KR20200006044A - Abrasive article and method of forming the same - Google Patents

Abstract

The present disclosure relates to an abrasive article comprising a body having a bonding material comprising a metal and a micro-porous body in the bonding material, with an average pore size (D50) of 10 microns or less and a pore size standard deviation of at least 0.2 microns. The body further comprises abrasive particles contained within the bonding material and has an ellipticity of 1.18 or less or an average toughness of at least 11257 cycles.

Description

Abrasive article and method of forming the same

This disclosure relates to an abrasive article and, in particular, to a bonded abrasive article comprising abrasive particles contained within a bonding material comprising a metal or metal alloy.

Abrasives used in machining applications typically include bonded abrasive articles and coated abrasive articles. Coated abrasive articles are generally layered articles having an adhesive and an adhesive coating that fixes the abrasive particles to the support, the most common example of which is sandpaper. Combined abrasive tools are hard and typically in the form of wheels, disks, segments, mounted points, horns and other tools in the form of monolithic, three-dimensional, abrasive composites, which are machine tools, such as grinding or polishing devices. It can be mounted on.

The bonded abrasive tool typically has at least two phases comprising abrasive particles and a binding material. Certain bonded abrasive articles may have additional phases in the form of porous bodies. Bonded abrasive tools are a variety of 'grades' and 'structures' defined according to practice in the art by relative hardness and density (grade) of abrasive composites and volume percentages of abrasive grains, bonds, and porous bodies (structures) in the composite. It can be prepared as.

Some combined abrasive tools may be particularly useful in the polishing and molding of certain types of products, including, for example, metals, ceramics and crystalline materials used in the electronics and optical industries. In other cases, certain bonded abrasive tools may be used in the molding of superabrasive materials for use in industrial applications. In the context of polishing and forming certain articles using metal-bonded abrasive articles, the process generally involves a significant amount of time and effort relating to the maintenance of the bonded abrasive article. That is, generally, metal-bonded abrasive articles require truing and dressing operations to maintain the abrasive ability of the abrasive article.

The art continues to require improved methods and articles that can be polished.

Embodiments are described by the embodiments and are not limited to the accompanying drawings.
1A includes a cross-sectional view of an abrasive article according to an embodiment.
1B includes a cross-sectional view of an abrasive article according to an embodiment.
2 includes a scanning electron microscope (SEM) image of a portion of a conventional abrasive article.
3 includes an SEM image of a portion of an abrasive article according to an example.
4 includes a plot of current versus product number for the samples described herein.
5 includes a plot of current versus product number for the samples described herein.
6 includes an SEM image of a portion of sample S5 according to an embodiment.
7 includes a graph of working lengths for the samples disclosed herein.
8 includes a plot of coolant flow rate versus dressing frequency in the samples disclosed herein.
The skilled person understands that elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale.

The following discussion will focus on specific examples and embodiments of the teachings. The detailed description is provided to help describe particular embodiments and should not be construed as a limitation on the scope and applicability of the disclosure and teachings. It is understood that other embodiments may be used based on the disclosure and teachings provided herein.

The terms "comprises" "comprising," "includes," "including," "has," "having" or other variations thereof It is intended to include non-exclusive inclusion. For example, a method, article, or apparatus that includes a list of features is not necessarily limited to such features, and may include other features that are not explicitly listed or unique to such method, article, or device. In addition, unless expressly stated to the contrary "or" refers to an inclusive-or, not exclusive-or. For example, condition A or B satisfies one of the following: A is true (or present) and B is false (or nonexistent), A is true (or nonexistent) and B is true (or present), And both A and B are true (or present).

In addition, the use of "a" or "an" is used to describe the elements and components described herein. This is done merely for convenience and to convey the general meaning of the scope of the present invention. This description should be construed to include one, at least one, or singular, and vice versa, to include one that also includes the plural unless it is expressly intended to be otherwise. For example, when a singular item is described herein, more than one item may be used instead of the singular item. Similarly, when more than one item is described herein, a singular item may be substituted for more than one item.

The abrasive article can be formed according to the following method. A mixture comprising abrasive particles is formed in the precursor binding material. The precursor binding material may comprise a raw powder comprising a metal, a metal alloy, or a metal forming a material or compound. In one embodiment, the powder material, which may be a precursor binding material, has a mean particle size (D50) of 25 microns or less or 10 microns or less or 1 micron or less or 0.75 microns or less or 0.5 microns or less or 0.25 microns or less or 0.1 microns or less. It can have Still, in one embodiment, it is understood that the precursor binding material may have an average particle size of at least 0.001 microns, such as at least 0.01 microns or at least 0.1 microns or even at least 0.5 microns. The average particle size of the precursor binding material may be within a range including any of the minimum and maximum values mentioned above.

According to one embodiment, the mixture may comprise a precursor binding material, which may be formed of one or more powdered metal materials. For example, in one embodiment, the precursor binding material forming the binding material of the body of the abrasive article may comprise at least one of cobalt, tin, tungsten, copper, or a combination thereof. In more particular embodiments, the precursor binding material may comprise cobalt, tin and tungsten.

According to certain embodiments, the precursor binding material may have a specific content of cobalt and tin that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may comprise [CSn / CCo] cobalt (CCo) and tin (CSn) in a ratio of 0.2 or less, where CCo is the weight percent of cobalt and CSn is the total weight of the precursor binding material. The weight percentage of tin relative to the total weight of the precursor binding material. In other cases, the ratio [CSn / CCo] is 0.19 or less, such as 0.18 or less or 0.17 or less or 0.16 or less or 0.15 or 0.14 or less 0.13 or less or 0.12 or 0.11 or less 0.10 or less or 0.09 or less or 0.08 or less or 0.07 or less Or 0.06 or less or 0.05 or less or 0.04 or less or 0.03 or less or 0.02 or less or 0.01 or less. In one non-limiting embodiment, the ratio [CSn / CCo] is at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 Or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1. It is understood that the ratio [CSn / CCo] can be within a range including any of the minimum and maximum values mentioned above.

According to certain embodiments, the precursor binding material may have a specific content of cobalt and tungsten, which may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may comprise [CW / CCo] cobalt (CCo) and tungsten (CW) in a ratio of 0.9 or less, where CCo is the weight percent of cobalt and CW is the total weight of the precursor binding material. The weight percentage of tungsten relative to the total weight of the precursor binding material. In another embodiment, the ratio [CW / CCo] is 0.8 or less, such as 0.7 or less or 0.6 or less or 0.5 or 0.4 or less or 0.3 or less or 0.2 or 0.10 or less or 0.09 or less or 0.08 or less or 0.07 or less or 0.06 or less 0.05 or less or 0.04 or less or 0.03 or less or 0.02 or less or 0.01 or less. In another embodiment, the ratio [CW / CCo] is at least about 0.001, such as at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 Or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7. It is understood that the ratio [CW / CCo] can be within a range including any of the minimum and maximum values mentioned above.

According to certain embodiments, the precursor binding material may have a specific content of tungsten and tin, which may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may comprise [CSn / CW] tin (CSn) and tungsten (CW) in a ratio of 1 or less, where CW is the weight percent of tungsten and CSn is the total weight of the precursor binding material. The weight percentage of tin relative to the total weight of the precursor binding material. In another embodiment, the ratio [CSn / CW] may be at most 0.9, such as at most 0.8 or at most 0.7 or at most 0.6 or at most 0.5 or at most 0.4 or at most 0.3 or at most 0.2 or at most 0.1. In one non-limiting embodiment, the ratio [CSn / CW] is at least 0.01, such as at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9. It is understood that the ratio [CSn / CW] may be within a range including any of the minimum and maximum values mentioned above.

The precursor binding material may have a specific content of cobalt that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be at least 40 wt% cobalt, such as at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least relative to the total weight of the precursor binding material. 54 wt% or at least 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt% or at least 72 wt% or at least 73 wt% or at least 74 wt% or at least 75 wt% or at least 76 wt% or at least 77 wt% or at least 78 wt% or at least 79 wt% or at least 80 wt% or at least 81 wt% or at least 82 wt% or at least 83 wt% or at least 84 wt% Or at least 85 wt% or at least 86 wt% or at least 87 wt% or at least 88 wt% or at least 89 wt% or at least 90 wt% or at least 91 wt% or at least 92 wt% or at least 93 wt% or at least 94 wt% Or at least 95 wt% cobalt. In one non-limiting embodiment, the precursor binding material can be up to 99 wt% of cobalt, such as up to 98 wt% or up to 97 wt% or up to 96 wt%, based on the total weight of the precursor binding material, or 95 wt% or less or 94 wt% or less or 93 wt% or less or 92 wt% or less or 91 wt% or less or 90 wt% or less or 89 wt% or less or 88 wt% or less or 87 wt% or less or 86 wt% or less 85 wt% or less or 84 wt% or less or 83 wt% or less or 82 wt% or less or 81 wt% or less or 80 wt% or less or 79 wt% or less or 78 wt% or less or 77 wt% or less or 76 wt% or less 75 wt% or less or 74 wt% or less or 73 wt% or less or 72 wt% or less or 71 wt% or less or 70 wt% or less or 69 wt% or less or 68 wt% or less or 67 wt% or less or 66 wt% or less And up to 65 wt% of cobalt. It is understood that the content of cobalt in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above.

The precursor binding material may have a specific content of tin that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be at least 0.1 wt% tin or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt% or at least 0.6 with respect to the total weight of the precursor binding material. wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 3.8 wt% or at least 3.9 wt% or at least 4 wt% or at least 4.1 wt% or at least 4.2 wt% or at least 4.3 wt% or at least 4.4 wt% or at least 4.5 wt% or at least 5 wt% tin. In one non-limiting embodiment, the precursor binding material has no more than 15 wt% tin or no greater than 10 wt% or no greater than 10 wt% or no greater than 9 wt% or 8.5 wt with respect to the total weight of the tin or precursor binding material relative to the total weight of the precursor binding material. Up to or below 8 wt% or up to 7.5 wt% or up to 7 wt% or up to 6.5 wt% or up to 6 wt% or up to 5.5 wt% or up to 5 wt% or up to 4.5 wt% or up to 4 wt% or 3.5 wt Or up to 3 wt% or up to 2.5 wt% or up to 2 wt% or up to 1.5 wt% or up to 1 wt% or up to 0.5 wt% tin. It is understood that the content of tin in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above.

The precursor binding material may have a specific content of tungsten that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may comprise at least 1 wt% tungsten relative to the total weight of the precursor binding material, such as at least 0.1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least relative to the total weight of the precursor binding material. 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 3.8 wt% or at least 3.9 wt% or at least 4 wt% or at least 4.1 wt% or at least 4.2 wt% or at least 4 .3 wt% or at least 4.4 wt% or at least 4.5 wt% or at least 4.6 wt% or at least 4.7 wt% or at least 4.8 wt% or at least 4.9 wt% or at least 5 wt% or at least 5.1 wt% or at least 5.2 wt% or At least 5.3 wt% or at least 5.4 wt% or at least 5.5 wt% or at least 5.6 wt% or at least 5.7 wt% or at least 5.8 wt% or at least 5.9 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or At least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% tungsten. Still, in at least one non-limiting embodiment, the precursor binding material can be up to 20 wt% tungsten relative to the total weight of the precursor binding material, such as up to 18 wt% or up to 16 wt% or up to 14 wt% relative to the total weight of the precursor binding material. Or up to 12 wt% or up to 10 wt% or up to 9 wt% or up to 8 wt% or up to 7 wt% or up to 6 wt% or up to 5 wt% or up to 4 wt% or up to 3 wt% or up to 2 wt% Or 1.5 wt% or less of tungsten. It is understood that the content of tungsten in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above. In at least one embodiment, the precursor binding material may be essentially free of tungsten.

The mixture may include a specific content of iron that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may comprise at least 0.05 wt% iron relative to the total weight of the precursor binding material, such as at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt%, or At least 0.1 wt% or at least 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or Or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% iron. In another non-limiting embodiment, the precursor binding material can be up to 5 wt%, such as up to 4 wt% or up to 3 wt% or up to 2 wt% or up to 1.5 wt% or up to 1 wt% relative to the total weight of the precursor binding material or Up to 0.9 wt% or up to 0.8 wt% or up to 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% or up to 0.3 wt% of iron. It is understood that the content of iron in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above. Still, in one embodiment, the precursor binding material may be essentially free of iron.

The mixture may include a specific content of aluminum that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be at most 1 wt%, such as at most 0.9 wt% or at most 0.8 wt% or at most 0.7 wt% or at most 0.6 wt% or at most 0.5 wt% or at most 0.4 wt%, relative to the total weight of the precursor binding material. Or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt% or up to 0.05 wt% or up to 0.01 wt% aluminum. Still in another non-limiting embodiment, the precursor binding material may comprise a content of aluminum of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the precursor binding material. It is understood that the content of aluminum in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above. Still, in one embodiment, the precursor binding material may be essentially free of aluminum.

The mixture may include a specific amount of copper that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be up to 20 wt%, such as up to 15 wt% or up to 10 wt% or up to 5 wt% or up to 2 wt% or up to 1 wt% or up to 0.9 wt% relative to the total weight of the precursor binding material. Or 0.8 wt% or less or 0.7 wt% or less or 0.6 wt% or less or 0.5 wt% or less or 0.4 wt% or less or 0.3 wt% or less or 0.2 wt% or less or 0.1 wt% or less or 0.09 wt% or less or 0.05 wt% or less Or less than 0.01 wt% copper. Still, in another non-limiting embodiment, the precursor binding material can comprise a content of copper of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the precursor binding material. It is understood that the content of copper in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above. Still, in one embodiment, the precursor binding material may be essentially free of copper.

The mixture may include a specific amount of manganese that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be at most 1 wt%, such as at most 0.9 wt% or at most 0.8 wt% or at most 0.7 wt% or at most 0.6 wt% or at most 0.5 wt% or at most 0.4 wt%, relative to the total weight of the precursor binding material. Or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt% or up to 0.05 wt% or up to 0.01 wt% manganese. Still, in another non-limiting embodiment, the precursor binding material can comprise a content of manganese of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the precursor binding material. It is understood that the content of manganese in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above. Still, in one embodiment, the precursor binding material may be essentially free of manganese.

The mixture may include a specific content of titanium that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be at most 1 wt%, such as at most 0.9 wt% or at most 0.8 wt% or at most 0.7 wt% or at most 0.6 wt% or at most 0.5 wt% or at most 0.4 wt%, relative to the total weight of the precursor binding material. Or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt% of titanium. Still in another non-limiting embodiment, the precursor binding material can comprise a content of titanium of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the precursor binding material. It is understood that the content of titanium in the precursor binding material may be within a range including any of the minimum and maximum values mentioned above. Still, in one embodiment, the precursor binding material may be essentially free of titanium.

In yet another embodiment, the precursor binding material may have a specific content of a particular metal that may promote improved formation and / or performance of the abrasive article. For example, the precursor binding material may be 20 wt% or less, such as 15 wt% or less or 10 wt% or less or 5 wt% or less or 2 wt% or less or 1 wt% or 0.9 wt% or less, relative to the total weight of the precursor binding material. Or up to 0.8 wt% or up to 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% aluminum, copper, manganese, lead, silicon , And the total content of titanium (ie, the sum of the weight percentages for each of the listed elements). Still, in one non-limiting embodiment, the precursor binding material may comprise at least 0.001 wt% or at least 0.01 wt% of the total content of aluminum, copper, manganese, lead, silicon, and titanium relative to the total weight of the precursor binding material. have. It is understood that the total content in aluminum, copper, manganese, lead, silicon, and titanium precursor binding materials may be within a range including any of the minimum and maximum values mentioned above.

In at least one embodiment, the precursor binding material may be essentially free of aluminum, copper, manganese, lead, silicon, and / or titanium. As used herein, the term essentially is intended to include a minimum amount of material that is limited to an impurity content, including but not limited to a content of 0.01 wt% or less. Thus, if a composition is described as consisting or consisting essentially of components X, Y, and Z, the composition may comprise components X, Y, and Z and other ingredients in only impurity amounts, or where such other components are dependent upon the properties or performance of the composition. It should be construed to include the minimum amount of the other ingredients that do not affect. Such reference is applicable to the description of any embodiment herein.

In another embodiment, the precursor binding material may be formed to include at least 95 wt% of cobalt, tin and tungsten relative to the total weight of the precursor binding material. Also in such embodiments, up to 5 wt% of the precursor binding material may comprise secondary elements selected from the group consisting of aluminum, copper, manganese, lead, silicon, and titanium. In still another embodiment, the precursor binding material comprises at least 95 wt% of cobalt and tin, such as at least 96 wt% or at least 97 wt% or at least 98 wt% or even at least 99 wt% cobalt and tin, relative to the total weight of the precursor binding material. It may be formed to include.

The mixture may include one or more other additives, including, for example, fillers that are present in the final abrasive article and that may facilitate improved operation of the abrasive article. Suitable fillers include, for example, pore formers and the like, and may include those known in the art. Some additives may be included in the mixture and may be consumed or removed during processing. Such additives may be added to the mixture to enhance the processing of the abrasive article. Some exemplary additives may include admixtures (eg, dispersants, surfactants, and the like).

According to one embodiment, the abrasive particles may comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, or combinations thereof. For example, the abrasive particles may comprise a super abrasive material such as diamond. In one particular case, the abrasive particles may consist of diamond as essential. It is also understood that the abrasive particles may comprise a mixture of abrasive particles that may differ from each other based on at least one property selected from the group consisting of average particle size, average toughness, hardness, ellipsity, composition, or a combination thereof. . For example, in one particular embodiment, the abrasive particles can include a blend of two different types of diamond particles, including a first type of diamond particles and a second type of diamond particles, wherein the first type Diamond particles are different from diamond particles of the second type based on average particle size, average toughness, hardness, ellipsity, or a combination thereof.

In another aspect, the abrasive particles can have a coating covering the outer surface. The coating can promote improved formation and performance of the abrasive article. In certain cases, the coating may include materials that reduce chemical changes to the abrasive particles during formation, such as oxidation of the abrasive particles. In other cases, the coating may limit the chemical interaction between the abrasive particles and the bonding material during formation. The coating may comprise a metal or a metal alloy. Some suitable metal materials may include one or more transition metal elements. In certain embodiments, the coating may comprise titanium and may consist essentially of titanium.

The weight and / or thickness of the coating may vary to facilitate proper processing and / or performance of the abrasive article. The coating may also be formed to cover most of the outer surface of the abrasive particles, such as at least 60% or at least 70% or at least 80% or at least 90% or at least 95% of the outer surface of the abrasive particles.

The abrasive particles can have a specific particle size distribution that can promote the improved performance of the abrasive article. For example, the abrasive particles are here also as an average particle size of at least 65 microns, such as at least 75 microns or at least 90 microns or at least 95 microns or at least 97 microns or at least 100 microns or at least 105 microns or at least 110 microns or at least 120 microns. It may have a median particle size (D50), which may be referred to. Still, in another non-limiting embodiment, the abrasive particles can have a median particle size (D50) of no greater than 150 microns or no greater than 140 microns or no greater than 130 microns or no greater than 120 microns or no greater than 110 microns or no greater than 105 microns or no greater than 100 microns. have. It is understood that the abrasive particles may have an intermediate particle size within a range including any of the minimum and maximum values mentioned above.

The abrasive particles may also have a specific D10 that can define the maximum particle size of the particles in the lowest 10% of the distribution (ie, the particle size of the abrasive particles in the 10th percentile of the distribution). For example, the abrasive particles can be at least 57 microns, such as at least 60 microns or at least 65 microns or at least 70 microns or at least 75 microns or at least 77 microns or at least 80 microns or at least 83 microns or at least 85 microns or at least 87 microns or at least 90 microns. Or D10 of at least 93 microns or at least 95 microns. In one non-limiting embodiment, the abrasive particles can be 127 microns or less or 120 microns or less or 110 microns or less or 100 microns or less or 95 microns or less or 93 microns or less or 90 microns or less or 87 microns or less or 85 microns or less or 83 microns or less Or D10 of 80 microns or less. It is understood that the abrasive particles may have D10 within a range including any of the minimum and maximum values mentioned above.

The abrasive particles can also have a specific D90 that can define the maximum particle size of the particles within the highest 10% of the distribution (ie, the particle size of the abrasive particles in the 90th percentile of the distribution). For example, the abrasive particles may be at least 97 microns, such as at least 100 microns or at least 103 microns or at least 105 microns or at least 108 microns or at least 110 microns or at least 113 microns or at least 115 microns or at least 118 microns or at least 120 microns or at least 123 Or D90 of at least 125 microns or at least 128 microns or at least 130 microns or at least 133 microns or at least 135 microns or at least 138 microns. In another non-limiting embodiment, the abrasive particles can be up to 165 microns, such as up to 160 microns or up to 155 microns or up to 150 microns or up to 145 microns or up to 140 microns or up to 135 microns or up to 133 microns or up to 130 microns or up to 128 microns Up to or below 125 microns or up to 123 or 120 microns or up to 118 microns or up to 115 microns or up to 113 microns or up to 110 microns or up to 108 microns or up to 105 microns. It is understood that the abrasive particles may have D90 within a range including any of the minimum and maximum values mentioned above.

Abrasive particles may also define a particle size distribution, especially with a limited size of particles greater than 120 microns. For example, in one case, the abrasive particles are 10 vol% or less of abrasive particles having a particle size greater than 120 microns relative to the total volume of abrasive particles in the distribution, such as greater than 120 microns relative to the total volume of abrasive particles in the distribution. 9 vol% or less or 8 vol% or less or 7 vol% or less or 6 vol% or less or 5 vol% or less or 4 vol% or less or 3 vol% or less or 2 vol% or less or 1.8 vol Define a particle size distribution with less than or equal to 1.5 vol% or less. Still, it is understood that in at least one case, the content of abrasive particles having a particle size greater than 120 microns relative to the total volume of abrasive particles in the distribution may be at least 0.1 vol% or at least 0.5 vol% or even at least 0.8 vol%. . The content of abrasive particles having a particle size greater than 120 microns relative to the total volume of abrasive particles in the distribution may be within a range including any of the minimum and maximum percentages mentioned above.

The abrasive particles can have a specific Vickers hardness that can promote the improved performance of the abrasive article. For example, the abrasive particles may have a Vickers hardness of at least 2000 kg / mm ² or at least 3000 kg / mm ² or at least 4000 kg / mm ² or at least 5000 kg / mm ² . In another non-limiting embodiment, the abrasive particles can have a Vickers hardness of 12,000 kg / mm ² or less. It is understood that the abrasive particles can have Vickers hardness within a range including any of the minimum and maximum values mentioned above.

According to another aspect, the abrasive particles can have a particular average toughness that can promote the improved performance of the abrasive article. The toughness of the abrasive particles is measured according to ANSIB74.23 for abrasive grains as obtained from the supplier under ambient conditions without processing or processing the granules prior to measurement. Average toughness as used herein is understood as an average calculated based on toughness test data that appears to have a 5% or less deviation. For example, the abrasive particles can have an average toughness of 11257 cycles, which can include a deviation of up to ± 563. In another embodiment, the average toughness is at least 11850 cycles or at least 11900 or at least 12000 cycles or at least 12100 cycles or at least 12200 cycles or at least 12300 cycles or at least 12400 cycles or at least 12500 cycles or at least 12600 cycles or at least 12700 cycles or at least 12800 Cycle or at least 12900 cycles or at least 13000 cycles or at least 13100 cycles or at least 13200 cycles. In another non-limiting embodiment, the abrasive particles are no more than 16000 cycles or no more than 15000 cycles or no more than 14500 cycles or no more than 14000 cycles or 13900 cycles or no more than 13800 cycles or no more than 13700 cycles or no more than 13600 cycles or no more than 13500 cycles or no more than 13400 cycles Or an average toughness of 13300 cycles or less. It is understood that the abrasive particles may have an average toughness within a range including any of the minimum and maximum values mentioned above.

In yet another aspect, the abrasive particles can have a particular shape, measured by ellipsity, which can promote the improved performance of the abrasive article. For example, the abrasive particles may have an ellipticity of no greater than 1.18, such as no greater than 1.17 or no greater than 1.16 or 1.15 or no greater than 1.14 or no greater than 1.13 or no greater than 1.12 or no greater than 1.11 or no greater than 1.10. Still, in one non-limiting embodiment, the abrasive particles can be at least 1.01 or at least 1.02 or at least 01.03 or at least 1.04 or at least 1.05 or at least 1.06 or at least 1.07 or at least 1.08 or at least 1.09 or at least 1.10 or at least 1.11 or at least 1.12 or at least It may have an ellipticity of 1.13 or at least 1.14 or at least 1.15 or at least 1.16. It is understood that the abrasive particles may have an ellipsity within a range including any of the minimum and maximum values mentioned above.

Ellipticity is measured using image analysis of a suitable number of randomly sampled particles. Random sampling of at least 2000 distinct abrasive particles is obtained and placed on the adhesive side of the tape. Care must be taken to distribute the particles evenly on the tape and to prevent agglomeration of the particles. The tape may be attached to a slide or other surface that may facilitate imaging of the particles contained on the tape. The Pro-scanner 7200, available from Reflecta, GmbH, is used to scan the diamond contained on the tape of the slide. You can scan multiple times until the scanner produces a clear image of each particle. Analyze the image, using Diashape software. Care must be taken to ensure that the number of particles identified by the software is the same as the number of particles sampled initially.

The mixture may be formed to include a particular content of abrasive particles that may promote the formation and performance of the abrasive article. For example, in one case, the mixture may contain at least 2 wt% abrasive particles or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or more based on the total weight of the mixture or At least 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or At least 9.5 wt% or at least 10 wt%. In one non-limiting embodiment, the mixture is 10 wt% or less abrasive particles relative to the total weight of the mixture, such as 9 wt% or less or 8.5 wt% or less or 8 wt% or less or 7.5 wt% or less based on the total weight of the mixture. Or up to 7 wt% or up to 6.5 wt% or up to 6 wt% or up to 5.5 wt% or up to 5 wt% or up to 4.5 wt% or up to 4 wt% or up to 3.5 wt% or up to 3 wt% or up to 2.5 wt% Or up to 2 wt% or up to 1.5 wt% or up to 1 wt%. It is understood that the mixture may comprise the content of abrasive particles within a range including any of the minimum and maximum values mentioned above.

The mixture can be formed to include a specific amount of binding material or precursor binding material that can promote the formation and performance of the abrasive article. For example, in one case, the mixture may comprise at least 20 wt% binding material or precursor binding material relative to the total weight of the mixture, such as at least 25 wt% or at least 30 wt% or at least 40 wt% relative to the total weight of the mixture or At least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt% or at least 95 wt%. In one non-limiting embodiment, the mixture can be up to 99 wt% of the binding material or precursor binding material relative to the total weight of the mixture, such as up to 95 wt% or up to 90 wt% or up to 80 wt% relative to the total weight of the mixture or Up to 70 wt% or up to 60 wt% or up to 50 wt% or up to 40 wt% or up to 30 wt% or up to 25 wt%. It is understood that the mixture may comprise a content of binding material or precursor binding material within a range comprising any of the minimum and maximum percentages mentioned above. It is also understood that the binding material or precursor binding material may be the total content of raw powder particles for the binding material.

After forming a mixture that combines the desired components, the mixture can be formed into green grass. Processes suitable for shaping raw material from the mixture may include molding, pressing, casting, punching, cutting, printing, spraying, depositing, or a combination thereof.

After or during the process for forming the dough, the body may be processed to form a finally-formed abrasive article. Some suitable treatments may include drying, curing, heating, calcination, or a combination thereof. In at least one embodiment, the mixture is placed into a mold and treated at a suitable pressure and temperature to facilitate the formation of a finally-formed abrasive article.

According to one embodiment, the process of forming the abrasive article may include heating of the mixture to form the body of the finally-formed abrasive article. Heating may be carried out at certain temperatures to ensure proper formation of the microstructures which may promote improved performance. For example, the mixture heating may be at least 700 or at least 725 or at least 750 or at least 775 or at least 800 or at least 825 or at least 850 or at least 875 or at least 900 or at least 925 or at least 950 Or at a temperature of at least 975 ° C or at least 1000 ° C. Still, in one non-limiting embodiment, the mixture heating can be performed at temperatures of 1100 ° C. or less or 1050 ° C. or less or 1000 ° C. or less or 975 ° C. or less or 950 ° C. or less or 925 ° C. or less or 900 ° C. or less. It is understood that the heating can be completed at a temperature in the range including any of the minimum and maximum values mentioned above. The heating temperature mentioned above may be the maximum temperature at which the mixture is calcined to promote the formation of the abrasive article. When a combination of heat and pressure is applied to the mixture to promote the formation of an abrasive article, the heating temperature may also be a maximum temperature that matches the maximum pressure applied to the mixture.

According to one embodiment, the process of forming the body of the finally-formed abrasive article when the combination of heat and pressure is applied to the mixture to promote the formation of the abrasive article may comprise hot pressing of the mixture. . In one embodiment, the hot pressing operation can be performed at a temperature within the range for any of the temperatures mentioned above. In one embodiment, the process of forming the body may comprise hot pressing of the mixture at a pressure of at least 1000 psi, such as at least 1500 psi or at least 2000 psi or at least 2200 psi. In another non-limiting embodiment, the hot pressing can be performed at a pressure temperature of 5000 psi or less, such as 4000 psi or less or 3000 psi or less or 2750 psi or less. It is understood that the pressure may be within a range including any of the minimum and maximum values mentioned above. The pressure mentioned above may be the maximum pressure applied to the mixture during formation. The pressure mentioned above may also be the maximum pressure that matches the maximum temperature applied to the mixture mixture during the forming process. The hot pressing may be one-way or isostatic pressing.

The resulting abrasive article may be a bonded abrasive body that includes a three-dimensional body that defines a matrix of material as a continuous phase and includes a three-dimensional bond of bonding material containing abrasive particles therein. In certain cases, the body of the abrasive article may comprise some phase or porous body.

According to one embodiment, the body may have a specific content of porous body that may promote improved performance of the abrasive article. For example, the body may be at least 0.5 vol%, such as at least 1 vol% or at least 1.5 vol% or at least 2 vol% or at least 2.5 vol% or at least 3 vol% or at least 3.5 vol% or at least 4, based on the total volume of the body. vol% or at least 4.5 vol% or at least 5 vol% or at least 5.5 vol% or at least 6 vol% or at least 7 vol% or at least 8 vol% or at least 9 vol% or at least 10 vol% of the porous body. have. In one non-limiting embodiment, the content of the porous body in the body is 50 vol% or less or 30 vol% or less or 20 vol% or less or 15 wt% or less or 12 wt% or less or 10 vol% or less relative to the total volume of the body or 9 vol% or less or 8 vol% or less or 7 vol% or less or 6 vol% or less or 5 vol% or less or 4 vol% or less or 3 vol% or less or 2 vol% or less or 1 vol% or less. It is understood that the content of the porous body in the body may be within a range including any of the minimum and maximum values mentioned above.

The body of the abrasive article may be formed to include a particular content of abrasive particles that may promote improved performance of the abrasive article. For example, in one case, the body may contain at least 2 wt% abrasive particles or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least relative to the total weight of the body or the total weight of the mixture. 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt%. In one non-limiting embodiment, the body is 10 wt% or less relative to the total weight of the body, such as 9 wt% or less or 8.5 wt% or less or 8 wt% or less or 7.5 wt% or less or 7 wt. Up to or below 6.5 wt% or up to 6 wt% or up to 5.5 wt% or up to 5 wt% or up to 4.5 wt% or up to 4 wt% or up to 3.5 wt% or up to 3 wt% or up to 2.5 wt% or 2 wt It may comprise up to% or up to 1.5 wt% or up to 1 wt% abrasive particles. It is understood that the body may comprise the content of abrasive particles within a range including any of the minimum and maximum values mentioned above.

The body may be formed to include a specific amount of bonding material that may promote improved performance of the abrasive article. For example, in one case, the body may comprise at least 20 wt% bonding material or material relative to the total weight of the body, such as at least 25 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt relative to the total weight of the body. % Or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt% or at least 95 wt%. In one non-limiting embodiment, the body is 99 wt% or less relative to the total weight of the body, such as 95 wt% or less or 90 wt% or less or 80 wt% or less or 70 wt% or less or 60 wt. It is understood that up to% or up to 50 wt% or up to 40 wt% or up to 30 wt% or up to 25 wt% binding material may be included. The body may comprise a content of the binding material within a range including any of the minimum and maximum values mentioned above.

The abrasive particles contained in the body may have any of the features described in the embodiments herein for the abrasive particles included in the mixture used to form the abrasive article. Importantly, the abrasive particles of the finally-formed abrasive article include the compositions, coatings, coating compositions, coating contents, particle size distribution (ie, D10, D50, D90, and percent by volume above 120 microns), Vickers hardness, as mentioned herein. , Average toughness, and / or ellipticity.

The bonding material contained in the body may have any of the features described in the embodiments herein for the mixture contained within the bonding material or precursor bonding material used to form the abrasive article. According to certain embodiments, the binding material may have a specific content of cobalt and tin that may promote improved performance of the abrasive article. For example, the binding material may comprise [CSn / CCo] in a cobalt (CCo) and tin (CSn) ratio of 0.2 or less, where CCo is the weight percent of cobalt and CSn is the binding material relative to the total weight of the binding material. The weight percentage of tin relative to the total weight of. In other cases, the ratio [CSn / CCo] is 0.19 or less, such as 0.18 or less or 0.17 or less or 0.16 or less or 0.15 or 0.1 or less 4 or 0.1 or less 3 or 0.1 or less 2 or 0.1 or less or 0.10 or less or 0.09 or less or 0.08 Or less than or 0.07 or less or 0.06 or less or 0.05 or less or 0.04 or less or 0.03 or less or 0.02 or less or 0.01. In one non-limiting embodiment, the ratio [CSn / CCo] is at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 Or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1. It is understood that the ratio [CSn / CCo] can be within a range including any of the minimum and maximum values mentioned above.

According to certain embodiments, the binding material may have a specific content of cobalt and tungsten that may promote improved formation and / or performance of the abrasive article. For example, the binding material may comprise [CW / CCo] cobalt (CCo) and tungsten (CW) in a ratio of 0.9 or less, where CCo is the weight percent of cobalt and CW is the binding material relative to the total weight of the binding material. Is the weight percent of tungsten relative to the total weight of. In another embodiment, the ratio [CW / CCo] is 0.8 or less, such as 0.7 or less or 0.6 or less or 0.5 or 0.4 or less or 0.3 or less or 0.2 or 0.10 or less or 0.09 or less or 0.08 or less or 0.07 or less or 0.06 or less 0.05 or less or 0.04 or less or 0.03 or less or 0.02 or less or 0.01 or less. In another embodiment, the ratio [CW / CCo] is at least about 0.001, such as at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 Or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7. It is understood that the ratio [CW / CCo] can be within a range including any of the minimum and maximum values mentioned above.

According to certain embodiments, the bonding material may have a specific content of tungsten and tin, which may promote improved formation and / or performance of the abrasive article. For example, the binding material may comprise tin (CSn) and tungsten (CW) in a ratio [CSn / CW] of 1 or less, where CW is the weight percent of tungsten and CSn is the bond relative to the total weight of the binding material. The weight percentage of tin relative to the total weight of the material. In another embodiment, the ratio [CSn / CW] may be at most 0.9, such as at most 0.8 or at most 0.7 or at most 0.6 or at most 0.5 or at most 0.4 or at most 0.3 or at most 0.2 or at most 0.1. In one non-limiting embodiment, the ratio [CSn / CW] is at least 0.01, such as at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9. It is understood that the ratio [CSn / CW] may be within a range including any of the minimum and maximum values mentioned above.

The binding material may have a specific content of cobalt that may promote improved performance of the abrasive article. For example, the binding material may be at least 40 wt% cobalt relative to the total weight of the binding material, such as at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least 54 wt%, Or at least 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% Or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt% or at least 72 wt% or at least 73 wt% or at least 74 wt% Or at least 75 wt% or at least 76 wt% or at least 77 wt% or at least 78 wt% or at least 79 wt% or at least 80 wt% or at least 81 wt% or at least 82 wt% or at least 83 wt% or at least 84 wt% Or at least 85 wt% or At least 86 wt% or at least 87 wt% or at least 88 wt% or at least 89 wt% or at least 90 wt% or at least 91 wt% or at least 92 wt% or at least 93 wt% or at least 94 wt% or at least 95 wt% cobalt It may include. In one non-limiting embodiment, the binding material can be up to 99 wt% cobalt, such as up to 98 wt% or 97 wt% or up to 96 wt% or 95 wt% relative to the total weight of the bonding material. Or below 94 wt% or below 93 wt% or below 92 wt% or below 91 wt% or below 90 wt% or below 89 wt% or below 88 wt% or below 87 wt% or below 86 wt% or 85 wt% Up to or below 84 wt% or up to 83 wt% or up to 82 wt% or up to 81 wt% or up to 80 wt% or up to 79 wt% or up to 78 wt% or up to 77 wt% or up to 76 wt% or 75 wt% Up to or below 74 wt% or up to 73 wt% or up to 72 wt% or up to 71 wt% or up to 70 wt% or up to 69 wt% or up to 68 wt% or up to 67 wt% or up to 66 wt% or 65 wt% It may include the content of cobalt. It is understood that the content of cobalt in the binding material may be within a range including any of the minimum and maximum values mentioned above.

The binding material of the finally formed abrasive article may have a specific content of tin that may promote improved performance of the abrasive article. For example, the bonding material may be at least 0.1 wt% tin or at least 0.2 wt% or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt% or at least 0.6 wt% relative to the total weight of the bonding material or At least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or At least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or At least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% Or at least 3.7 wt% or at least 3.8 wt% or at least 3.9 wt% or at least 4 wt% or at least 4.1 wt% or at least 4.2 wt% or at least 4.3 wt% or at least 4.4 wt% or at least 4.5 wt% or at least 5 wt% Can include comments. In one non-limiting embodiment, the binding material can be up to 15 wt% tin or up to 10 wt% or up to 9 wt% or up to 9 wt% or up to 8.5 wt% or less relative to the total weight of the tin or bonding material or 8 wt% or less or 7.5 wt% or less or 7 wt% or less or 6.5 wt% or less or 6 wt% or less or 5.5 wt% or less or 5 wt% or less or 4.5 wt% or less or 4 wt% or less or 3.5 wt% or less Tin content up to 3 wt% or up to 2.5 wt% or up to 2 wt% or up to 1.5 wt% or up to 1 wt% or 0.5 wt%. It is understood that the content of tin in the binding material may be within a range including any of the minimum and maximum values mentioned above.

The bonding material of the finally-formed abrasive article may have a specific content of tungsten that may promote the improved performance of the abrasive article. For example, the bonding material may comprise at least 1 wt% tungsten relative to the total weight of the bonding material, such as at least 0.1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% relative to the total weight of the bonding material. Or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% Or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% Or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 3.8 wt% or at least 3.9 wt% or at least 4 wt% or at least 4.1 wt% or at least 4.2 wt% or at least 4.3 wt% or at least 4.4 wt % Or at least 4.5 wt% or at least 4.6 wt% or at least 4.7 wt% or at least 4.8 wt% or at least 4.9 wt% or at least 5 wt% or at least 5.1 wt% or at least 5.2 wt% or at least 5.3 wt% or at least 5.4 wt % Or at least 5.5 wt% or at least 5.6 wt% or at least 5.7 wt% or at least 5.8 wt% or at least 5.9 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt % Or at least 8.5 wt% or at least 9 wt% tungsten. Still, in at least one non-limiting embodiment, the bonding material is 20 wt% or less tungsten relative to the total weight of the bonding material, such as 18 wt% or less or 16 wt% or less or 14 wt% or less or 12 wt. Up to or below 10 wt% or up to 9 wt% or up to 8 wt% or up to 7 wt% or up to 6 wt% or up to 5 wt% or up to 4 wt% or up to 3 wt% or up to 2 wt% or up to 1.5 wt It may comprise up to% tungsten. It is understood that the content of tungsten in the bonding material may be within a range including any of the minimum and maximum values mentioned above. In at least one non-limiting embodiment, the bonding material can be essentially free of tungsten.

The bonding material of the finally-formed abrasive article may comprise a specific content of iron that may promote the improved performance of the abrasive article. For example, the binding material may comprise at least 0.05 wt% iron relative to the total weight of the binding material, such as at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 wt relative to the total weight of the binding material. % Or at least 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt % Or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% iron. In another non-limiting embodiment, the binding material can be up to 5 wt% iron, such as up to 4 wt% or up to 3 wt% or up to 2 wt% or up to 1.5 wt% or up to 1 wt% or Up to 0.9 wt% or up to 0.8 wt% or up to 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% or up to 0.3 wt%. It is understood that the iron content in the binding material may be within a range including any of the minimum and maximum values mentioned above.

The bonding material of the finally-formed abrasive article may comprise a specific amount of aluminum that may promote the improved performance of the abrasive article. For example, the bonding material may be up to 1 wt% aluminum, such as up to 0.9 wt% or up to 0.8 wt% or up to 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% relative to the total weight of the joining material or Or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt% or up to 0.05 wt% or up to 0.01 wt%. Still in another non-limiting embodiment, the binding material may comprise a content of aluminum of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the binding material. It is understood that the content of aluminum in the bonding material may be within a range including any of the minimum and maximum values mentioned above. In at least one non-limiting embodiment, the bonding material can be essentially free of aluminum.

The bonding material of the finally-formed abrasive may comprise a certain amount of copper that may promote the improved performance of the abrasive article. For example, the binding material may be up to 20 wt% copper, such as up to 15 wt% or up to 10 wt% or up to 5 wt% or up to 2 wt% or up to 1 wt% or up to 0.9 wt% relative to the total weight of the bonding material or 0.8 wt% or less or 0.7 wt% or less or 0.6 wt% or less or 0.5 wt% or less or 0.4 wt% or less or 0.3 wt% or less or 0.2 wt% or less or 0.1 wt% or less or 0.09 wt% or less or 0.05 wt% or less And up to 0.01 wt%. Still in another non-limiting embodiment, the bonding material may comprise a content of copper of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the bonding material. It is understood that the content of copper in the bonding material may be within a range including any of the minimum and maximum values mentioned above. In at least one non-limiting embodiment, the bonding material can be essentially free of copper.

The binding material of the finally-formed abrasive may comprise a certain amount of manganese that may promote improved performance of the abrasive article. For example, the binding material may be 1 wt% or less, such as 0.9 wt% or less or 0.8 wt% or less or 0.7 wt% or less or 0.6 wt% or less or 0.5 wt% or less or 0.4 wt% or 0.3, based on the total weight of the bonding material. It may comprise up to wt% or up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt% or up to 0.05 wt% or up to 0.01 wt% manganese. Still in another non-limiting embodiment, the binding material may comprise a content of manganese of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the binding material. It is understood that the content of manganese in the binding material may be within a range including any of the minimum and maximum values mentioned above. In at least one non-limiting embodiment, the binding material can be essentially manganese free.

The binding material of the finally-formed abrasive may comprise a specific content of titanium that may promote the improved performance of the abrasive article. For example, the bonding material may be 1 wt% or less, such as 0.9 wt% or less or 0.8 wt% or less or 0.7 wt% or less or 0.6 wt% or less or 0.5 wt% or less or 0.4 wt% or less, based on the total weight of the bonding material. and up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt% of titanium. Still in another non-limiting embodiment, the binding material can comprise a content of titanium of at least 0.001 wt% or at least 0.01 wt% relative to the total weight of the binding material. It is understood that the content of titanium in the bonding material may be within a range including any of the minimum and maximum values mentioned above. In at least one non-limiting embodiment, the bonding material may be essentially free of titanium.

In yet another embodiment, the binding material of the finally-formed abrasive may have a specific content of a particular metal that may promote the improved performance of the abrasive article. For example, the binding material may be up to 20 wt%, such as up to 15 wt% or up to 10 wt% or up to 5 wt% or up to 2 wt% or up to 1 wt% or 0.9 wt% or 0.8 wt. Up to or below 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% of aluminum, copper, manganese, lead, silicon, and titanium It may have a total content (ie, the sum of the weight percentages for each of the listed elements). Still, in one non-limiting embodiment, the bonding material may comprise at least 0.001 wt% or at least 0.01 wt% of the total content of aluminum, copper, manganese, lead, silicon, and titanium relative to the total weight of the bonding material. It is understood that the total content of aluminum, copper, manganese, lead, silicon, and titanium in the bonding material may be within a range including any of the minimum and maximum values mentioned above. In at least one embodiment, the bonding material may be essentially free of aluminum, copper, manganese, lead, silicon, and / or titanium.

According to another aspect, the binding material of the finally-formed abrasive may be formed to include at least 95 wt% of cobalt, tin and tungsten. Also in such embodiments, up to 5 wt% of the bonding material may include secondary elements selected from the group comprising aluminum, copper, manganese, lead, silicon, and titanium. In still another embodiment, the binding material comprises at least 95 wt% of cobalt and tin, such as at least 96 wt% or at least 97 wt% or at least 98 wt% or even at least 99 wt% cobalt and tin relative to the total weight of the precursor binding material. It can be formed to.

The finally-formed body of the abrasive article may have certain microstructures that can promote improved performance. For example, the body may have a micro-porous body comprising discrete porous bodies in the form of discrete pores contained within the bonding material. Micro-porous bodies can be constructed with discontinuous porous bodies as essential. The entire body may comprise a micro-porous body, and in certain cases, the body may comprise only a micro-porous body having the features described herein. That is, in one embodiment, the porous body of all the bodies is a micro-porous body having the features described herein.

In at least one aspect, the micro-porous body can have a specific pore size distribution that can promote improved performance of the abrasive article. For example, the micro-porous body may be at least 0.01 microns or at least 0.05 microns or at least 0.1 microns or at least 0.2 microns or at least 0. 25 microns or at least 0.3 microns or at least 0.35 microns or at least 0.4 microns or at least 0.45 microns or at least 0.5 microns Average pore size (D50). Still, in one non-limiting embodiment, the microporous body is no more than 9 microns or no more than 8 microns or no more than 7 microns or no more than 6 microns or no more than 5 microns or no more than 4 microns or no more than 4 microns or no more than 3 microns or no more than 2 microns or It may have an average pore size (D50) of 1 micron or less or 0.9 micron or less or 0.8 micron or less or 0.7 micron or less or 0.6 micron or less or 0.5 micron or less. It is understood that the average pore size (D50) of the micro-porous body in the body may be within a range including any of the minimum and maximum values mentioned above.

The micro-porous body may also have a certain standard deviation, which is the first standard deviation of the porous body distribution in the body, calculated from the porous body distribution measured from an image taken from a sample of the finally-formed abrasive article. A finally-formed sample of the abrasive article is obtained, and four cubic samples having a size of 0.3 inches per face are removed from the abrasive article. Samples are taken from random locations of the abrasive article. Cubic samples are mounted in epoxy and polished to reveal the abrasive surface for image analysis. For each cubic sample, a portion of the sample having an area of at least 50 × 40 microns, including no abrasive particles, was identified using a scanning electron microscope in backscattering mode (10 kv). Several images of representative areas are obtained and further analyzed using suitable image processing software (eg ImageJ) to form binary images of representative areas. The imaging software is used to identify the number and size of the pores and to form a pore size distribution plot. The mean pore size and standard deviation of the pore size are then calculated from the pore size distribution plot.

According to one embodiment, the microporous body is at least 0.2 microns, such as at least 0.22 microns or at least 0.24 microns or at least 0.26 microns or at least 0.28 microns or at least 0.3 microns or at least 0.32 microns or at least 0.34 microns or at least 0.36 microns or at least 0.38 It may have a pore size standard deviation of at least 0.4 microns or at least 0.42 microns or at least 0.44 microns. In one non-limiting embodiment, the microporous body has pores of 2 microns or less, such as 1.8 microns or less or 1.6 microns or less or 1.4 microns or less or 1.2 microns or less or 1 micron or 0.8 microns or less or 0.6 microns or less or 0.5 microns or less May have a size standard deviation. It is understood that the micro-porous body may have a pore size standard deviation within a range including any of the minimum and maximum values mentioned above.

The abrasive particles can have a specific particle size distribution that can promote the improved performance of the abrasive article. For example, the abrasive particles may be referred to herein as average particle sizes, at least 65 microns, such as at least 75 microns or at least 90 microns at least 95 microns, such as at least 97 microns or at least 100 microns or at least 105 microns or at least 110 microns. Or have a median particle size (D50) of at least 120 microns. Still, in another non-limiting embodiment, the abrasive particles can have a median particle size (D50) of no greater than 150 microns or no greater than 140 microns or no greater than 130 microns or no greater than 120 microns or no greater than 110 microns or no greater than 105 microns or no greater than 100 microns. have. It is understood that the abrasive particles may have an intermediate particle size within a range including any of the minimum and maximum values mentioned above.

The abrasive particles of the abrasive article may also have a particular D10 corresponding to any D10 value of the abrasive particles in the mixture used to form the abrasive article described herein in other embodiments. In addition, the abrasive particles in the abrasive body may have a D90 corresponding to any D90 value of the abrasive particles included in the mixture used to form the abrasive article.

1A includes a cross-sectional view of an abrasive article according to an embodiment. The abrasive article 100 formed by the above-described method includes a core 101 and an abrasive body 103 disposed on a peripheral surface of the core 101. In one particular case, the abrasive body 103 may be disposed in an internal recess of the peripheral surface of the core 101, as described, for example, in FIG. 1A. The core 101 may further include an opening 107, which may be configured to engage the shaft and promote rotation of the abrasive article 100.

As also shown in the embodiment of FIG. 1A, the abrasive body 103 may comprise a molded surface 105, which may have a particular shape suitable for polishing the edges of the article. Although the shaped surface 105 of FIG. 1A is shown generally or having a U-shaped or concave contour, other forms may be used, including but not limited to planar profiles, V-shaped profiles, and the like. have.

The core 101 can include various materials, including but not limited to inorganic materials (eg, metals, metal alloys, ceramics, etc.), organic materials, or combinations thereof. In one embodiment, core 101 may include, but is not limited to, organic materials that include aspects of strength, abrasion resistance, vibration damping, and capacity, and that can promote improved performance of the bonded abrasive body. Can be.

In one embodiment the core 101 is polyamide (PA), polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), polyetherketone (PEEK), poly Ester (PE), Polyethylenimine (PEI), Polyethersulfone (PESU), Polyethylene Terephthalate (PET), Polyphthalamide (PPA), Poly (p-phenylene sulfide), Polycarbonate (PC), Acrylonitrile Butadiene-styrene (ABS), PC-ABS, or combinations thereof. In one aspect, the polymeric material can be nylon, PBT, PPS, or PC-ABS. Nylon can be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46. In certain embodiments, the polymeric material of the core may be constructed with PPS as essential. In another particular embodiment, the polymeric material of the core may be constructed with PC-ABS as essential. In another embodiment, the polymeric material of the core may be essentially free of nylon.

In another embodiment, the core 101 may further contain reinforcing fibers and / or powders distributed within the polymeric material. Reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof. Suitable powders can be, for example, calcium carbonate, glass powder, mineral powder, or talc.

1B includes a cross-sectional view of a portion of an abrasive article in accordance with an embodiment. Like the abrasive article described in FIG. 1A, a portion of the abrasive article of FIG. 1B includes a core 101 and an abrasive body 103 disposed on a peripheral surface of the core 101. The abrasive body 103 may comprise a molded surface 105, which may have a particular shape suitable for polishing the edges of an article.

As further described in FIG. 1B, the abrasive body 103 includes a first region 151, a second region 161, and a third region 171. Although the embodiment of FIG. 1B includes three regions, it is understood that other abrasive bodies may be formed to have fewer or more regions. According to one aspect, the grade and / or structure of the regions may be different from each other. For example, the region may include different amounts of abrasive particles, different sizes of abrasive particles (eg, D10, D50 and / or D90), different compositions of abrasive particles, different contents of bonding materials, different compositions of bonding materials, It can have different porous bodies, different microstructural features, or a combination thereof. It is contemplated that such controlled differences between regions can facilitate improved operation of the abrasive article. Any of the regions may have one or more of the features of any of the embodiments herein.

According to one embodiment, the first region 151 may have a first content of abrasive 153 particles contained within the bonding material 152 and the second region 161 may be contained within the bonding material 162. It may have a second content of abrasive 163 particles, and further the first content and the second content may be different compared to each other. In one particular case, the second content may be greater than the first content. The content of abrasive particles can be measured as volume percent or weight percent of abrasive particles in a given region. If the distinction between the areas is not clearly visible, at least three random samplings of the material may be selected from the parts of the body suspected as part of the different areas, and the content and average of abrasive particles may be measured. The average content can be representative of the content for a given region. The volume percent or weight percent can be based on the weight or volume sampled from the region.

In one particular embodiment, the abrasive body 103 having the first and second regions 151 and 161 can define a ratio C1 / C2 of no greater than 0.97, where C1 is the abrasive in the first region. The first content (vol% or wt%) of the particles and C2 represents the second content (vol% or wt%) of the abrasive particles in the second region. According to one embodiment, the ratio (C1 / C2) is 0.95 or less, such as 0.93 or less or 0.90 or less or 0.87 or 0.85 or 0.83 or less or 0.80 or 0.77 or less or 0.75 or less or 0.73 or less or 0.70 or less or 0.67 or less It may be 0.65 or less or 0.63 or less or 0.60 or less or 0.57 or less or 0.55 or less or 0.53 or 0.50 or less or 0.47 or less or 0.45 or less or 0.43 or less or 0.40 or less. Still, in another non-limiting embodiment, the ratio (C1 / C2) is at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 Or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It is understood that the ratio C1 / C2 may be within a range including any of the minimum and maximum values mentioned above.

In certain cases, the abrasive particles 153 of the first region 151 may be the same type as the abrasive particles 163 contained in the second region 161. Reference to the type of abrasive particles herein may be a reference to at least one property selected from the group of median particle size (D50), D10, D90, Vickers hardness, ellipsity, average toughness, composition, or combinations thereof. For example, the abrasive particles 153 and 163 may have the same composition as each other. However, in other embodiments, it is understood that the composition of the abrasive particles 153 may be different compared to the composition of the abrasive particles 163. In another aspect, the abrasive particles 153 of the first region 151 may be the same size (eg, D10, D50, and / or D90) as the abrasive particles 163 contained in the second region 161. Can be. For example, abrasive particles 153 and 163 can have an average particle size (ie, D50) relative to each other. However, it is understood that in other embodiments, the composition of the abrasive particles 153 may have a different average particle size (ie, D50) compared to the abrasive particles 163.

In certain cases, as described in FIG. 1B, the first region 151 may be in the form of a layer extending radially between the inner wall 112 of the cavity and the shaped surface 105. Additionally, second region 161 may be in the form of a layer, such as a layer extending radially between inner wall 112 and shaped surface 105. The second region 161 may be in direct contact with the first region 151 such that no layer or object is located between the first and second regions 151 and 161.

In another aspect, the first region 151 may have a first content of the first bonding material 152 and the second region 161 may have a second content of the second bonding material 162. For certain abrasive articles of the embodiments herein, the second content of the second bonding material 162 may be different from the first content of the first bonding material 152. Still, in an alternative design, the second content of the second bonding material 162 may be the same as the first content of the first bonding material 152.

For certain embodiments, the first bonding material 152 of the first region 151 may have the same composition as the second region 161 of the second bonding material 162. The first and second bonding materials 152 and 162 may have any composition for the bonding materials mentioned in the embodiments herein. In one particular case, the first and second bonding materials 152 and 162 may be inorganic materials, such as metals, metal alloys, amorphous materials, glass, ceramics, or combinations thereof. As will be appreciated, in certain cases, the first and second bonding materials 152 and 162 may have different compositions compared to each other. The compositions may be considered different from one another when at least one component (eg, element, compound or complex) is at least 5% different between the two compositions.

As described in FIG. 1B, certain abrasive bodies may include a third region 171 having a third content of abrasive particles 173. In addition, as described in FIG. 1B, the second region 161 may be disposed between the first region 151 and the third region 171. In at least one embodiment, the third content of abrasive particles 173, measured in volume percent or weight percent, may be different compared to the second content of abrasive particles 163 contained in second region 161. . In still other cases, the first content of abrasive particles 153 and the third content of abrasive particles 173 may be equal to each other.

For one particular embodiment, the second content of abrasive particles 163 in second region 161 may be greater than the third content of abrasive particles 173 in third region 171. This is advantageous because the second region 161 can perform most of the material removal operation compared to the third region 171. In addition, the second content of the abrasive particles 163 in the second region 161 may be greater than the first content of the abrasive particles 153 in the first region 151.

The abrasive body 103 may comprise a ratio C3 / C2 of no greater than 0.97, where C3 represents a third content of the abrasive particles 173 in the third region 171 and C2 represents the second region 161. A second content of abrasive particles 163 is shown. In one embodiment, the ratio (C3 / C2) is 0.95 or less, such as 0.93 or less or 0.90 or less or 0.87 or 0.85 or 0.83 or less or 0.80 or 0.77 or 0.75 or less or 0.73 or less or 0.70 or 0.67 or 0.65 or 0.65. Up to 0.63 or up to 0.60 or up to 0.57 or up to 0.55 or up to 0.53 or up to 0.50 or up to 0.47 or up to 0.45 or up to 0.43 or up to 0.40. Still, in another non-limiting embodiment, the ratio (C3 / C2) is at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 Or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It is understood that the ratio C3 / C2 may be within a range including any of the minimum and maximum values mentioned above.

According to another aspect, the abrasive particles 173 of the third region 171 may be the same as the type of abrasive particles 163 contained in the second region 161. Reference here to the type in the context of abrasive particles refers to at least one property selected from the group of medium particle size (D50), D10, D90, Vickers hardness, ellipsity, average toughness, composition, or combinations thereof. For example, the abrasive particles 173 and 163 can have the same composition with each other. However, in other embodiments, it is understood that the abrasive particles 163 and 173 may be of different types compared to each other. For example, in one embodiment, the composition of the abrasive particles 173 may be different compared to the composition of the abrasive particles 163. In another aspect, the abrasive particles 173 of the third region 171 are the same size (eg, D10, D50, and / or D90) as the abrasive particles 163 contained in the second region 161. Can be. For example, abrasive particles 173 and 163 may have an average particle size (ie, D50) relative to each other. However, in other embodiments, it is understood that the composition of the abrasive particles 173 may have a different average particle size (ie, D50) compared to the abrasive particles 163.

In certain embodiments, like the first region 151, the third region 171 can be in the form of a layer extending radially between the inner wall 112 and the shaped surface 105. In addition, the second region 161 may be in the form of a layer. The second region 161 may be in direct contact with the first region 171 such that no layer or object is located between the second and third regions 171 and 161.

In another aspect, the third region 171 may have a third content of the third bonding material 172 and the second region 161 may have a second content of the second bonding material 162. For certain abrasive articles of the embodiments herein, the second content of the second bonding material 162 may be different from the third content of the third bonding material 172. Still, in an alternative design, the second content of the second bonding material 162 may be the same as the third content of the third bonding material 172. Additionally, the first content of the first bonding material 152 may be the same as the third content of the third bonding material 172. Still, in a non-limiting embodiment, the second content of the second bonding material 162 can be the same as the third content of the third bonding material 172.

For certain embodiments, the third bonding material 172 of the third region 171 can have the same composition as the second region 161 of the second bonding material 162. The second and third bonding materials 162 and 172 can have any composition for the bonding materials mentioned in the embodiments herein. In one particular case, the second and third bonding materials 162 and 172 can be inorganic materials such as metals, metal alloys, amorphous materials, glass, ceramics, or combinations thereof. As will be appreciated, in certain cases, the second and third bonding materials 162 and 172 can have different compositions compared to each other. The compositions may be considered different from one another when at least one component (eg, element, compound or complex) is at least 5% different between the two compositions.

According to one particular embodiment, the first region 151 comprises abrasive particles of the first type having a first intermediate particle size D50 ₁ and the second region 161 comprises a second intermediate particle size D50. _{And 2} ) abrasive particles of the second type. In certain cases, the first intermediate particle size D50 ₁ may be different from the second intermediate particle size D50 ₂ . In one particular embodiment, the abrasive particle of the second type has a larger median particle size (D50 ₂ ) compared to the abrasive particle (D50 ₁ ) of the first type. In one aspect, the abrasive body may be at most 0.97, such as at most 0.95 or at most 0.93 or at most 0.90 or at most 0.87 or at most 0.85 or 0.83 or at most 0.80 or 0.77 or at most 0.75 or at most 0.73 or at most 0.70 or at 0.67 or at most 0.65. Or up to 0.63 or up to 0.60 or up to 0.57 or up to 0.55 or up to 0.53 or up to 0.50 or up to 0.47 or up to 0.45 or up to 0.43 or up to 0.40 (D50 ₁ / D50 ₂ ). Still, in one non-limiting embodiment, the ratio (D50 ₁ / D50 ₂ ) is at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or At least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It is understood that the ratio D50 ₁ / D50 ₂ may be within a range including any of the minimum and maximum values provided above.

As described in the embodiments herein, the third region 171 may comprise a third type of abrasive particles 173. In at least one case, the third type abrasive particle 173 may be different from the second type abrasive particle 163 in the second region 161. In certain cases, the abrasive body 103 may have a ratio (D50 ₃ / D50 ₂ ) of 0.97 or less, where D50 ₃ represents the median particle size of the third type of abrasive particles 173 and D50 ₂ is the second Median particle size of the abrasive particles 163 of the type. For example, the ratio (D50 ₃ / D50 ₂ ) can be 0.95 or less, such as 0.93 or less or 0.90 or less or 0.87 or 0.85 or 0.83 or less or 0.80 or 0.77 or less or 0.75 or less or 0.73 or less or 0.70 or less or 0.67 or 0.65 or less. Up to 0.63 or up to 0.60 or up to 0.57 or up to 0.55 or up to 0.53 or up to 0.50 or up to 0.47 or up to 0.45 or up to 0.43 or up to 0.40. Still, in one non-limiting embodiment, the ratio D50 ₃ / D50 ₂ is at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or It is understood that at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. The ratio D50 ₃ / D50 ₂ may be within a range including any of the minimum and maximum values provided above.

In yet another embodiment, the third type of abrasive particles 173 and the first type of abrasive particles 153 may be abrasive particles of the same type. Thus, the abrasive particles 153 of the first type and the abrasive particles 173 of the third type may have the same median particle size (D50), D10, D90, Vickers hardness, ellipsity, average toughness, and composition.

Embodiment

Embodiment 1. An abrasive article comprising:

Body that contains:

A bonding material comprising a metal and further comprising a micro-porous body in the binding material, the micro-porous body comprising an average pore size (D50) of 10 microns or less and a pore size standard deviation of at least 0.2 microns;

Abrasive particles contained in the binding material and further comprising at least one of the following:

Ellipticity less than or equal to 1.18; or

Average toughness of at least 11257 cycles according to ANSIB74.23.

Embodiment 2 The abrasive article of embodiment 1, wherein the abrasive particles comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, or combinations thereof.

Embodiment 3 The abrasive article of Embodiment 1, wherein the abrasive particles comprise a super abrasive material.

Embodiment 4 The abrasive article of embodiment 1, wherein the abrasive particles comprise diamond.

Embodiment 5 The abrasive article of embodiment 1, wherein the abrasive particles are composed essentially of diamond.

Embodiment 6. The abrasive article of embodiment 1, wherein the abrasive particles comprise a coating.

Embodiment 7 The abrasive article of embodiment 6, wherein the coating comprises a metal or metal alloy comprising a transition metal element.

Embodiment 8. The abrasive article of Embodiment 6, wherein the coating comprises titanium.

Embodiment 9. The abrasive article of embodiment 6, wherein the coating covers most or at least 60% or at least 70% or at least 80% or at least 90% or at least 95% of the outer surface of the abrasive particles.

Embodiment 10. The method of embodiment 1, wherein the abrasive particles are at least 65 microns or at least 75 microns or at least 90 microns or at least 95 microns or at least 97 microns or at least 100 microns or at least 105 microns or at least 110 microns or at least 120 microns An abrasive article comprising particle size (D50).

Embodiment 11. The particle of embodiment 1, wherein the abrasive particles comprise a median particle size (D50) of 150 microns or less or 140 microns or less or 130 microns or less or 120 microns or less or 110 microns or less or 105 microns or less or 100 microns or less. Abrasive article.

Embodiment 12. The method of embodiment 1, wherein the abrasive particles are at least 57 microns or at least 60 microns or at least 65 microns or at least 70 microns or at least 75 microns or at least 77 microns or at least 80 microns or at least 83 microns or at least 85 microns or at least An abrasive article comprising a D10 of 87 microns or at least 90 microns or at least 93 microns or at least 95 microns.

Embodiment 13. The particle of embodiment 1, wherein the abrasive particles are no greater than 127 microns or no greater than 120 microns or no greater than 110 microns or no greater than 100 microns or no greater than 95 microns or no greater than 93 microns or no greater than 90 microns or no greater than 87 microns or no greater than 85 microns or 83 An abrasive article comprising a D10 of less than or equal to 80 microns.

Embodiment 14. The particle of embodiment 1, wherein the abrasive particles are at least 97 microns or at least 100 microns or at least 103 microns or at least 105 microns or at least 108 microns or at least 110 microns or at least 113 microns or at least 115 microns or at least 118 microns or at least An abrasive article comprising a D90 of 120 microns or at least 123 microns or at least 125 microns or at least 128 microns or at least 130 microns or at least 133 microns or at least 135 microns or at least 138 microns.

Embodiment 15. The method of embodiment 1, wherein the abrasive particles are no greater than 165 microns or no greater than 160 microns or no greater than 155 microns or no greater than 150 microns or no greater than 145 microns or no greater than 140 microns or no greater than 135 microns or no greater than 133 microns or no greater than 130 microns or 128 An abrasive article comprising a D90 of less than or equal to 125 microns or less than 123 or less than 120 microns or less than 118 microns or less than 115 microns or less than 113 microns or less than 110 microns or less than 108 microns or less than 105 microns.

Embodiment 16. The abrasive article of embodiment 1, wherein the abrasive particles comprise a Vickers hardness of at least 2000 kg / mm 2 or at least 3000 kg / mm 2 or at least 4000 kg / mm 2 or at least 5000 kg / mm 2.

Embodiment 17. The abrasive article of embodiment 16, wherein the abrasive particles comprise diamond.

Embodiment 18. The method of embodiment 1, wherein the abrasive particles are at least 11900 cycles or at least 12000 cycles at least 12100 cycles or at least 12200 cycles or at least 12300 cycles or at least 12400 cycles or at least 12500 cycles or at least 12600 cycles or at least 12700 cycles or at least 12800 cycles. An abrasive article having an average toughness of cycles or at least 12900 cycles or at least 13000 cycles or at least 13100 cycles or at least 13200 cycles.

Embodiment 19. The method of embodiment 18, wherein the abrasive particles have an average toughness of 16000 or less or 15000 or less or 14500 or less or 14000 or less or 13900 or less 13800 or less 13700 or less or 13600 or less than 13500 or 13400 or less 13400 or 13300 or less. Abrasive article.

Embodiment 20. The abrasive article of embodiment 1, wherein the abrasive particles have an ellipticity of 1.17 or less or 1.16 or less or 1.15 or less or 1.14 or less or 1.13 or less or 1.12 or less or 1.11 or less or 1.10 or less.

Embodiment 21. The method of embodiment 20, wherein the abrasive particles are at least 1.01 or at least 1.02 or at least 01.03 or at least 1.04 or at least 1.05 or at least 1.06 or at least 1.07 or at least 1.08 or at least 1.09 or at least 1.10 or at least 1.11 or at least 1.12 or at least An abrasive article comprising an ellipticity of 1.13 or at least 1.14 or at least 1.15 or at least 1.16.

Embodiment 22. The body of embodiment 1, wherein the body has at least 2 wt% or at least 2.5 wt% or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least 4.5 wt% or at least 5 wt% or at least 5.5 wt % Or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt% of the abrasive particles. Abrasive article comprising the content.

Embodiment 23. The body of embodiment 1, wherein the body is 10 wt% or less or 9 wt% or less or 8.5 wt% or less or 8 wt% or less or 7.5 wt% or less or 7 wt% or less or 6.5 wt% or less or 6 wt%. Up to or below 5.5 wt% or up to 5 wt% or up to 4.5 wt% or up to 4 wt% or up to 3.5 wt% or up to 3 wt% or up to 2.5 wt% or up to 2 wt% or up to 1.5 wt% or up to 1 wt% An abrasive article comprising the following abrasive grain content.

Embodiment 24. The body of embodiment 1, wherein the body has at least 20 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt 10. An abrasive article comprising a content of binding material of% or at least 95 wt%.

Embodiment 25. The body of embodiment 1, wherein the body is 99 wt% or less or 95 wt% or less or 90 wt% or less or 80 wt% or less or 70 wt% or less or 60 wt% or less or 50 wt% relative to the total weight of the body. An abrasive article comprising a content of up to or less than 40 wt% or up to 30 wt% or up to 25 wt% binding material.

Embodiment 26. The abrasive article of embodiment 1, wherein the binding material comprises at least one of cobalt, tin, tungsten, copper, or a combination thereof.

Embodiment 27 The compound of embodiment 1, wherein the binding material comprises [CSn / CCo] cobalt (CCo) and tin (CSn) in a ratio of 0.2 or less, wherein CCo is the weight percent of cobalt and the CSn relative to the total weight of the body Is the weight percent of tin to the total weight of the body or is 0.19 or less or 0.18 or less or 0.17 or less or 0.16 or less or 0.15 or 0.14 or 0.13 or less or 0.12 or 0.11 or 0.10 or less or 0.09 or less or 0.08 or less or 0.07 An abrasive article of no greater than or equal to 0.06 or no greater than 0.05 or no greater than 0.04 or no greater than 0.03 or no greater than 0.02 or no greater than 0.01.

Embodiment 28. The method of embodiment 27, wherein the binding material is at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least An abrasive article comprising a ratio [CSn / CCo] of 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1.

Embodiment 29 The compound of embodiment 1, wherein the bonding material comprises a ratio [CW / CCo] of no greater than 0.9, wherein CCo is the weight percent of cobalt to the total weight of the body and CW is the weight of tungsten relative to the total weight of the body. Weight percent or less than 0.8 or less than 0.7 or less than 0.6 or less than 0.5 or less than 0.4 or less than 0.3 or 0.2 or less than 0.10 or less than 0.09 or 0.08 or less than 0.07 or less than 0.06 or less than 0.05 or less than 0.04 or less than 0.03 or less than 0.03 An abrasive article of no greater than or equal to 0.01.

Embodiment 30. The compound of embodiment 1, wherein the bonding material comprises a ratio [CW / CCo] of at least about 0.001, wherein CCo is the weight percent of cobalt to the total weight of the body and CW is tungsten relative to the total weight of the body. At least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or An abrasive article that is at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7.

Embodiment 31 The compound of embodiment 1, wherein the bonding material comprises tungsten (CW) and tin (CSn) in a ratio [CSn / CW] of 1 or less, wherein CW is the weight percentage of tungsten relative to the total weight of the body CSn is the weight percent of tin relative to the total weight of the bonding material, or is less than 0.9 or less than 0.8 or less than 0.7 or less than 0.6 or less than 0.5 or less than 0.4 or less than 0.3 or less than 0.2 or less than 0.1.

Embodiment 32. The compound of embodiment 1, wherein the bonding material comprises tungsten (CW) and tin (CSn) in a ratio [CSn / CW] of at least 0.01, wherein CW is the weight percentage of tungsten relative to the total weight of the body. CSn is the weight percent of tin relative to the total weight of the body, or is an abrasive article that is at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9. .

Embodiment 33. The method of embodiment 1, wherein the bonding material is at least 40 wt% or at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least 54 wt% or at least relative to the total weight of the body. 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt% or at least 72 wt% or at least 73 wt% or at least 74 wt% or at least 75 wt% or at least 76 wt% or at least 77 wt% or at least 78 wt% or at least 79 wt% or at least 80 wt% or at least 81 wt% or at least 82 wt% or at least 83 wt% or at least 84 wt% or at least 85 wt% or at least 86 wt% or Cobalt in an amount of at least 87 wt% or at least 88 wt% or at least 89 wt% or at least 90 wt% or at least 91 wt% or at least 92 wt% or at least 93 wt% or at least 94 wt% or at least 95 wt% Abrasive articles.

Embodiment 34 The compound of embodiment 1, wherein the bonding material is 99 wt% or less or 98 wt% or less or 97 wt% or less or 96 wt% or less or 95 wt% or less or 94 wt% or less or 93 wt% or 92 wt% Below% or below 91 wt% or below 90 wt% or below 89 wt% or below 88 wt% or below 87 wt% or below 86 wt% or below 85 wt% or below 84 wt% or below 83 wt% or 82 wt Below% or below 81 wt% or below 80 wt% or below 79 wt% or below 78 wt% or below 77 wt% or below 76 wt% or below 75 wt% or below 74 wt% or below 73 wt% or 72 wt An abrasive article comprising cobalt in an amount of up to or less than 71 wt% or up to 70 wt% or up to 69 wt% or up to 68 wt% or up to 67 wt% or up to 66 wt% or up to 65 wt%.

Embodiment 35. The method of embodiment 1, wherein the bonding material is at least 0.1 wt% or at least 0.2 wt% or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt% or at least 0.6 wt% or at least relative to the total weight of the body. 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% Or tin in an amount of at least 3.8 wt% or at least 3.9 wt% or at least 4 wt% or at least 4.1 wt% or at least 4.2 wt% or at least 4.3 wt% or at least 4.4 wt% or at least 4.5 wt% or at least 5 wt%. An abrasive article comprising.

Embodiment 36. The compound of embodiment 1, wherein the bonding material is 15 wt% or less or 12 wt% or less or 10 wt% or less or 9 wt% or less or 8.5 wt% or less or 8 wt% or less or 7.5, based on the total weight of the body. up to or below 7 wt% or up to 6.5 wt% or up to 6 wt% or up to 5.5 wt% or up to 5 wt% or up to 4.5 wt% or up to 4 wt% or up to 3.5 wt% or up to 3 wt% or 2.5 An abrasive article comprising tin in an amount of up to wt or up to 2 wt% or up to 1.5 wt% or up to 1 wt% or 0.5 wt%.

Embodiment 37 The compound of embodiment 1, wherein the bonding material is at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least relative to the total weight of the body. 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt% or at least 3.2 wt% or at least 3.3 wt% or at least 3.4 wt% or at least 3.5 wt% or at least 3.6 wt% or at least 3.7 wt% or at least 3.8 wt% or at least 3.9 wt% or at least 4 wt% or at least 4.1 wt% or at least 4.2 wt% or at least 4.3 wt% or at least 4.4 wt% or at least 4.5 wt% or at least 4.6 wt% Is at least 4.7 wt% or at least 4.8 wt% or at least 4.9 wt% or at least 5 wt% or at least 5.1 wt% or at least 5.2 wt% or at least 5.3 wt% or at least 5.4 wt% or at least 5.5 wt% or at least 5.6 wt% Or at least 5.7 wt% or at least 5.8 wt% or at least 5.9 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% An abrasive article comprising tungsten in the content of.

Embodiment 38. The compound of embodiment 1, wherein the bonding material is at most 20 wt% or at most 18 wt% or at most 16 wt% or at most 14 wt% or at most 12 wt% or at most 10 wt% or 9 relative to the total weight of the body. up to 8 wt% or up to 7 wt% or up to 6 wt% or up to 5 wt% or up to 4 wt% or up to 3 wt% or up to 2 wt% or up to 1.5 wt% Abrasive articles.

Embodiment 39. The method of embodiment 1, wherein the bonding material is at least 0.05 wt% or at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 wt% or at least relative to the total weight of the body. 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt% or at least An abrasive article comprising iron in an amount of 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt%.

Embodiment 40 The compound of embodiment 1, wherein the bonding material is 5 wt% or less or 4 wt% or less or 3 wt% or less or 2 wt% or less or 1.5 wt% or less or 1 wt% or 0.9 wt. Relative to the total weight of the body. An abrasive article comprising iron in an amount of up to or below 0.8 wt% or up to 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% or up to 0.3 wt%.

Embodiment 41. The compound of embodiment 1, wherein the bonding material is at most 1 wt% or at most 0.9 wt% or at most 0.8 wt% or at most 0.7 wt% or at most 0.6 wt% or at most 0.5 wt% or 0.4, relative to the total weight of the body. Abrasive articles comprising aluminum in an wt% or less or 0.3 wt% or less or 0.2 wt% or less or 0.1 wt% or less or 0.09 wt% or less or 0.05 wt% or less or 0.01 wt% or less content

Embodiment 42. The compound of embodiment 1, wherein the bonding material is 20 wt% or less or 15 wt% or less or 10 wt% or less or 5 wt% or less or 2 wt% or less or 1 wt% or 0.9 wt relative to the total weight of the body. Below% or below 0.8 wt% or below 0.7 wt% or below 0.6 wt% or below 0.5 wt% or below 0.4 wt% or below 0.3 wt% or below 0.2 wt% or below 0.1 wt% or below 0.09 wt% or 0.05 wt An abrasive article comprising copper in an amount of up to% or up to 0.01 wt%.

Embodiment 43. The method of embodiment 1, wherein the bonding material is at most 1 wt% or at most 0.9 wt% or at most 0.8 wt% or at most 0.7 wt% or at most 0.6 wt% or at most 0.5 wt% or 0.4, relative to the total weight of the body. An abrasive article comprising manganese in an wt% or less or 0.3 wt% or less or 0.2 wt% or less or 0.1 wt% or less or 0.09 wt% or less or 0.05 wt% or less or 0.01 wt% or less content

Embodiment 44. The compound of embodiment 1, wherein the bonding material is at most 1 wt% or at most 0.9 wt% or at most 0.8 wt% or at most 0.7 wt% or at most 0.6 wt% or at most 0.5 wt% or 0.4, relative to the total weight of the body. An abrasive article comprising titanium in an amount of up to wt or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% or up to 0.09 wt%.

Embodiment 45 The body of embodiment 1, wherein the body is 20 wt% or less or 15 wt% or less or 10 wt% or less or 5 wt% or less or 2 wt% or less or 1 wt% or 0.9 wt% relative to the total weight of the body. Up to or below 0.8 wt% or up to 0.7 wt% or up to 0.6 wt% or up to 0.5 wt% or up to 0.4 wt% or up to 0.3 wt% or up to 0.2 wt% or up to 0.1 wt% aluminum, copper, manganese, lead, silicon And an abrasive article comprising a total content of titanium.

Embodiment 46. The group of embodiment 1, wherein at least 95 wt% of the bonding material comprises cobalt, tin, and tungsten, and no more than 5 wt% of the bonding material consisting of aluminum, copper, manganese, lead, silicon, and titanium An abrasive article comprising a secondary element selected from.

Embodiment 47. The microporous body of embodiment 1, wherein the microporous body is no more than 9 microns or no more than 8 microns or no more than 7 microns or no more than 6 microns or no more than 5 microns or no more than 4 microns or no more than 4 microns or no more than 3 microns or no more than 2 microns or An abrasive article comprising an average pore size (D50) of 1 micron or 0.9 microns or less or 0.8 microns or less or 0.7 microns or less or 0.6 microns or less or 0.5 microns or less.

Embodiment 48. The compound of embodiment 1, wherein the micro-porous body is at least 0.01 micron or at least 0.05 micron or at least 0.1 micron or at least 0.2 micron or at least 0. 25 micron or at least 0.3 micron or at least 0.35 micron or at least 0.4 micron or at least 0.45 An abrasive article comprising an average pore size (D50) of microns or at least 0.5 microns.

Embodiment 49. The compound of embodiment 1, wherein the micro-porous body is at least 0.2 microns or at least 0.22 microns or at least 0.24 microns or at least 0.26 microns or at least 0.28 microns or at least 0.3 microns or at least 0.32 microns or at least 0.34 microns or at least 0.36 microns or An abrasive article comprising a pore size standard deviation of at least 0.38 microns or at least 0.4 microns or at least 0.42 microns or at least 0.44 microns.

Embodiment 50. The microporous body of embodiment 1, wherein the microporous body is less than 2 microns or less than 1.8 microns or less than 1.6 microns or less than 1.4 microns or less than 1.2 microns or less than 1 micron or less than 0.8 microns or less than 0.6 microns or less than 0.5 microns An abrasive article comprising a size standard deviation.

Embodiment 51. The body of embodiment 1, wherein the body is at least 0.5 vol% or at least 1 vol% or at least 1.5 vol% or at least 2 vol% or at least 2.5 vol% or at least 3 vol% or at least 3.5 relative to the total volume of the body. vol% or at least 4 vol% or at least 4.5 vol% or at least 5 vol% or at least 5.5 vol% or at least 6 vol% or at least 7 vol% or at least 8 vol% or at least 9 vol% or at least 10 vol% of the porous body Abrasive article comprising the content.

Embodiment 52. The body of embodiment 1, wherein the body is 50 vol% or less or 30 vol% or less or 20 vol% or less or 15 wt% or less or 12 wt% or less or 10 vol% or less or 9 vol relative to the total volume of the body. An abrasive comprising a porous body content of at most% or at most 8 vol% or at most 7 vol% or at most 6 vol% or at most 5 vol% or at most 4 vol% or at most 3 vol% or at most 2 vol% or at most 1 vol%. article.

Embodiment 53. The body of embodiment 1, wherein the body comprises a first area comprising a first content of abrasive particles and a second area comprising a second content of abrasive particles, wherein the first content and the second content are Different abrasive articles in comparison to each other.

Embodiment 54. The abrasive article of embodiment 53, wherein the second content is greater than the first content.

Embodiment 55. The compound of embodiment 53, further comprising a ratio (C1 / C2) of no greater than 0.97, wherein C1 represents a first content and C2 represents a second content, wherein the ratio (C1 / C2) is 0.95 Or below 0.93 or below 0.90 or below 0.87 or 0.85 below or 0.83 or below 0.80 or 0.77 or below 0.75 or 0.73 or below 0.70 or below 0.67 or below 0.65 or 0.63 or below 0.60 or below 0.57 or below 0.55 or 0.53 An abrasive article of no greater than or equal to 0.50 or no greater than 0.47 or no greater than 0.45 or no greater than 0.43 or no greater than 0.40.

Embodiment 56. The compound of embodiment 53, further comprising a ratio (C1 / C2) of at least 0.1, wherein C1 represents a first content and C2 represents a second content, wherein the ratio (C1 / C2) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or An abrasive article that is at least 0.95.

Embodiment 57 The abrasive article of embodiment 53, wherein the abrasive particles in the first region and the abrasive particles in the second region are abrasive particles of the same type.

Embodiment 58. The abrasive article of embodiment 53, wherein the abrasive particles in the first region and the abrasive particles in the second region are different types of abrasive particles.

Embodiment 59. The abrasive article of embodiment 53, wherein the first region is in the form of a layer.

Embodiment 60. The abrasive article of embodiment 53, wherein the second region is in the form of a layer.

Embodiment 61. The abrasive article of embodiment 53, wherein the second region is in direct contact with the first region.

Embodiment 62. The method of embodiment 53, wherein the first region comprises a first content of the first binding material, wherein the second region comprises a second content of the second binding material, wherein the second of the second binding material 2 The abrasive article is different in content from the first content of the first bonding material.

Embodiment 63. The abrasive article of embodiment 62, wherein the first binding material and the second binding material have the same composition.

Embodiment 64. The abrasive article of embodiment 62, wherein the first binding material and the second binding material have different compositions compared to each other.

Embodiment 65. The abrasive article of embodiment 62, further comprising a third region comprising a third content of abrasive particles, wherein the third content is different than the second content.

Embodiment 66. The abrasive article of embodiment 65, wherein the second region is disposed between the first region and the third region.

Embodiment 67 The abrasive article of embodiment 65, wherein the first content and the third content are the same.

Embodiment 68. The abrasive article of embodiment 65, wherein the second content is greater than the third content.

Embodiment 69. The compound of embodiment 65, further comprising a ratio (C3 / C2) of no greater than 0.97, wherein C3 represents a third content and C2 represents a second content, wherein the ratio (C3 / C2) is 0.95 Or below 0.93 or below 0.90 or below 0.87 or 0.85 below or 0.83 or below 0.80 or 0.77 or below 0.75 or 0.73 or below 0.70 or below 0.67 or below 0.65 or 0.63 or below 0.60 or below 0.57 or below 0.55 or 0.53 An abrasive article of no greater than or equal to 0.50 or 0.47 or less or 0.45 or less than 0.43 or 0.40.

Embodiment 70. The compound of embodiment 65, further comprising a ratio (C3 / C2) of at least 0.1, wherein C3 represents a third content and C2 represents a second content, wherein the ratio (C3 / C2) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or An abrasive article that is at least 0.95.

Embodiment 71. The abrasive article of embodiment 65, wherein the abrasive particles in the third region and the abrasive particles in the second region are abrasive particles of the same type.

Embodiment 72. The abrasive article of embodiment 65, wherein the abrasive particles in the third region and the abrasive particles in the second region are different types of abrasive particles.

Embodiment 73. The abrasive article of embodiment 65, wherein the abrasive particles in the third region and the abrasive particles in the first region are abrasive particles of the same type.

Embodiment 74. The abrasive article of embodiment 65, wherein the third region is in the form of a layer.

Embodiment 75. The abrasive article of embodiment 65, wherein the second region is in the form of a layer and is in direct contact with the third region.

Embodiment 76 The embodiment of embodiment 65, wherein the third region comprises a third content of the third bonding material, and the second region comprises a second content of the second bonding material, wherein the second of the second bonding material Wherein the content is different from the third content of the third bonding material.

Embodiment 77. The abrasive article of embodiment 76, wherein the third binding material and the second binding material have the same composition.

Embodiment 78 The abrasive article of embodiment 76, wherein the third binding material and the second binding material have different compositions compared to each other.

Embodiment 79 The body of embodiment 1, wherein the body comprises a first area comprising abrasive particles of a first type and a second area comprising abrasive particles of a second type, wherein the first type and the second type are The abrasive particles are different from each other in the abrasive article.

Embodiment 80. The compound of embodiment 79, wherein the first and second types are at least one selected from the group of median particle size (D50), D10, D90, Vickers hardness, ellipsity, average toughness, composition, or combinations thereof. Different abrasive articles compared to each other based on the properties of the.

Embodiment 81. The abrasive article of embodiment 79, wherein the first type and the second type are different from each other based on the median particle size.

Embodiment 82. The abrasive article of embodiment 79, wherein the abrasive particles of the second type have a larger median particle size compared to the abrasive particles of the first type.

Embodiment 83. The compound of embodiment 79, further comprising a ratio (D501 / D502) of no greater than 0.97, wherein D501 represents an intermediate particle size of abrasive particles of the first type and D502 is intermediate of an abrasive particle of the second type. Particle size, wherein the ratio (D501 / D502) is 0.95 or less or 0.93 or less or 0.90 or less or 0.87 or less or 0.85 or 0.83 or less or 0.80 or 0.77 or 0.75 or less or 0.73 or less or 0.70 or less or 0.67 or less or 0.65 or less Or 0.63 or less or 0.60 or less or 0.57 or less or 0.55 or less or 0.53 or 0.50 or 0.47 or less or 0.45 or less or 0.43 or less or 0.40 or less.

Embodiment 84. The compound of embodiment 79, further comprising a ratio (D501 / D502) of at least 0.1, wherein D501 represents the median particle size of the abrasive particles of the first type and D502 is the median of the abrasive particles of the second type. Particle size, wherein the ratio (D501 / D502) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least An abrasive article that is 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95.

Embodiment 85 The compound of embodiment 79, wherein the first region comprises a first content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the first content and the second content are different from one another. Abrasive articles.

Embodiment 86. The method of embodiment 79, wherein the first region comprises a first content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the first content and the second content are the same as compared to each other. Abrasive articles.

Embodiment 87 The abrasive article of embodiment 79, wherein the first region is in the form of a layer.

Embodiment 88 The abrasive article of embodiment 79, wherein the second region is in the form of a layer.

Embodiment 89. The abrasive article of embodiment 79, wherein the second region is in direct contact with the first region.

Embodiment 90 The embodiment of embodiment 79, wherein the first region comprises a first content of the first binding material, wherein the second region comprises a second content of the second binding material, wherein 2 The abrasive article is different in content from the first content of the first bonding material.

Embodiment 91 The abrasive article of embodiment 90, wherein the first binding material and the second binding material have the same composition.

Embodiment 92. The abrasive article of embodiment 90, wherein the first binding material and the second binding material have different compositions compared to each other.

Embodiment 93 The abrasive article of embodiment 79, further comprising a third region comprising a third type of abrasive particles, wherein the third type is different from the second type.

Embodiment 94 The abrasive article of embodiment 93, wherein the second region is disposed between the first region and the third region.

Embodiment 95 The abrasive article of embodiment 93, wherein the first type and the third type are identical to each other.

Embodiment 96. The compound of embodiment 93, further comprising a ratio (D503 / D502) of no greater than 0.97, wherein D503 represents an intermediate particle size of the abrasive particle of the third type and D502 is an intermediate of an abrasive particle of the second type. Particle size, wherein the ratio (D503 / D502) is 0.95 or less or 0.93 or less or 0.90 or less or 0.87 or less or 0.85 or 0.83 or 0.80 or 0.77 or less or 0.75 or less or 0.73 or less or 0.70 or less or 0.67 or less or 0.65 or less Or 0.63 or less or 0.60 or less or 0.57 or less or 0.55 or less or 0.53 or 0.50 or 0.47 or less or 0.45 or less or 0.43 or less or 0.40 or less.

Embodiment 97. The method of embodiment 93, further comprising a ratio (D503 / D502) of at least 0.1, wherein D503 represents the median particle size of the abrasive particles of the third type and D502 is the median of the abrasive particles of the second type. Particle size, wherein the ratio (D503 / D502) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least An abrasive article that is 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95.

Embodiment 98 The abrasive article of embodiment 93, wherein the third region is in the form of a layer.

Embodiment 99 The abrasive article of embodiment 93, wherein the second region is in the form of a layer and is in direct contact with the third region.

Embodiment 100 The method of embodiment 93, wherein the third region comprises a third content of the third bonding material, and the second region comprises a second content of the second bonding material, wherein the second of the second bonding material Wherein the content is different from the third content of the third bonding material.

Embodiment 101 The abrasive article of embodiment 100, wherein the third binding material and the second binding material have the same composition.

Embodiment 102 The abrasive article of embodiment 100, wherein the third binding material and the second binding material have different compositions compared to each other.

Embodiment 103. The abrasive article of embodiment 93, wherein the third region comprises a third content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the third content is different from the second content. .

Embodiment 104. A method for forming an abrasive article comprising

Forming a mixture comprising precursor binding material and abrasive particles; And

Heating the mixture to form a body comprising:

The binding material comprises a metal and further comprises a micro-porous body in the binding material, the micro-porous body comprising an average pore size (D50) of 10 microns or less and a pore size standard deviation of at least 0.2 microns;

Abrasive particles contained in the binding material and further comprising at least one of the following:

Ellipticity less than or equal to 1.18; or

Average toughness of at least 11257 cycles.

Embodiment 105. The compound of embodiment 104, wherein the mixture comprises a precursor binding material having an average particle size of 25 microns or less or 10 microns or less or 1 micron or 0.75 microns or less or 0.5 microns or less or 0.25 microns or less or 0.1 microns or less. How to.

Embodiment 106. The method of embodiment 104, wherein the mixture comprises a precursor binding material having an average particle size of at least 0.001 microns, such as at least 0.01 microns or even at least 0.1 microns.

Embodiment 107. The method of embodiment 104, wherein the mixture heating is at least 700 ° C or at least 725 ° C or at least 750 ° C or at least 775 ° C or at least 800 ° C or at least 825 ° C or at least 850 ° C or at least 875 ° C or at least 900 ° C or At least 925 ° C or at least 950 ° C or at least 975 ° C or at least 1000 ° C.

Embodiment 108 The method of embodiment 104, wherein the mixture heating is performed at a temperature of 1100 ° C. or less or 1050 ° C. or less or 1000 ° C. or less or 975 ° C. or less or 950 ° C. or less or 925 ° C. or less or 900 ° C. or less.

Embodiment 109. The method of embodiment 104, wherein the forming comprises hot pressing of the mixture.

Embodiment 110. The method of embodiment 104, wherein the forming comprises hot pressing of the mixture at a pressure of at least 1000 psi or at least 1500 psi or at least 2000 psi or at least 2200 psi.

Embodiment 111. The method of embodiment 104, wherein the forming comprises hot pressing of the mixture at pressures of up to 5000 psi or up to 4000 psi or up to 3000 psi or up to 2750 psi.

Example 1

The following samples were prepared and tested for performance comparison. The first sample, sample C1, is a commercially available glass polishing wheel having approximately 92 vol% metal bonds of approximately 93% cobalt, 2% tin and 5% tungsten. The abrasive article of Sample C1 also includes approximately 16 vol% diamond abrasive particles having an approximately toughness of approximately 93 microns, a D50 of 76 microns, a D10 of 76 microns, a D90 of 113 microns, an ellipticity of 1.19, and an average toughness of approximately 11676 cycles. Abrasive particles have a particle size greater than 120 microns. The porous body of sample C1 is approximately 1 vol% relative to the total volume of the body and has an average pore size (D50) of 0.38 microns with a standard deviation of 0.19 microns. 2 includes a scanning electron microscope (SEM) image of a portion of the abrasive article of Sample C1 without abrasive particles.

The second sample, sample S2, is formed by preparing a mixture of abrasive particles, precursor binding material, and additives. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have approximately 104 microns D50, 113 microns D90, 88 microns D10, and 1.5 vol% abrasive particles have a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 13135 cycles and an ellipticity of approximately 1.17.

Precursor binding materials include cobalt powders commercially available as "Extrafine Cobalt" from Umicore and further include commercially available tin as Tin201 from ACupowder.

The mixture was hot pressed uniaxially at a temperature of 975 ° C. for a duration of approximately 5 minutes under a pressure of 2500 psi. The abrasive article of the finally-formed sample S2 comprises approximately 16% vol% abrasive particles and approximately 81 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and 3 wt% tin. The body further comprises approximately 3 vol% porous body, the porous body having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of 0.42 microns. to be.

The third sample, sample S3, is formed using the same process disclosed for preparing sample S2, except that the abrasive particles are titanium-coated diamond particles available as IMD-F from ILJIN. The abrasive particles have approximately 97 microns of D50, 113 microns of D90, 84 microns of D10, and 6 vol% of abrasive particles have a particle size of greater than 120 microns. The abrasive particles have an average toughness of approximately 10683 cycles and an ellipticity of approximately 1.15.

The abrasive article of Sample S3 is formed through hot pressing at a temperature of 975 ° C. for a duration of approximately 5 minutes under 2500 psi pressure. The finally formed abrasive article of Sample S3 comprises approximately 16 vol% abrasive particles and approximately 81 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and 3 wt% tin. The body comprises approximately 3 vol% porous body, which is a micro-porous body having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of approximately 0.42 microns.

A fourth sample, sample S4, is formed using the same process disclosed to prepare sample S2 except that the abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have approximately 101 microns D50, 113 D90, 88 D10 and 1.5 vol% abrasive particles have a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15.

The abrasive article of Sample S4 is formed via hot pressing at a temperature of 975 ° C. under a pressure of 2500 psi for a duration of approximately 5 minutes. The finally formed abrasive article of Sample S4 comprises approximately 14 vol% abrasive particles and approximately 83 vol% binding material. The binding material comprises 97 wt% cobalt and 3 wt% tin. The body comprises approximately 3 vol% porous body.

Each sample was used to polish the edges of the glass article of white tempered glass. The length of the machined surface was approximately four linear meters for each glass article sample. The sample was run at a cross speed of 15 m / min and a 45 m / s axis speed.

4 and 5 include plots of current versus number of two different dressing cycles, number of finished glass articles for each sample for each. As described in FIG. 4, samples S2 and S3 had the lowest currents. Sample S3 finished most glass samples and the samples required dressing before the current climbed to an undesirable level. Each sample was dressed according to the same conditions and tested again to form the date provided in FIG. 5. As illustrated in FIG. 5, samples S2 and S3 had significantly lower current conditions and finished more glass articles than samples C1 and S4. Sample S2 showed a significant improvement in the number of finished glass articles.

Example 2

Sample (Sample S5) was subjected to the process described for Sample S2 except for sub-sieving using a stack of four screens having approximate micron size openings of 106 microns, 97 microns, 90 microns, and 75 microns. Thus formed. All abrasive particles above the 106 micron screen and below the 75 micron screen were discarded. The abrasive particles were titanium-coated diamond particles available as IMD-Mc from ILJIN. The abrasive particles have a D50 of about 95 microns, a D90 of about 103 microns, a D10 of about 80 microns, and an abrasive particle of about 0.1 vol% has a particle size of greater than 120 microns. 6 includes an SEM image of a portion of sample S5 according to an embodiment.

Example 3

Sample (Sample S6) is formed according to the process disclosed for Sample S2. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 104 microns, a D90 of approximately 113 microns, and a D10 of approximately 88 microns, and approximately 1.5 vol% of abrasive particles have a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 13135 cycles and an ellipticity of approximately 1.17. The finally formed abrasive article of Sample S6 comprises approximately 14 vol% abrasive particles and approximately 83 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin. The body comprises approximately 3 vol% porous body, which is a micro-porous body having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of approximately 0.42 microns.

Example 4

The sample (Sample S7) is formed according to the process disclosed for Sample S3 except for the difference in content of abrasive particles and bonding material. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of about 97 microns, a D90 of about 113 microns, a D10 of about 84 microns, and an abrasive particle of about 6 vol% has a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 10683 cycles and an ellipticity of approximately 1.15. The finally formed abrasive article of sample S7 comprises approximately 14.5 vol% abrasive particles and approximately 82.5 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin. The body comprises approximately 3 vol% porous body, which is a micro-porous body having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of approximately 0.42 microns.

Example 5

The sample (Sample S8) is formed according to the process disclosed for Sample S4 except for the difference in content of abrasive particles and binding material. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 101 microns, a D90 of approximately 113, and a D10 of approximately 88, and approximately 1.5 vol% abrasive particles have a particle size of greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15. The finally formed abrasive article of Sample S8 comprises approximately 11 vol% abrasive particles and approximately 86 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin. The body comprises approximately 3 vol% porous body.

Example 6

The sample (Sample S9) is formed according to the process disclosed for Sample S2 except for the difference in content of abrasive particles and binding material. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 104 microns, a D90 of approximately 113 microns, and a D10 of approximately 88 microns, and approximately 1.5 vol% of abrasive particles have a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 13135 cycles and an ellipticity of approximately 1.17. The abrasive article of the finally-formed sample S9 comprises approximately 14.5% vol% abrasive particles and approximately 82.5 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin.

Example 7

The sample (sample S10) is formed according to the process disclosed for sample S2 except for the difference in the size and content of the abrasive particles and the content of the binding material. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 101 microns, a D90 of approximately 113, and a D10 of approximately 88, and approximately 1.5 vol% abrasive particles have a particle size of greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15. The abrasive article of the finally-formed sample S10 comprises approximately 11% vol% abrasive particles and approximately 86 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin.

Example 8

The sample (sample S11) is formed according to the process disclosed for sample S2 except for the difference in the size and content of the abrasive particles and the content of the binding material. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 101 microns, a D90 of approximately 113, and a D10 of approximately 88, and approximately 1.5 vol% abrasive particles have a particle size of greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15. The abrasive article of the finally-formed sample S11 comprises approximately 11% vol% abrasive particles and approximately 86 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin.

Example 9

The sample (sample S12) is formed according to the process disclosed for sample S2 except for the difference in the size and content of the abrasive particles and the content of the binding material. Abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of about 106 microns, a D90 of about 115 microns, and a D10 of about 92 microns, and an abrasive particle of about 2 vol% has a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15. The abrasive article of the finally-formed sample S12 comprises approximately 15 vol% abrasive particles and approximately 85 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin.

Example 10

The sample (Sample S13) is made of a multilayer of abrasive material and it is calcined together according to the conditions provided in Sample S2. In particular, the abrasive zone is made of three layers comprising a first layer, a third layer, and a second layer disposed between the first and third layers. Each layer is prepared separately as a green (ie, uncalcined) layer and combined before final calcination and abrasive body formation. The first layer comprises titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 97 microns, a D90 of approximately 105 microns, and a D10 of approximately 76 microns, and the 2 vol% abrasive particles have a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15. The first layer is formed to include approximately 14 vol% abrasive particles and approximately 86 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and approximately 3 wt% tin.

 The second layer comprises titanium-coated diamond particles available from ILJIN. The abrasive particles have a D50 of approximately 104 microns, a D90 of approximately 113 microns, and a D10 of approximately 88 microns, and approximately 1.5 vol% of abrasive particles have a particle size greater than 120 microns. The abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15. The second layer is formed to include approximately 14 vol% abrasive particles and approximately 83 vol% binding material. The bonding material comprises 97 wt% cobalt and approximately 3 wt% tin.

The third layer is formed to have the same configuration as the first layer. The three layers are co-calcined together according to the conditions provided in sample S2. The finally formed abrasive body comprises approximately 3 vol% porous body relative to the total volume of the body.

Example 11

Samples S2 and S6, and conventional Sample C2 obtained from 3M ™ under the trademark K20P, were subjected to an abrasive test on laminated glass articles having a thickness of 2.1 mm using a Bystronic® polisher. Samples were run at 18 m / min crossing speed and 38 m / s axis speed. The same dressing was applied at the same frequency to the sample. The working length for the sample is as described in FIG. 7. Compared with C2, samples S2 and S6 can polish longer linear lengths.

Example 12

Sample S2 and, under the trademark GNAA, Daotian High Technology Co. Ltd, and conventional samples, C3 and C4, obtained from Shanghai Xingsheng Industrial Co., Ltd, were subjected to abrasive testing on laminated windshields. The test is performed using a Bystronic grinder, and the working parameters and working lengths are included in Tables 1 and 2.

Sample Traverse speed Axis speed Dressing frequency Onboard working length C3 16 m / min 30 m / s 13pcs 8000-11000 m S2 18 m / min 36 m / s 13pcs 9537 m

Sample Traverse speed Axis speed Dressing frequency Onboard working length C4 12 m / min 22 m / s 16pcs / 2imp 6000-8000 m S2 16 m / min 22 m / s 16pcs / 2imp 9680 m

As disclosed in Table 1, sample S2 was able to polish at a faster rate compared to C3 and finish polishing of similar linear length. Sample S2 could be polished for longer linear lengths at faster traversal speeds compared to C4 (Table 2).

Example 13

Sample S14 is formed using the same process disclosed for the preparation of Sample S2 except that the abrasive particles are titanium coated diamond particles (200/230 mesh sizes) available from Warren Amplex Superabrasives. The abrasive particles have an average toughness of approximately 12392 cycles and an ellipticity of approximately 1.1176. The finally formed abrasive article of sample S14 comprises approximately 16 vol% diamond abrasive particles and approximately 81 vol% binding material. The bonding material comprises approximately 97 wt% cobalt and 3 wt% tin. The body further comprises approximately 3 vol% porous body, which is a micro-porous body having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of 0.42 microns.

Samples S6 and S14 were tested for glass articles under optimal and low coolant flow conditions. For optimum conditions, the coolant flow rate was 67 l / min, running sample S6 at 15 m / min crossing speed and 30 m / s axis speed, and sample S14 with same traverse speed and 37.5 m / s wheel speed as S6 It worked at For low coolant flow conditions, the flow rate is 40 l / min and samples S6 and S14 were operated at 12 m / min cross speed and 53 m / s wheel speed.

Operation at low coolant flow rates can cause a burning effect on glass articles (spark formation during polishing), which can be solved by adjusting the dressing frequency. As illustrated in FIG. 8, under optimal cooling water flow, samples S6 and S14 were dressed at similar frequencies, and at low flow rate conditions, 10 glass pieces versus S6 versus 25 for S14 to achieve the desired polishing results. With dog glass pieces, it was necessary to dress sample S6 more frequently than sample S14.

Note that not all of the activities in the above general description or embodiments are necessary, some of the specific activities may not be required, and one or more additional activities may be performed other than as described. Still further, the order of the listed activities is not necessarily the order in which they are performed.

For certain embodiments, benefits, other advantages, and problem solutions have been described above. However, the benefits, advantages, problem solutions, and features that may cause the benefits, advantages, problem solutions to occur or become more evident should not be regarded as the mandatory, necessary, or essential features of any claim.

It is intended to provide a general understanding of the structure of the various embodiments. The descriptions and examples are not intended to serve as an exclusive and comprehensive description of all members and features of the devices and systems using the structures or methods described herein. Separate embodiments may also be provided in combination with a single embodiment, and, conversely, for simplicity, various features described in the context of a single embodiment may also be provided separately or in sub-combination. In addition, reference to values stated within a range includes each and every value within that range. Many other embodiments may be apparent to the skilled artisan only after reading the specification. Other embodiments may be used and derived from the present disclosure so that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the present disclosure. Accordingly, this disclosure is to be regarded as illustrative rather than restrictive.

Claims (15)

Abrasive articles, including:
Body that contains:
A bonding material comprising a metal and further comprising a micro-porous body in the binding material, the micro-porous body comprising an average pore size (D50) of 10 microns or less and a pore size standard deviation of at least 0.2 microns;
Abrasive particles contained in the binding material and further comprising at least one of the following:
a) ellipticity less than or equal to 1.18; or
b) average toughness of at least 11257 cycles according to ANSIB74.23. The abrasive article of claim 1, wherein the abrasive particles comprise a super abrasive material. The abrasive article of claim 1, wherein the abrasive particles comprise diamond. 3. The abrasive article of claim 1 or 2, wherein the abrasive particles comprise a coating, wherein the coating comprises a metal or metal alloy comprising a transition metal element. The abrasive article of claim 4, wherein the coating comprises titanium. The abrasive article of claim 1 or 2, wherein the abrasive particles comprise a particle size distribution comprising at least one of the following:
A D50 of at least 65 microns and no more than 150 microns;
D10 of at least 57 microns and below 127 microns; And
A D90 of at least 97 microns and no greater than 165 microns. The abrasive article of claim 1, wherein the abrasive particles comprise a Vickers hardness of at least 2000 kg / mm ² . The abrasive article of claim 1, wherein the abrasive particles have an average toughness of at least 11257 cycles and no more than 16000 cycles. The abrasive article of claim 1, wherein the abrasive particles have an ellipticity of at least 1.01 and no greater than 1.17. The abrasive article according to claim 1 or 2, wherein the body comprises a content of:
At least 2 wt% and up to 10 wt% of abrasive particles relative to the total weight of the body;
At least 20 wt% and up to 95 wt% of the binding material relative to the total weight of the body; And
At least 0.5 vol% and at most 50 vol% of the porous body relative to the total volume of the body. The abrasive article according to claim 1 or 2, wherein the bonding material comprises:
Cobalt in an amount of at least 0.1 wt% and up to 99 wt% with respect to the total weight of the body;
Tin in an amount of at least 1 wt% and up to 15 wt%, based on the total weight of the body,
Tungsten in an amount of at least 0.05 wt% and up to 20 wt% relative to the total weight of the body;
Copper in an amount of up to 20 wt%, based on the total weight of the body; or
Combination of these. The method of claim 1, wherein at least 95 wt% of the bonding material comprises cobalt, tin and tungsten, and 5 wt% or less of the bonding material is selected from the group consisting of aluminum, copper, manganese, lead, silicon, and titanium. An abrasive article comprising the secondary element to be made. 3. The body of claim 1 or 2, wherein the body comprises a first region comprising a first content of abrasive particles and a second region comprising a second content of abrasive particles, wherein the first content and the second content are compared with each other. And wherein the first and second regions are in the form of layers. A method for forming an abrasive article comprising:
Forming a mixture comprising precursor binding material and abrasive particles; And
Heating the mixture to form a body comprising:
A bonding material comprising a metal and further comprising a micro-porous body in the binding material, the micro-porous body comprising an average pore size (D50) of 10 microns or less and a pore size standard deviation of at least 0.2 microns;
Abrasive particles contained in the binding material and further comprising at least one of the following:
a) ellipticity less than or equal to 1.18; or
b) average toughness of at least 11257 cycles. 15. The method of claim 14, wherein the mixture comprises a precursor binding material having an average particle size of 25 microns or less.

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