country of ref document: DE

REG Reference to a national code

Ref country code: BE

Ref legal event code: MM

Effective date: 20211231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: MC

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: IS

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20220408

PLBE No opposition filed within time limit

Free format text: ORIGINAL CODE: 0009261

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LU

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211217

Ref country code: IE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211217

Ref country code: DK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: AL

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

26N No opposition filed

Effective date: 20220909

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: SI

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

Ref country code: BE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: LI

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211231

Ref country code: CH

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211231

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IT

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211217

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: HU

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT; INVALID AB INITIO

Effective date: 20141217

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: CY

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208

P01 Opt-out of the competence of the unified patent court (upc) registered

Effective date: 20230530

REG Reference to a national code

Ref country code: DE

Ref legal event code: R082

Ref document number: 602014081684

Country of ref document: DE

Representative=s name: KRAUS & LEDERER PARTGMBB, DE

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: GB

Payment date: 20231121

Year of fee payment: 10

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: IT

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20211217

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: IT

Payment date: 20231121

Year of fee payment: 10

Ref country code: FR

Payment date: 20231122

Year of fee payment: 10

Ref country code: DE

Payment date: 20231121

Year of fee payment: 10

PGRI Patent reinstated in contracting state [announced from national office to epo]

Ref country code: IT

Effective date: 20220502

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: PL

Payment date: 20231127

Year of fee payment: 10

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: MK

Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT

Effective date: 20211208