EP3642295A1 - Articles abrasifs et leurs procédés de formation - Google Patents

Articles abrasifs et leurs procédés de formation

Info

Publication number
EP3642295A1
EP3642295A1 EP18821511.5A EP18821511A EP3642295A1 EP 3642295 A1 EP3642295 A1 EP 3642295A1 EP 18821511 A EP18821511 A EP 18821511A EP 3642295 A1 EP3642295 A1 EP 3642295A1
Authority
EP
European Patent Office
Prior art keywords
vol
bond
content
abrasive article
component
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.)
Pending
Application number
EP18821511.5A
Other languages
German (de)
English (en)
Other versions
EP3642295A4 (fr
Inventor
Naresh Saha
Varadharajan Ranganathan
Sabine Schmidt
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 claimed from PCT/US2018/037989 external-priority patent/WO2018236705A1/fr
Publication of EP3642295A1 publication Critical patent/EP3642295A1/fr
Publication of EP3642295A4 publication Critical patent/EP3642295A4/fr
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • 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
    • B24D3/34—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
    • B24D3/342—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent
    • 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
    • B24D3/06—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 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • 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
    • B24D3/06—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 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • B24D3/10—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 metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for porous or cellular structure, e.g. for use with diamonds as abrasives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1436—Composite particles, e.g. coated particles
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1436—Composite particles, e.g. coated particles
    • C09K3/1445—Composite particles, e.g. coated particles the coating consisting exclusively of metals

Definitions

  • the following is directed to an abrasive article and a method of forming an abrasive article. More particularly, the following is directed to an abrasive article including abrasive particles within a bond material.
  • Abrasive articles used in machining applications typically include bonded abrasive articles and coated abrasive articles.
  • Coated abrasive articles are generally layered articles having a backing and an adhesive coat to fix abrasive particles to the backing, the most common example of which is sandpaper.
  • Bonded abrasive articles consist of rigid, and typically monolithic, three-dimensional, abrasive composites in the form of wheels, discs, segments, mounted points, hones and other article shapes, which can be mounted onto a machining apparatus, such as a grinding, polishing or cutting apparatus.
  • Some bonded abrasive articles may be particularly useful in grinding, shaping or cutting certain types of workpieces, including for example, ceramic materials as used in refractory products.
  • an abrasive article may include a body.
  • the body may include a bond component and abrasive particles within the bond component.
  • the bond component may include a Fe-Co-Cu-Ni-Sn based bond material and a performance enhancing material.
  • the performance enhancing material may include hex-boron nitride. The content of the performance enhancing material may be at least about 6 vol.% and not greater than about 14 vol.% for a total volume of the bond component.
  • an abrasive article may include a body.
  • the body may include a bond component and abrasive particles within the bond component.
  • the bond component may include a Fe-Co-Cu-Ni-Sn based bond material and a performance enhancing material.
  • the performance enhancing material may include hex-boron nitride.
  • the body may include a hardness of at least about 50 HRB and not greater than about 85 HRB.
  • an abrasive article comprising a body.
  • the body may include a continuous bond material phase, abrasive particles within the continuous bond material phase and a discontinuous performance enhancing material phase dispersed within the continuous bond material phase.
  • the bond material phase may include a Fe-Co-Cu-Ni-Sn based bond material.
  • a hardness of the performance enhancing material phase H PEM p may be less than a hardness of the bond material phase 3 ⁇ 4 ⁇
  • a method of forming an abrasive article may include providing an abrasive article forming mixture, and forming the abrasive article forming mixture into the abrasive article.
  • the abrasive article forming mixture may include a bond forming mixture, and abrasive particles.
  • the bond forming mixture may include an unprocessed bond material and an unprocessed performance enhancing material.
  • the unprocessed bond material may include a Fe-Co-Cu-Ni-Sn based bond material.
  • the unprocessed performance enhancing material may include hex-boron nitride.
  • the content of the unprocessed performance enhancing material in the abrasive article forming mixture is at least about 6 vol.% and not greater than about 14 vol.% for a total volume of the bond forming mixture.
  • a method of forming an abrasive article may include providing an abrasive article forming mixture; and forming the mixture into the abrasive article.
  • the bond forming mixture may include an unprocessed bond material and an unprocessed performance enhancing material.
  • the unprocessed bond material may include a Fe-Co-Cu-Ni-Sn based bond material.
  • the unprocessed performance enhancing material may include hex-boron nitride.
  • the abrasive article may include a body and the body may have a hardness of at least about 50 HRB and not greater than about 85 HRB.
  • a method of forming an abrasive article may include providing an abrasive article forming mixture and forming the mixture into the abrasive article.
  • the abrasive article may include a continuous bond material phase, abrasive particles within the continuous bond material phase and a discontinuous performance enhancing material phase dispersed within the continuous bond material phase.
  • the bond material phase may include a Fe-Co-Cu-Ni-Sn based bond material.
  • a hardness of the performance enhancing material phase HPEMP may be less than a hardness of the bond material phase
  • FIG. 1 includes a flow chart illustrating a process for forming an abrasive article according to embodiments described herein;
  • FIG. 2 includes a plot showing the performance of an abrasive article formed according to embodiments described herein as compared to the performance of a comparative sample abrasive article;
  • FIG. 3 includes a plot showing the performance of an abrasive article formed according to embodiments described herein as compared to the performance of comparative sample abrasive articles;
  • FIG. 4 includes a plot showing the performance of an abrasive article formed according to embodiments described herein as compared to the performance of comparative sample abrasive articles;
  • FIGS. 5a and 5b include images of the micro structure of an abrasive article formed according to embodiments described herein;
  • FIGS. 6a and 6b include images of the micro structure of a comparative abrasive article.
  • Abrasive articles and techniques are disclosed that can be used for grinding, including for example, grinding of various workpieces, such as ceramics and glass.
  • abrasive articles described herein may be used for grinding refractory materials, and have been demonstrated to have improved performance, life, and efficiency over conventional grinding tools used in grinding refractory materials.
  • abrasive articles as described herein may include abrasive particles within a bond component.
  • the bond component may include a Fe- Co-Cu-Ni-Sn based bond material and a performance enhancing material.
  • the Fe-Co-Cu-Ni-Sn based bond material may be defined as bond material having a total content of iron (Fe), cobalt (Co), copper (Cu), nickel (Ni) and tin (Sn) that accounts for a majority of the total volume of the bond material, such as, at least about 50 vol.% for a total volume of the bond material.
  • the performance enhancing material may include hexagonal boron nitride (hBN). According to yet other embodiments, the performance enhancing material may consist essentially of hexagonal boron nitride.
  • FIG. 1 includes a flow chart illustrating a method of forming an abrasive article in accordance with embodiments described herein.
  • a process 100 can be initiated at step 101 by providing an abrasive article forming mixture containing abrasive particles and bond forming mixture.
  • the bond forming mixture may include an unprocessed bond material and an unprocessed performance enhancing material.
  • Reference herein to "unprocessed" materials refers to starting materials that may or may not necessarily undergo a chemical or physical change during processing.
  • the abrasive article forming mixture may include a particular content of the abrasive particles.
  • the abrasive article forming mixture may include an abrasive particle content of at least about 5 vol.% for a total volume of the abrasive article forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or at least about 12 vol.% or at least about 13 vol.% or even at least about 14 vol.%.
  • the abrasive article forming mixture may include an abrasive particle content of not greater than about 25 vol.%, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or not greater than about 19 vol.% or not greater than about 18 vol.% or not greater than about 17 vol.% or not greater than about 16 vol.% or even not greater than about 15 vol.%. It will be
  • the abrasive article forming mixture may include an abrasive particle content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the abrasive article forming mixture may include an abrasive particle content of any value within a range between any of the minimum and maximum values noted above.
  • the abrasive particles can include an inorganic material, such as a naturally occurring material (e.g., a mineral) or synthetically created composition.
  • a naturally occurring material e.g., a mineral
  • suitable inorganic materials may include oxides, carbides, nitrides, oxycarbides, oxynitrides, diamonds, other natural minerals or a combination thereof.
  • the abrasive particle may be cubic boron nitride (cBN), fused alumina, sintered alumina, silicon carbide, or mixtures thereof.
  • the abrasive particles may be a superabrasive material.
  • the abrasive material may include a material selected from the group consisting of diamond, cubic boron nitride, and a combination thereof.
  • the super abrasive material may consist essentially of diamond.
  • the super abrasive material may consist essentially of cubic boron nitride.
  • the super abrasive material may have a Mohs hardness of at least about 8, such as, at least about 8.5 or even at least about 9.
  • the abrasive particles may have a particular average particle size.
  • the abrasive particles may have an average particle size of at least about 100 microns, such as, at least about 150 microns or at least about 200 microns or at least about 250 microns or at least about 300 microns or at least about 350 microns or at least about 400 microns or even at least about 450 microns.
  • the abrasive particles may have an average particle size of not greater than about 1000 microns, such as, not greater than about 950 microns or not greater than about 900 microns or not greater than about 850 microns or not greater than about 800 microns or not greater than about 750 microns or not greater than about 700 microns or not greater than about 650 microns or not greater than about 600 microns or even not greater than about 550 microns. It will be appreciated that the abrasive particles may have an average particle size of any value between any of the minimum and maximum values noted above. It will be further appreciated that the abrasive particles may have an average particle size any value within a range between any of the minimum and maximum values noted above.
  • the abrasive particles may include a coating, which may facilitate formation and performance of the abrasive article.
  • the coating may be a metal coating, for example, nickel.
  • the coating may be iron oxide, a silane, such as, gamma amino propyl triethoxy silane, or even silica.
  • the coating of the abrasive particles may have a specific thickness.
  • the average thickness of the coating of the abrasive particles can be at least about 1.25 microns, such as, at least about 1.5 microns, at least about 1.75 microns, at least about 2.0 microns, at least about 2.25 microns, at least about 2.5 microns, or at least about 3.0 microns.
  • the average thickness can be limited, however, such as not greater than about 8.0 microns, not greater than about 7.5 microns, not greater than 7.0 microns, not greater than 6.5 microns, not greater than 6.0 microns, not greater than 5.5 microns, not greater than 5.0 microns, not greater than 4.5 microns, or not greater than 4.0 microns. It will be appreciated that the average thickness of the coating may be any value between any of the minimum and maximum values noted above. It will be further appreciated that the average thickness of the coating may be any value within a range between any of the minimum and maximum values noted above.
  • the coating of the abrasive particles can be formed to overlie specific portion of the exterior surface of the abrasive particle.
  • the coating may overly at least about 50% of the exterior surface area of the abrasive particle, such as, at least about 60%, at least about 70%, at least about 80%, at least about 90%, even at least about 95%, or essentially the entire exterior surface of the abrasive particles.
  • the coating may overly not greater than about 99% of the exterior surface area of the abrasive particle, such as, not greater than about 95%, not greater than about 90%, not greater than about 80%, not greater than about 70% or even not greater than about 60% of the exterior surface of the abrasive particles.
  • the coating may overly any percent of the abrasive particle between any of the minimum and maximum values noted above. It will be further appreciated that the coating may overly any percent of the abrasive particle within a range between any of the minimum and maximum values noted above.
  • the morphology of the abrasive particles may be described by an aspect ratio, which is a ratio between the dimensions of length to width. It will be appreciated that the length is the longest dimension of the abrasive particle and the width is the second longest dimension of a given abrasive particle.
  • the abrasive particles may have an aspect ratio (length: width) of not greater than about 2: 1 or even not greater than about 1.5: 1. In particular instances, the abrasive particles may be essentially equiaxed, such that they have an aspect ratio of approximately 1: 1.
  • the abrasive article forming mixture may include a particular content of the bond forming mixture.
  • the abrasive article forming mixture may include a bond forming mixture content of at least about 55 vol.% for a total volume of the abrasive article forming mixture, such as, at least about 58 vol.% or at least about 60 vol.% or at least about 63 vol.% or at least about 65 vol.% or at least about 68 vol.% or at least about 70 vol.% or at least about 73 vol.% or at least about 75 vol.% or at least about 78 vol.% or at least about 80 vol.% or at least about 83 vol.% or at least about 85 vol.% or at least about 88 vol.% or even at least about 90 vol.%.
  • the abrasive article forming mixture may include a bond forming mixture content of not greater than about 95 vol.%, such as, not greater than about 92 vol.% or not greater than about 90 vol.% or not greater than about 87 vol.% or not greater than about 85 vol.% or not greater than about 82 vol.% or not greater than about 80 vol.% or not greater than about 77 vol.% or not greater than about 75 vol.% or not greater than about 72 vol.% or not greater than about 70 vol.% or not greater than about 67 vol.% or even not greater than about 65 vol.%.
  • the abrasive article forming mixture may include a bond forming mixture content of any value between any of the minimum and maximum values noted above.
  • the abrasive article forming mixture may include a bond forming mixture content of any value within a range between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a particular content of the unprocessed bond material.
  • the bond forming mixture may include an unprocessed bond material content of at least about 60 vol.% for a total volume of the bond forming mixture, such as, at least about 63 vol.% or at least about 63 vol.% or at least about 68 vol.% or at least about 70 vol.% or at least about 73 vol.% or at least about 75 vol.% or at least about 78 vol.% or at least about 80 vol.% or at least about 83 vol.% or at least about 85 vol.% or at least about 88 vol.% or even at least about 90 vol.%.
  • the bond forming mixture may include an unprocessed bond material content of not greater than about 94 vol.%, such as, not greater than about 92 vol.% or not greater than about 90 vol.% or not greater than about 87 vol.% or not greater than about 85 vol.% or not greater than about 82 vol.% or not greater than about 80 vol.% or not greater than about 77 vol.% or not greater than about 75 vol.% or not greater than about 72 vol.% or not greater than about 70 vol.% or not greater than about 67 vol.% or even not greater than about 65 vol.%. It will be appreciated that the bond forming mixture may include an unprocessed bond material content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond forming mixture may include an unprocessed bond material content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed bond material may include an unprocessed Fe-Co-Cu-Ni-Sn based bond material.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material may be defined as an unprocessed bond material having a total content of iron (Fe), cobalt (Co), copper (Cu), nickel (Ni) and tin (Sn) that accounts for a majority of the total volume of the unprocessed bond material, such as, at least about 50 vol.% for a total volume of the bond material.
  • the bond forming mixture may include a particular content of iron (Fe).
  • the bond forming mixture may include an iron (Fe) content of at least about 30 vol.% for a total volume of the bond forming mixture, such as, at least about 35 vol.% or at least about 38 vol.% or at least about 40 vol.% or at least about 43 vol.% or at least about 45 vol.% or at least about 48 vol.% or even at least about 50 vol.%.
  • the bond forming mixture may include an iron (Fe) content of not greater than about 70 vol.% for a total volume of the bond forming mixture, such as, not greater than about 67 vol.% or not greater than about 65 vol.% or not greater than about 62 vol.% or not greater than about 60 vol.% or not greater than about 57 vol.% or even not greater than about 55 vol.%. It will be appreciated that the bond forming mixture may include an iron (Fe) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond forming mixture may include an iron (Fe) content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a particular content of iron (Fe).
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material may include an iron (Fe) content of at least about 30 vol.% for a total volume of the unprocessed Fe-Co-Cu-Ni-Sn based bond material, such as, at least about 35 vol.% or at least about 38 vol.% or at least about 40 vol.% or at least about 43 vol.% or at least about 45 vol.% or at least about 48 vol.% or even at least about 50 vol.%.
  • the unprocessed Fe- Co-Cu-Ni-Sn based bond material in the bond forming mixture may include an iron (Fe) content of not greater than about 70 vol.% for a total volume of the unprocessed Fe-Co-Cu- Ni-Sn based bond material, such as, not greater than about 67 vol.% or not greater than about 65 vol.% or not greater than about 62 vol.% or not greater than about 60 vol.% or not greater than about 57 vol.% or even not greater than about 55 vol.%.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include an iron (Fe) content of any value between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include an iron (Fe) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a particular content of cobalt (Co).
  • the bond forming mixture may include a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond forming mixture may include a cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond forming mixture, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%. It will be appreciated that the bond forming mixture may include a cobalt (Co) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond forming mixture may include a cobalt (Co) content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a particular content of cobalt (Co).
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material may include a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond forming mixture, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a cobalt (Co) content of any value between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a cobalt (Co) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a particular content of copper (Cu).
  • the bond forming mixture may include a copper (Cu) content of at least about 20 vol.% for a total volume of the bond forming mixture, such as, at least about 21 vol.% or at least about 22 vol.% or at least about 23 vol.% or at least about 24 vol.% or at least about 25 vol.% or at least about 26 vol.% or at least about 27 vol.% or at least about 28 vol.% or at least about 29 vol.% or even at least about 30 vol.%.
  • the bond forming mixture may include a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond forming mixture, such as, not greater than about 49 vol.% or not greater than about 48 vol.% or not greater than about 47 vol.% or not greater than about 46 vol.% or not greater than about 45 vol.% or not greater than about 44 vol.% or not greater than about 43 vol.% or not greater than about 42 vol.% or not greater than about 41 vol.% or even not greater than about 40 vol.%.
  • the bond forming mixture may include a copper (Cu) content of any value between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a copper (Cu) content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a particular content of copper (Cu).
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material may include a copper (Cu) content of at least about 20 vol.% for a total volume of the bond forming mixture, such as, at least about 21 vol.% or at least about 22 vol.% or at least about 23 vol.% or at least about 24 vol.% or at least about 25 vol.% or at least about 26 vol.% or at least about 27 vol.% or at least about 28 vol.% or at least about 29 vol.% or even at least about 30 vol.%.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond forming mixture, such as, not greater than about 49 vol.% or not greater than about 48 vol.% or not greater than about 47 vol.% or not greater than about 46 vol.% or not greater than about 45 vol.% or not greater than about 44 vol.% or not greater than about 43 vol.% or not greater than about 42 vol.% or not greater than about 41 vol.% or even not greater than about 40 vol.%.
  • Cu copper
  • the unprocessed Fe-Co-Cu- Ni-Sn based bond material in the bond forming mixture may include a copper (Cu) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a copper (Cu) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a particular content of nickel (Ni).
  • the bond forming mixture may include a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond forming mixture may include a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond forming mixture, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the bond forming mixture may include a nickel (Ni) content of any value between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a nickel (Ni) content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a particular content of nickel (Ni).
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material may include a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond forming mixture, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • Ni nickel
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a nickel (Ni) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the unprocessed Fe-Co- Cu-Ni-Sn based bond material in the bond forming mixture may include a nickel (Ni) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a particular content of tin (Sn).
  • the bond forming mixture may include a tin (Sn) content of at least about 5 vol.% for a total volume of the bond forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond forming mixture may include a tin (Sn) content of not greater than about 30 vol.% for a total volume of the bond forming mixture, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the bond forming mixture may include a tin (Sn) content of any value between any of the minimum and maximum values noted above.
  • the bond forming mixture may include a tin (Sn) content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a particular content of tin (Sn).
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material may include a tin (Sn) content of at least about 5 vol.% for a total volume of the bond forming mixture, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a tin (Sn) content of not greater than about 30 vol.% for a total volume of the bond forming mixture, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • Sn tin
  • the unprocessed Fe-Co-Cu-Ni-Sn based bond material in the bond forming mixture may include a tin (Sn) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the unprocessed Fe-Co-Cu- Ni-Sn based bond material in the bond forming mixture may include a tin (Sn) content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed bond material may be in the form of a bond powder.
  • the unprocessed bond particles in the bond powder may have an average diameter, for instance, of not more than 50 microns or even 40 microns or less.
  • the bond forming mixture may include a particular content of the unprocessed performance enhancing component.
  • the bond forming mixture may include an unprocessed performance enhancing component content of at least about 6 vol.% for a total volume of the bond forming mixture, such as, at least about 6.25 vol.% or at least about 6.5 vol.% or at least about 6.75 vol.% or at least about 7.0 vol.% or at least about 7.25 vol.% or at least about 7.5 vol.% or at least about 7.75 vol.% or even at least about 8.0 vol.%.
  • the bond forming mixture may include an unprocessed performance enhancing component content of not greater than about 14 vol.%, such as, not greater than about 13.75 vol.% or not greater than about 13.5 vol.% or not greater than about 13.25 vol.% or not greater than about 13.0 vol.% or not greater than about 12.75 vol.% or not greater than about 12.5 vol.% or not greater than about 12.25 vol.% or even not greater than about 12.0 vol.%. It will be appreciated that the bond forming mixture may include an unprocessed performance enhancing component content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond forming mixture may include an unprocessed performance enhancing component content of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed performance enhancing component may have a particular average particle size.
  • the unprocessed performance enhancing component may have an average particle size of at least about 10 microns, such as, at least about 10.1 microns or at least about 10.2 microns or at least about 10.3 microns or at least about 10.4 microns or at least about 10.5 microns or at least about 10.6 microns or at least about 10.7 microns or at least about 10.8 microns or at least about 10.9 microns or even at least about 11.0 microns.
  • microns or not greater than about the unprocessed performance enhancing component may have an average particle size of not greater than about 12 microns, such as, not greater than about 11.9 microns or not greater than about 11.8 microns or not greater than about 11.7 microns or not greater than about 11.6 microns or not greater than about 11.5 microns or not greater than about 11.4 microns or not greater than about 11.3 microns or not greater than about 11.2 or even not greater than about 11.1 microns. It will be appreciated that the unprocessed performance enhancing component may have an average particle size of any value between any of the minimum and maximum values noted above. It will be further appreciated that the unprocessed performance enhancing component may have an average particle size of any value within a range between any of the minimum and maximum values noted above.
  • the unprocessed performance enhancing component may include particles having a particular shape.
  • the particles of the performance enhancing component may have a spherical shape.
  • the particles of the performance enhancing component may have an agglomerate shape.
  • the particles of the performance enhancing component may have an irregular shape.
  • the particles of the performance enhancing component may have a platelet shape.
  • the particles of the performance enhancing component may have a dendritic shape.
  • the particles of the performance enhancing component may have a rod like shape.
  • the process may continue at step 102 by forming a bonded abrasive article from the abrasive article forming mixture, incorporating abrasive particles within the bond forming mixture.
  • the Abrasive article forming mixture may be formed into any desired three-dimensional shape of any desired size, for example, the mixture may be formed into wheels, discs, segments, mounted points, hones and other article shapes, which may be mounted onto a machining apparatus, such as a grinding or polishing apparatus.
  • the mixture may be formed into a bonded abrasive article using hot-pressing.
  • Hot-pressing of the mixture may be carried out at a temperature of at least about 750 °C, such as, at least about 800 °C, at least about 850 °C, at least about 900 °C, at least about 950 °C or even at least about 990 °C .
  • hot-pressing of the mixture may be carried out at a temperature of not greater than about 1000 °C, 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 750 °C or even not greater than about 710 °C. It will be appreciated that hot-pressing of the mixture may be carried out at any temperature within a range between any of the minimum and maximum values noted above.
  • hot-pressing of the mixture may be carried out at a pressure of at least about 0.5 tons/in 2 , such as, at least about 1.0 tons/in 2 , at least about 1.5 tons/in 2 , at least about 2.0 tons/in 2 , at least about 2.5 tons/in 2 or even a least about 2.9 tons/in .
  • hot-pressing of the mixture may be carried out at a temperature of not greater than about 3 tons/in 2 , not greater than about 2.5 tons/in 2 , not greater than about 2.0 tons/in 2 , not greater than about 1.5 tons/in 2 or even not greater than about 2.0 tons/in . It will be appreciated that hot-pressing of the mixture may be carried out at any pressure within a range between any of the minimum and maximum values noted above.
  • the mixture may be formed into a bonded abrasive article using cold-pressing.
  • Cold-pressing of the mixture may be carried out at a temperature of at least about 750 °C, such as, at least about 800 °C, at least about 850 °C, at least about 900 °C, at least about 950 °C or even at least about 990 °C .
  • cold-pressing of the mixture may be carried out at a temperature of not greater than about 1000 °C, 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 750 °C or even not greater than about 710 °C. It will be appreciated that cold-pressing of the mixture may be carried out at any temperature within a range between any of the minimum and maximum values noted above.
  • cold-pressing of the mixture may be carried out at a pressure of at least about 0.5 tons/in 2 , such as, at least about 1.0 tons/in 2 , at least about 1.5 tons/in 2 , at least about 2.0 tons/in 2 , at least about 2.5 tons/in 2 or even a least about 2.9 tons/in .
  • cold-pressing of the mixture may be carried out at a temperature of not greater than about 3 tons/in 2 , not greater than about 2.5 tons/in 2 , not greater than about 2.0 tons/in 2 , not greater than about 1.5 tons/in 2 or even not greater than about 2.0 tons/in . It will be appreciated that hot-pressing of the mixture may be carried out at any pressure within a range between any of the minimum and maximum values noted above.
  • the formed abrasive article may have a body having particular features.
  • the body of the abrasive article may include a bond component and abrasive particles within the bond component.
  • the body of the abrasive article may include a particular content of the abrasive particles.
  • the body of the abrasive article may include an abrasive particle content of at least about 5 vol.% for a total volume of the body of the abrasive article, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or at least about 12 vol.% or at least about 13 vol.% or even at least about 14 vol.%.
  • the body of the abrasive article may include an abrasive particle content of not greater than about 25 vol.%, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or not greater than about 19 vol.% or not greater than about 18 vol.% or not greater than about 17 vol.% or not greater than about 16 vol.% or even not greater than about 15 vol.%.
  • the body of the abrasive article may include an abrasive particle content of any value between any of the minimum and maximum values noted above.
  • the body of the abrasive article may include an abrasive particle content of any value within a range between any of the minimum and maximum values noted above.
  • the abrasive particles can include an inorganic material, such as a naturally occurring material (e.g., a mineral) or synthetically created composition.
  • a naturally occurring material e.g., a mineral
  • suitable inorganic materials may include oxides, carbides, nitrides, oxycarbides, oxynitrides, diamonds, other natural minerals or a combination thereof.
  • the abrasive particle may be cubic boron nitride (cBN), fused alumina, sintered alumina, silicon carbide, or mixtures thereof.
  • the abrasive particles may be a superabrasive material.
  • the abrasive material may include a material selected from the group consisting of diamond, cubic boron nitride, and a combination thereof.
  • the super abrasive material may consist essentially of diamond.
  • the super abrasive material may consist essentially of cubic boron nitride.
  • the super abrasive material may have a Mohs hardness of at least about 8, such as, at least about 8.5 or even at least about 9.
  • the abrasive particles may have a particular average particle size.
  • the abrasive particles may have an average particle size of at least about 100 microns, such as, at least about 150 microns or at least about 200 microns or at least about 250 microns or at least about 300 microns or at least about 350 microns or at least about 400 microns or even at least about 450 microns.
  • the abrasive particles may have an average particle size of not greater than about 1000 microns, such as, not greater than about 950 microns or not greater than about 900 microns or not greater than about 850 microns or not greater than about 800 microns or not greater than about 750 microns or not greater than about 700 microns or not greater than about 650 microns or not greater than about 600 microns or even not greater than about 550 microns. It will be appreciated that the abrasive particles may have an average particle size of any value between any of the minimum and maximum values noted above. It will be further appreciated that the abrasive particles may have an average particle size any value within a range between any of the minimum and maximum values noted above.
  • the abrasive particles may include a coating, which may facilitate formation and performance of the abrasive article.
  • the coating may be a metal coating, for example, nickel.
  • the coating may be iron oxide, a silane, such as, gamma amino propyl triethoxy silane, or even silica.
  • the coating of the abrasive particles may have a specific thickness.
  • the average thickness of the coating of the abrasive particles can be at least about 1.25 microns, such as, at least about 1.5 microns, at least about 1.75 microns, at least about 2.0 microns, at least about 2.25 microns, at least about 2.5 microns, or at least about 3.0 microns.
  • the average thickness can be limited, however, such as not greater than about 8.0 microns, not greater than about 7.5 microns, not greater than 7.0 microns, not greater than 6.5 microns, not greater than 6.0 microns, not greater than 5.5 microns, not greater than 5.0 microns, not greater than 4.5 microns, or not greater than 4.0 microns. It will be appreciated that the average thickness of the coating may be any value between any of the minimum and maximum values noted above. It will be further appreciated that the average thickness of the coating may be any value within a range between any of the minimum and maximum values noted above.
  • the coating of the abrasive particles can be formed to overlie specific portion of the exterior surface of the abrasive particle.
  • the coating may overly at least about 50% of the exterior surface area of the abrasive particle, such as, at least about 60%, at least about 70%, at least about 80%, at least about 90%, even at least about 95%, or essentially the entire exterior surface of the abrasive particles.
  • the coating may overly not greater than about 99% of the exterior surface area of the abrasive particle, such as, not greater than about 95%, not greater than about 90%, not greater than about 80%, not greater than about 70% or even not greater than about 60% of the exterior surface of the abrasive particles.
  • the coating may overly any percent of the abrasive particle between any of the minimum and maximum values noted above. It will be further appreciated that the coating may overly any percent of the abrasive particle within a range between any of the minimum and maximum values noted above.
  • the morphology of the abrasive particles may be described by an aspect ratio, which is a ratio between the dimensions of length to width. It will be appreciated that the length is the longest dimension of the abrasive particle and the width is the second longest dimension of a given abrasive particle.
  • the abrasive particles may have an aspect ratio (length: width) of not greater than about 2: 1 or even not greater than about 1.5: 1. In particular instances, the abrasive particles may be essentially equiaxed, such that they have an aspect ratio of approximately 1: 1.
  • the body of the abrasive article may include a particular content of the bond component.
  • the body of the abrasive article may include a bond component content of at least about 55 vol.% for a total volume of the body of the abrasive article, such as, at least about 58 vol.% or at least about 60 vol.% or at least about 63 vol.% or at least about 65 vol.% or at least about 68 vol.% or at least about 70 vol.% or at least about 73 vol.% or at least about 75 vol.% or at least about 78 vol.% or at least about 80 vol.% or at least about 83 vol.% or at least about 85 vol.% or at least about 88 vol.% or even at least about 90 vol.%.
  • the body of the abrasive article may include a bond component content of not greater than about 95 vol.%, such as, not greater than about 92 vol.% or not greater than about 90 vol.% or not greater than about 87 vol.% or not greater than about 85 vol.% or not greater than about 82 vol.% or not greater than about 80 vol.% or not greater than about 77 vol.% or not greater than about 75 vol.% or not greater than about 72 vol.% or not greater than about 70 vol.% or not greater than about 67 vol.% or even not greater than about 65 vol.%.
  • the body of the abrasive article may include a bond component content of any value between any of the minimum and maximum values noted above.
  • the body of the abrasive article may include a bond component content of any value within a range between any of the minimum and maximum values noted above.
  • the bond component may include a particular content of the bond material.
  • the bond component may include a bond material content of at least about 60 vol.% for a total volume of the bond component, such as, at least about 63 vol.% or at least about 63 vol.% or at least about 68 vol.% or at least about 70 vol.% or at least about 73 vol.% or at least about 75 vol.% or at least about 78 vol.% or at least about 80 vol.% or at least about 83 vol.% or at least about 85 vol.% or at least about 88 vol.% or even at least about 90 vol.%.
  • the bond component may include a bond material content of not greater than about 94 vol.%, such as, not greater than about 92 vol.% or not greater than about 90 vol.% or not greater than about 87 vol.% or not greater than about 85 vol.% or not greater than about 82 vol.% or not greater than about 80 vol.% or not greater than about 77 vol.% or not greater than about 75 vol.% or not greater than about 72 vol.% or not greater than about 70 vol.% or not greater than about 67 vol.% or even not greater than about 65 vol.%.
  • the bond component may include a bond material content of any value between any of the minimum and maximum values noted above.
  • the bond component may include a bond material content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material may include an Fe-Co-Cu- Ni-Sn based bond material.
  • the Fe-Co-Cu-Ni-Sn based bond material may be defined as a bond material having a total content of iron (Fe), cobalt (Co), copper (Cu), nickel (Ni) and tin (Sn) that accounts for a majority of the total volume of the bond material, such as, at least about 50 vol.% for a total volume of the bond material.
  • the bond component may include a particular content of iron (Fe).
  • the bond component may include an iron (Fe) content of at least about 30 vol.% for a total volume of the bond component, such as, at least about 35 vol.% or at least about 38 vol.% or at least about 40 vol.% or at least about 43 vol.% or at least about 45 vol.% or at least about 48 vol.% or even at least about 50 vol.%.
  • the bond component may include an iron (Fe) content of not greater than about 70 vol.% for a total volume of the bond component, such as, not greater than about 67 vol.% or not greater than about 65 vol.% or not greater than about 62 vol.% or not greater than about 60 vol.% or not greater than about 57 vol.% or even not greater than about 55 vol.%. It will be appreciated that the bond component may include an iron (Fe) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond component may include an iron (Fe) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a particular content of iron (Fe).
  • the Fe-Co-Cu- Ni-Sn based bond material may include an iron (Fe) content of at least about 30 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material, such as, at least about 35 vol.% or at least about 38 vol.% or at least about 40 vol.% or at least about 43 vol.% or at least about 45 vol.% or at least about 48 vol.% or even at least about 50 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include an iron (Fe) content of not greater than about 70 vol.% for a total volume of the Fe-Co-Cu- Ni-Sn based bond material, such as, not greater than about 67 vol.% or not greater than about 65 vol.% or not greater than about 62 vol.% or not greater than about 60 vol.% or not greater than about 57 vol.% or even not greater than about 55 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include an iron (Fe) content of any value between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include an iron (Fe) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond component may include a particular content of cobalt (Co).
  • the bond component may include a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond component, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond component may include a cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond component, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%. It will be appreciated that the bond component may include a cobalt (Co) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond component may include a cobalt (Co) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a particular content of cobalt (Co).
  • the Fe-Co- Cu-Ni-Sn based bond material may include a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond component, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the Fe- Co-Cu-Ni-Sn based bond material in the bond component may include a cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond component, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a cobalt (Co) content of any value between any of the minimum and maximum values noted above.
  • the Fe- Co-Cu-Ni-Sn based bond material in the bond component may include a cobalt (Co) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond component may include a particular content of copper (Cu).
  • the bond component may include a copper (Cu) content of at least about 20 vol.% for a total volume of the bond component, such as, at least about 21 vol.% or at least about 22 vol.% or at least about 23 vol.% or at least about 24 vol.% or at least about 25 vol.% or at least about 26 vol.% or at least about 27 vol.% or at least about 28 vol.% or at least about 29 vol.% or even at least about 30 vol.%.
  • the bond component may include a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond component, such as, not greater than about 49 vol.% or not greater than about 48 vol.% or not greater than about 47 vol.% or not greater than about 46 vol.% or not greater than about 45 vol.% or not greater than about 44 vol.% or not greater than about 43 vol.% or not greater than about 42 vol.% or not greater than about 41 vol.% or even not greater than about 40 vol.%.
  • the bond component may include a copper (Cu) content of any value between any of the minimum and maximum values noted above.
  • the bond component may include a copper (Cu) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a particular content of copper (Cu).
  • the Fe-Co- Cu-Ni-Sn based bond material may include a copper (Cu) content of at least about 20 vol.% for a total volume of the bond component, such as, at least about 21 vol.% or at least about 22 vol.% or at least about 23 vol.% or at least about 24 vol.% or at least about 25 vol.% or at least about 26 vol.% or at least about 27 vol.% or at least about 28 vol.% or at least about 29 vol.% or even at least about 30 vol.%.
  • the Fe-Co-Cu- Ni-Sn based bond material in the bond component may include a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond component, such as, not greater than about 49 vol.% or not greater than about 48 vol.% or not greater than about 47 vol.% or not greater than about 46 vol.% or not greater than about 45 vol.% or not greater than about 44 vol.% or not greater than about 43 vol.% or not greater than about 42 vol.% or not greater than about 41 vol.% or even not greater than about 40 vol.%.
  • Cu copper
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a copper (Cu) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a copper (Cu) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond component may include a particular content of nickel (Ni).
  • the bond component may include a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond component, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond component may include a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond component, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the bond component may include a nickel (Ni) content of any value between any of the minimum and maximum values noted above.
  • the bond component may include a nickel (Ni) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a particular content of nickel (Ni).
  • the Fe-Co-Cu- Ni-Sn based bond material may include a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond component, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the Fe-Co- Cu-Ni-Sn based bond material in the bond component may include a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond component, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • Ni nickel
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a nickel (Ni) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a nickel (Ni) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond component may include a particular content of tin (Sn).
  • the bond component may include a tin (Sn) content of at least about 5 vol.% for a total volume of the bond component, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond component may include a tin (Sn) content of not greater than about 30 vol.% for a total volume of the bond component, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the bond component may include a tin (Sn) content of any value between any of the minimum and maximum values noted above.
  • the bond component may include a tin (Sn) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a particular content of tin (Sn).
  • the Fe-Co-Cu-Ni- Sn based bond material may include a tin (Sn) content of at least about 5 vol.% for a total volume of the bond component, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the Fe-Co-Cu- Ni-Sn based bond material in the bond component may include a tin (Sn) content of not greater than about 30 vol.% for a total volume of the bond component, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • Sn tin
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a tin (Sn) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the Fe-Co-Cu-Ni-Sn based bond material in the bond component may include a tin (Sn) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond component may include a particular content of the performance enhancing component.
  • the bond component may include an performance enhancing component content of at least about 6 vol.% for a total volume of the bond forming mixture, such as, at least about 6.25 vol.% or at least about 6.5 vol.% or at least about 6.75 vol.% or at least about 7.0 vol.% or at least about 7.25 vol.% or at least about 7.5 vol.% or at least about 7.75 vol.% or even at least about 8.0 vol.%.
  • the bond component may include an performance enhancing component content of not greater than about 14 vol.%, such as, not greater than about 13.75 vol.% or not greater than about 13.5 vol.% or not greater than about 13.25 vol.% or not greater than about 13.0 vol.% or not greater than about 12.75 vol.% or not greater than about 12.5 vol.% or not greater than about 12.25 vol.% or even not greater than about 12.0 vol.%. It will be appreciated that the bond component may include a performance enhancing component content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond component may include an performance enhancing component content of any value within a range between any of the minimum and maximum values noted above.
  • the performance enhancing component may have a particular average particle size.
  • the performance enhancing component may have an average particle size of at least about 10 microns, such as, at least about 10.1 microns or at least about 10.2 microns or at least about 10.3 microns or at least about 10.4 microns or at least about 10.5 microns or at least about 10.6 microns or at least about 10.7 microns or at least about 10.8 microns or at least about 10.9 microns or even at least about 11.0 microns.
  • microns or not greater than about the performance enhancing component may have an average particle size of not greater than about 12 microns, such as, not greater than about 11.9 microns or not greater than about 11.8 microns or not greater than about 11.7 microns or not greater than about 11.6 microns or not greater than about 11.5 microns or not greater than about 11.4 microns or not greater than about 11.3 microns or not greater than about 11.2 or even not greater than about 11.1 microns. It will be appreciated that the performance enhancing component may have an average particle size of any value between any of the minimum and maximum values noted above. It will be further appreciated that the performance enhancing component may have an average particle size of any value within a range between any of the minimum and maximum values noted above.
  • the performance enhancing component may include particles having a particular shape.
  • the particles of the performance enhancing component may have a spherical shape.
  • the particles of the performance enhancing component may have an agglomerate shape.
  • the particles of the performance enhancing component may have an irregular shape. According to still other embodiments, the particles of the performance enhancing component may have a platelet shape. According to still other embodiments, the particles of the performance enhancing component may have a dendritic shape. According to still other embodiments, the particles of the performance enhancing component may have a rod like shape.
  • the body may include a particular content of porosity, which may be present through the entire volume of the body of the abrasive article.
  • the porosity may be open porosity.
  • the porosity may be closed porosity.
  • the porosity may be a combination of open porosity and closed porosity.
  • the body can have a porosity of at least about 2 vol.% for the total volume of the body, such as, at least about 3 vol.% or at least about 4 vol.% or at least about 5 vol.% or at least about 6 vol.% or at least about 7 vol.% or even at least about 8 vol.%.
  • the boy can have a porosity of not greater than about 20 vol.% porosity for a total volume of the body, such as, not greater than about 19 vol.% or not greater than about 18 vol.% or not greater than about 17 vol.% or not greater than about 16 vol.% or not greater than about 15 vol.% or not greater than about 14 vol.% or not greater than about 13 vol.% or even not greater than about 12 vol.%.
  • the body may include a porosity of any value between any of the minimum and maximum values noted above.
  • the body may include a porosity of any value within a range between any of the minimum and maximum values noted above.
  • the body may have a particular HRB hardness as measured according to ASTM E18-16.
  • the body may have a hardness of at least about 50 HRB, such as, at least about 52 HRB or at least about 55 HRB or at least about 58 HRB or at least about 60 HRB or at least about 63 HRB or even at least about 65 HRB.
  • the body may have a hardness of not greater than about 85 HRB, such as, not greater than about 82 HRB or not greater than about 80 HRB or not greater than about 78 HRB or not greater than about 75 HRB or not greater than about 73 HRB or even not greater than about 70 HRB. It will be appreciated that the body may have a hardness of any value between any of the minimum and maximum values noted above. It will be further appreciated that the body may have a hardness of any value within a range between any of the minimum and maximum values noted above.
  • the body may include phase material portion having specific phases.
  • the phase material portion of the body may include a bond material phase and a performance enhancing material phase dispersed within the bond material phase.
  • the bond material phase may be a continuous phase.
  • a continuous phase may be defined as defined regions of the phase material distributed throughout the body and interconnected to at least one other region of the same phase material.
  • the performance enhancing material phase may be a discontinuous phase.
  • a discontinuous phase may be defined as defined regions of the phase material distributed throughout the body and are not connected to each other.
  • the body of the abrasive article may include a particular content of the phase material portion.
  • the body of the abrasive article may include a phase material portion content of at least about 55 vol.% for a total volume of the abrasive article forming mixture, such as, at least about 58 vol.% or at least about 60 vol.% or at least about 63 vol.% or at least about 65 vol.% or at least about 68 vol.% or at least about 70 vol.% or at least about 73 vol.% or at least about 75 vol.% or at least about 78 vol.% or at least about 80 vol.% or at least about 83 vol.% or at least about 85 vol.% or at least about 88 vol.% or even at least about 90 vol.%.
  • the body of the abrasive article may include a phase material portion content of not greater than about 95 vol.%, such as, not greater than about 92 vol.% or not greater than about 90 vol.% or not greater than about 87 vol.% or not greater than about 85 vol.% or not greater than about 82 vol.% or not greater than about 80 vol.% or not greater than about 77 vol.% or not greater than about 75 vol.% or not greater than about 72 vol.% or not greater than about 70 vol.% or not greater than about 67 vol.% or even not greater than about 65 vol.%.
  • the body of the abrasive article may include a phase material portion content of any value between any of the minimum and maximum values noted above.
  • the body of the abrasive article may include a phase material portion content of any value within a range between any of the minimum and maximum values noted above.
  • the phase material portion may include a particular content of the bond material phase.
  • the phase material portion may include a bond material phase content of at least about 60 vol.% for a total volume of the phase material portion, such as, at least about 63 vol.% or at least about 63 vol.% or at least about 68 vol.% or at least about 70 vol.% or at least about 73 vol.% or at least about 75 vol.% or at least about 78 vol.% or at least about 80 vol.% or at least about 83 vol.% or at least about 85 vol.% or at least about 88 vol.% or even at least about 90 vol.%.
  • the phase material portion may include a bond material phase content of not greater than about 94 vol.%, such as, not greater than about 92 vol.% or not greater than about 90 vol.% or not greater than about 87 vol.% or not greater than about 85 vol.% or not greater than about 82 vol.% or not greater than about 80 vol.% or not greater than about 77 vol.% or not greater than about 75 vol.% or not greater than about 72 vol.% or not greater than about 70 vol.% or not greater than about 67 vol.% or even not greater than about 65 vol.%.
  • the phase material portion may include a bond material phase content of any value between any of the minimum and maximum values noted above.
  • the phase material portion may include a bond material phase content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material phase may include an Fe-Co- Cu-Ni-Sn based bond material.
  • the Fe-Co-Cu-Ni-Sn based bond material may be defined as a bond material phase having a total content of iron (Fe), cobalt (Co), copper (Cu), nickel (Ni) and tin (Sn) that accounts for a majority of the total volume of the bond material phase, such as, at least about 50 vol.% for a total volume of the bond material.
  • the bond material phase may include a particular content of iron (Fe).
  • the bond material phase may include an iron (Fe) content of at least about 30 vol.% for a total volume of the bond material phase, such as, at least about 35 vol.% or at least about 38 vol.% or at least about 40 vol.% or at least about 43 vol.% or at least about 45 vol.% or at least about 48 vol.% or even at least about 50 vol.%.
  • the bond material phase may include an iron (Fe) content of not greater than about 70 vol.% for a total volume of the bond material phase, such as, not greater than about 67 vol.% or not greater than about 65 vol.% or not greater than about 62 vol.% or not greater than about 60 vol.% or not greater than about 57 vol.% or even not greater than about 55 vol.%. It will be appreciated that the bond material phase may include an iron (Fe) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond material phase may include an iron (Fe) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a particular content of iron (Fe).
  • the Fe-Co- Cu-Ni-Sn based bond material may include an iron (Fe) content of at least about 30 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material, such as, at least about 35 vol.% or at least about 38 vol.% or at least about 40 vol.% or at least about 43 vol.% or at least about 45 vol.% or at least about 48 vol.% or even at least about 50 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include an iron (Fe) content of not greater than about 70 vol.% for a total volume of the Fe- Co-Cu-Ni-Sn based bond material, such as, not greater than about 67 vol.% or not greater than about 65 vol.% or not greater than about 62 vol.% or not greater than about 60 vol.% or not greater than about 57 vol.% or even not greater than about 55 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include an iron (Fe) content of any value between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include an iron (Fe) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material phase may include a particular content of cobalt (Co).
  • the bond material phase may include a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond material phase, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond material phase may include a cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond material phase, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%. It will be appreciated that the bond material phase may include a cobalt (Co) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the bond material phase may include a cobalt (Co) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a particular content of cobalt (Co).
  • the Fe- Co-Cu-Ni-Sn based bond material may include a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond material phase, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond material phase, such as, not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a cobalt (Co) content of any value between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a cobalt (Co) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material phase may include a particular content of copper (Cu).
  • the bond material phase may include a copper (Cu) content of at least about 20 vol.% for a total volume of the bond material phase, such as, at least about 21 vol.% or at least about 22 vol.% or at least about 23 vol.% or at least about 24 vol.% or at least about 25 vol.% or at least about 26 vol.% or at least about 27 vol.% or at least about 28 vol.% or at least about 29 vol.% or even at least about 30 vol.%.
  • the bond material phase may include a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond material phase, such as, not greater than about 49 vol.% or not greater than about 48 vol.% or not greater than about 47 vol.% or not greater than about 46 vol.% or not greater than about 45 vol.% or not greater than about 44 vol.% or not greater than about 43 vol.% or not greater than about 42 vol.% or not greater than about 41 vol.% or even not greater than about 40 vol.%.
  • the bond material phase may include a copper (Cu) content of any value between any of the minimum and maximum values noted above.
  • the bond material phase may include a copper (Cu) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a particular content of copper (Cu).
  • the Fe- Co-Cu-Ni-Sn based bond material may include a copper (Cu) content of at least about 20 vol.% for a total volume of the bond material phase, such as, at least about 21 vol.% or at least about 22 vol.% or at least about 23 vol.% or at least about 24 vol.% or at least about 25 vol.% or at least about 26 vol.% or at least about 27 vol.% or at least about 28 vol.% or at least about 29 vol.% or even at least about 30 vol.%.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond material phase, such as, not greater than about 49 vol.% or not greater than about 48 vol.% or not greater than about 47 vol.% or not greater than about 46 vol.% or not greater than about 45 vol.% or not greater than about 44 vol.% or not greater than about 43 vol.% or not greater than about 42 vol.% or not greater than about 41 vol.% or even not greater than about 40 vol.%.
  • Cu copper
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a copper (Cu) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a copper (Cu) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material phase may include a particular content of nickel (Ni).
  • the bond material phase may include a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond material phase, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond material phase may include a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond material phase, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the bond material phase may include a nickel (Ni) content of any value between any of the minimum and maximum values noted above.
  • the bond material phase may include a nickel (Ni) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a particular content of nickel (Ni).
  • the Fe-Co- Cu-Ni-Sn based bond material may include a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond material phase, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the Fe- Co-Cu-Ni-Sn based bond material in the bond material phase may include a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond material phase, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • Ni nickel
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a nickel (Ni) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a nickel (Ni) content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material phase may include a particular content of tin (Sn).
  • the bond material phase may include a tin (Sn) content of at least about 5 vol.% for a total volume of the bond material phase, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the bond material phase may include a tin (Sn) content of not greater than about 30 vol.% for a total volume of the bond material phase, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • the bond material phase may include a tin (Sn) content of any value between any of the minimum and maximum values noted above.
  • the bond material phase may include a tin (Sn) content of any value within a range between any of the minimum and maximum values noted above.
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a particular content of tin (Sn).
  • the Fe-Co- Cu-Ni-Sn based bond material may include a tin (Sn) content of at least about 5 vol.% for a total volume of the bond material phase, such as, at least about 6 vol.% or at least about 7 vol.% or at least about 8 vol.% or at least about 9 vol.% or at least about 10 vol.% or at least about 11 vol.% or even at least about 12 vol.%.
  • the Fe- Co-Cu-Ni-Sn based bond material in the bond material phase may include a tin (Sn) content of not greater than about 30 vol.% for a total volume of the bond material phase, such as, not greater than about 29 vol.% or not greater than about 28 vol.% or not greater than about 27 vol.% or not greater than about 26 vol.% or not greater than about 25 vol.% or not greater than about 24 vol.% or not greater than about 23 vol.% or not greater than about 22 vol.% or not greater than about 21 vol.% or not greater than about 20 vol.% or even not greater than about 19 vol.%.
  • Sn tin
  • the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a tin (Sn) content of any value between any of the minimum and maximum values noted above. It will be further appreciated that the Fe-Co-Cu-Ni-Sn based bond material in the bond material phase may include a tin (Sn) content of any value within a range between any of the minimum and maximum values noted above. According to yet other embodiments, the phase material portion may include a particular content of the performance enhancing material phase.
  • the phase material portion may include an performance enhancing material phase content of at least about 6 vol.% for a total volume of the phase material portion, such as, at least about 6.25 vol.% or at least about 6.5 vol.% or at least about 6.75 vol.% or at least about 7.0 vol.% or at least about 7.25 vol.% or at least about 7.5 vol.% or at least about 7.75 vol.% or even at least about 8.0 vol.%.
  • the phase material portion may include an performance enhancing material phase content of not greater than about 14 vol.%, such as, not greater than about 13.75 vol.% or not greater than about 13.5 vol.% or not greater than about 13.25 vol.% or not greater than about 13.0 vol.% or not greater than about 12.75 vol.% or not greater than about 12.5 vol.% or not greater than about 12.25 vol.% or even not greater than about 12.0 vol.%.
  • the phase material portion may include an performance enhancing material phase content of any value between any of the minimum and maximum values noted above.
  • the phase material portion may include an performance enhancing material phase content of any value within a range between any of the minimum and maximum values noted above.
  • the bond material phase may have a particular VHN hardness H BMP as measured according to ASTM E384.
  • the bond material phase may have a hardness of at least about 100 VHN, such as, at least about 102 VHN or at least about 105 VHN or at least about 107 VHN or at least about 110 VHN or at least about 112 VHN or at least about 115 VHN or at least about 117 VHN or even at least about 120 VHN.
  • the bond material phase may have a hardness of not greater than about 500 VHN, such as, not greater than about 490 VHN or not greater than about 480 VHN or not greater than about 475 VHN or not greater than about 470 VHN or not greater than about 465 VHN or not greater than about 460 VHN or not greater than about 455 VHN or even not greater than about 450 VHN.
  • the hardness of the bond material phase may be any value between any of the minimum and maximum values noted above. It will be further appreciated that the hardness of the bond material phase may be any value within a range between any of the minimum and maximum values noted above.
  • the performance enhancing material phase may have a particular VHN hardness H PEMP as measured according to ASTM E384.
  • the performance enhancing material phase may have a hardness of at least about 10 VHN, such as, at least about 12 VHN or at least about 15 VHN or at least about 17 VHN or at least about 20 VHN or at least about 22 VHN or at least about 25 VHN or at least about 27 VHN or even at least about 30 VHN.
  • the performance enhancing material phase may have a hardness of not greater than about 300 VHN, such as, not greater than about 290 VHN or not greater than about 280 VHN or not greater than about 270 VHN or not greater than about 260 VHN or not greater than about 250 VHN or not greater than about 240 VHN or not greater than about 230 VHN or not greater than about 220 VHN or not greater than about 210 VHN or even not greater than about 200 VHN.
  • the hardness of performance enhancing material phase may be any value between any of the minimum and maximum values noted above. It will be further appreciated that the hardness of the performance enhancing material phase may be any value within a range between any of the minimum and maximum values noted above.
  • the hardness of the performance enhancing material phase HPEMP may be less than the hardness of the bond material phase HBMP.
  • Embodiment 1 An abrasive article comprising a body, wherein the body comprises: a bond component; and abrasive particles within the bond component, wherein the bond component comprises a Fe-Co-Cu-Ni-Sn based bond material and a performance enhancing material, wherein the performance enhancing material comprises hexagonal boron nitride, and wherein a content of the performance enhancing material is at least about 6 vol.% and not greater than about 14 vol.% for a total volume of the bond component.
  • Embodiment 2 An abrasive article comprising a body, wherein the body comprises: a bond component; and abrasive particles within the bond component, wherein the bond component comprises a Fe-Co-Cu-Ni-Sn based bond material and a performance enhancing material, wherein the performance enhancing material comprises hexagonal boron nitride, and wherein the body comprises a hardness of at least about 50 HRB and not greater than about 85 HRB.
  • Embodiment 3 An abrasive article comprising a body, wherein the body comprises: a continuous bond material phase; abrasive particles within the continuous bond material phase; and a discontinuous performance enhancing material phase dispersed within the continuous bond material phase, wherein the bond material phase comprises an Fe-Co-Cu-Ni- Sn based bond material, and wherein a hardness of the performance enhancing material phase HpEMP is less than a hardness of the bond material phase H BMP -
  • Embodiment 4 A method of forming an abrasive article, wherein the method comprises: providing an abrasive article forming mixture, and forming the abrasive article forming mixture into the abrasive article, wherein the abrasive article forming mixture comprises a bond forming mixture, and abrasive particles, wherein the bond forming mixture comprises a unprocessed bond material and a unprocessed performance enhancing material, wherein the unprocessed bond material comprises a Fe-Co-Cu-Ni-Sn based bond material, wherein the unprocessed performance enhancing material comprises hexagonal boron nitride, and wherein a content of the unprocessed performance enhancing material in the abrasive article forming mixture is at least about 6 vol.% and not greater than about 14 vol.% for a total volume of the bond forming mixture.
  • Embodiment 5 A method of forming an abrasive article, wherein the method comprises: providing an abrasive article forming mixture; and forming the mixture into the abrasive article, wherein the bond forming mixture comprises an unprocessed bond material and an unprocessed performance enhancing material, wherein the unprocessed bond material comprises a Fe-Co-Cu-Ni-Sn based bond material, wherein the unprocessed performance enhancing material comprises hexagonal boron nitride, and wherein the abrasive article comprising a body having a hardness of at least about 50 HRB and not greater than about 85 HRB .
  • Embodiment 6 A method of forming an abrasive article, wherein the method comprises: providing an abrasive article forming mixture; and forming the mixture into the abrasive article, wherein the abrasive article comprises: a continuous bond material phase; abrasive particles within the continuous bond material phase; and a discontinuous
  • the bond material phase comprises an Fe-Co-Cu-Ni-Sn based bond material
  • a hardness of the performance enhancing material phase H PEMP is less than a hardness of the bond material phase H BMP -
  • Embodiment 7 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the performance enhancing component consists of hexagonal boron nitride.
  • Embodiment 8 The method of any one of embodiments 4, 5, and 6, wherein the unprocessed performance enhancing component consists of hexagonal boron nitride.
  • Embodiment 9 The composite film or method of any one of embodiments 2, 3, 4, 5, and 6, wherein a content of the performance enhancing component in the abrasive article is at least about 6 vol.% and not greater than about 14 vol.% for a total volume of the abrasive article.
  • Embodiment 10 The method of any one of embodiments 4, 5, and 6, wherein a content of the unprocessed performance enhancing component in the abrasive article forming mixture is at least about 6 vol.% and not greater than about 14 vol.% for a total volume of the bond forming mixture.
  • Embodiment 11 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the performance enhancing component has an average particle size of at least about 10 microns.
  • Embodiment 12 The method of any one of embodiments 4, 5, and 6, wherein the unprocessed performance enhancing component has an average particle size of at least about 10 microns.
  • Embodiment 13 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the performance enhancing component has an average particle size of not greater than about 12 microns.
  • Embodiment 14 The method of any one of embodiments 4, 5, and 6, wherein the unprocessed performance enhancing component has an average particle size of not greater than about 12 microns.
  • Embodiment 15 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the body has a hardness of at least about 50 HRB.
  • Embodiment 16 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the body has a hardness of not greater than about 85 HRB.
  • Embodiment 17 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article comprises a bond component content of at least about 55 vol.% for a total volume of abrasive article.
  • Embodiment 18 The method of any one of embodiments 4, 5, and 6, wherein the abrasive article forming mixture comprises a bond forming mixture content of at least about 55 vol.% for a total volume of abrasive article forming mixture.
  • Embodiment 19 The composite film or method of any one of one embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article comprises a bond component content of not greater than about 95 vol.% for a total volume of abrasive article.
  • Embodiment 20 The method of any one of embodiments 4, 5, and 6, wherein the abrasive article forming mixture comprises a bond forming mixture content of not greater than about 95 vol.% for a total volume of abrasive article forming mixture.
  • Embodiment 21 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article comprises an abrasive particle content of at least about 5 vol.% for a total volume of abrasive article.
  • Embodiment 22 The method of any one of embodiments 4, 5, and 6, wherein the abrasive article forming mixture comprises an abrasive particle content of at least about 5 vol.% for a total volume of abrasive article forming mixture.
  • Embodiment 23 The composite film or method of any one of embodiments 1, 2, 3,
  • abrasive article comprises an abrasive particle content of not greater than about 25 vol.% for a total volume of abrasive article.
  • Embodiment 24 The method of any one of embodiments 4, 5, and 6, wherein the abrasive article forming mixture comprises an abrasive particle content of not greater than about 25 vol.% for a total volume of abrasive article forming mixture.
  • Embodiment 25 The composite film or method of any one of embodiments 1, 2, 3, 4,
  • the abrasive article comprises porosity, wherein the porosity is
  • Embodiment 26 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article further comprises a porosity content of at least about 2 vol.% for a total volume of abrasive article.
  • Embodiment 27 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article further comprises a porosity content of not greater than about 20 vol.% for a total volume of abrasive article.
  • Embodiment 28 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises an iron (Fe) content of at least about 30 vol.% for a total volume of the bond component.
  • the bond component comprises an iron (Fe) content of at least about 30 vol.% for a total volume of the bond component.
  • Embodiment 29 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises an iron (Fe) content of at least about 30 vol.% for a total volume of the bond forming mixture.
  • Embodiment 30 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises an iron (Fe) content of not greater than about 70 vol.% for a total volume of the bond component.
  • Embodiment 31 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises an iron (Fe) content of not greater than about 70 vol.% for a total volume of the bond component.
  • Embodiment 32 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises an Fe content of at least about 30 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 33 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises an Fe content of at least about 70 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 34 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises an cobalt (Co) content of at least about 5 vol.% for a total volume of the bond component.
  • Co cobalt
  • Embodiment 35 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a cobalt (Co) content of at least about 5 vol.% for a total volume of the bond forming mixture.
  • Co cobalt
  • Embodiment 36 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises an cobalt (Co) content of not greater than about 25 vol.% for a total volume of the bond component.
  • Co cobalt
  • Embodiment 37 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises an cobalt (Co) content of not greater than about 25 vol.% for a total volume of the forming mixture.
  • Co cobalt
  • Embodiment 38 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises an Co content of at least about 5 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 39 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises an Co content of at least about 25 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 40 The composite film or method of any one of embodiments 1, 2, 3, 4,
  • the bond component comprises a copper (Cu) content of at least about 20 vol.% for a total volume of the bond component.
  • Embodiment 41 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a copper (Cu) content of at least about 20 vol.% for a total volume of the bond forming mixture.
  • Cu copper
  • Embodiment 42 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond component.
  • Embodiment 43 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a copper (Cu) content of not greater than about 50 vol.% for a total volume of the bond forming mixture.
  • Embodiment 44 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises a copper (Cu) content of at least about 20 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Cu copper
  • Embodiment 45 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises a copper (Cu) content of at least about 50 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Cu copper
  • Embodiment 46 The composite film or method of any one of embodiments 1, 2, 3, 4,
  • the bond component comprises a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond component.
  • Embodiment 47 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a nickel (Ni) content of at least about 5 vol.% for a total volume of the bond forming mixture.
  • Embodiment 48 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond component.
  • Embodiment 49 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a nickel (Ni) content of not greater than about 30 vol.% for a total volume of the bond forming mixture.
  • Embodiment 50 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises a nickel (Ni) content of at least about 5 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 51 The composite film or method of any one of embodiments 1, 2, 3, 4,
  • the Fe-Co-Cu-Ni-Sn based bond material comprises a nickel (Ni) content of at least about 30 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 52 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises a tin (Sn) content of at least about 2 vol.% for a total volume of the bond component.
  • the bond component comprises a tin (Sn) content of at least about 2 vol.% for a total volume of the bond component.
  • Embodiment 53 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a tin (Sn) content of at least about 2 vol.% for a total volume of the bond forming mixture.
  • Embodiment 54 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the bond component comprises a tin (Sn) content of not greater than about 20 vol.% for a total volume of the bond component.
  • Embodiment 55 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a tin (Sn) content of not greater than about 20 vol.% for a total volume of the bond forming mixture.
  • Embodiment 56 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe-Co-Cu-Ni-Sn based bond material comprises a tin (Sn) content of at least about 2 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 57 The composite film or method of any one of embodiments 1, 2, 3, 4,
  • the Fe-Co-Cu-Ni-Sn based bond material comprises a tin (Sn) content of at least about 20 vol.% for a total volume of the Fe-Co-Cu-Ni-Sn based bond material.
  • Embodiment 58 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive particles comprise diamond, wherein the abrasive particles comprise cubic boron nitride (cBN), wherein the abrasive particles consists of diamond, wherein the abrasive particles consists of cubic boron nitride (cBN).
  • cBN cubic boron nitride
  • Embodiment 59 The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive particles have an average particle size of at least about 100 microns.
  • Embodiment 60 The composite film or method of any one of embodiments 1, 2, 3, 4,
  • abrasive particles have an average particle size of not greater than about 1000 microns.
  • a sample abrasive article S 1 were formed according to embodiments described herein and compared to a comparative sample abrasive article CS 1.
  • Sample abrasive article S I and comparative sample abrasive article CS 1 were formed from the abrasive article forming mixtures provided in Table 1 below. Table 1
  • Table 1 The mixtures described in Table 1 were formed into sample abrasive articles. All sample abrasive articles were tested to compare grinding performance by measuring the power draw of each article of each sample. The grinding test was conducted according to parameters as provided in Table 2 below. Table 2 - Grinding Test Parameters
  • FIG. 2 is graph showing the average power drawn per grind cycle for each sample abrasive wheel. As shown in FIG. 2, when compared to comparative sample 1 (i.e., an abrasive wheel with no hBN added as a performance enhancing component), the sample abrasive articles S 1 formed according to embodiments described herein, showed improved power draw.
  • comparative sample 1 i.e., an abrasive wheel with no hBN added as a performance enhancing component
  • sample abrasive article S2 were formed according to embodiments described herein and compared to comparative sample abrasive articles CS2 and CS3.
  • Sample abrasive article S I and comparative sample abrasive articles CS2 and CS3 were formed from the abrasive article forming mixtures provided in Table 3 below.
  • FIG. 3 is graph showing the normalized average wear for each sample abrasive wheel. As shown in FIG. 3, the average wear experienced by each abrasive article increases (i.e., the wheel life decreases) as to concentration of hBN increases.
  • FIG. 4 is a graph showing the average power drawn over time for each sample abrasive wheel. As shown in FIG. 4, the average power drawn shown for each abrasive article decreases (i.e., wheel grinding performance improves) as to concentration of hBN increases.
  • Sample S3 and comparative sample CS4 were formed from the bond component mixtures provided in Table 5 below. Table 5
  • FIG. 5 includes multiple images of the microstructure of sample abrasive article S3.
  • FIG. 6 includes multiple images of the microstructure of comparative sample abrasive article CS4.
  • hBN creates a microstructure with multiple imperfections, discontinuities and ruptured sites.
  • the microstructure of sample abrasive article S3 shows that the presence of hBN causes the bond matrix to becoming more brittle and thus more wearable, which improves grinding performance.
  • the present application represents a departure from the state of the art.
  • the embodiments herein demonstrate improved and unexpected performance over abrasive articles formed according to conventional methods. While not wishing to be bound to a particular theory, it is suggested that the combination of certain features including processes, materials, and the like may facilitate such improvements.
  • the combination of features can include, but is not limited to, a composition that includes a particular concentration of hBN, which acts as a performance enhancing component of the abrasive article and balancing the hardness of the bond material phase in the abrasive article as compared to the hardness of the performance enhancing component phase of the abrasive article.

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

Abstract

La présente invention concerne un article abrasif qui peut comprendre un corps. Le corps peut comprendre un composant de liaison et des particules abrasives à l'intérieur du composant de liaison. Le composant de liaison peut comprendre un matériau de liaison à base de Fe-Co-Cu-Ni-Sn et un matériau d'amélioration des performances. Le matériau d'amélioration des performances peut comprendre du nitrure de bore hexagonal. La teneur du matériau d'amélioration des performances peut être d'au moins environ 6 % en volume et non supérieur à environ 14 % en volume pour un volume total du composant de liaison.
EP18821511.5A 2017-06-19 2018-06-18 Articles abrasifs et leurs procédés de formation Pending EP3642295A4 (fr)

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PCT/US2018/037989 WO2018236705A1 (fr) 2017-06-19 2018-06-18 Articles abrasifs et leurs procédés de formation

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JP2020528363A (ja) 2020-09-24
CN110770318A (zh) 2020-02-07
CA3067641A1 (fr) 2018-12-27
EP3642295A4 (fr) 2021-06-30
JP7175308B2 (ja) 2022-11-18
KR20200006632A (ko) 2020-01-20
BR112019027340A2 (pt) 2020-07-07

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