KR20200006632A - Abrasive article and method of forming the same - Google Patents

Abstract

An abrasive article is provided that can include a body. The body may comprise a bonding component and abrasive particles in the bonding component. The coupling component may include a Fe-Co-Cu-Ni-Sn-based coupling material and a performance improving material. The performance enhancing material may comprise hexagonal boron nitride. The content of the performance enhancing material may be at least about 6 vol.% And at most about 14 vol.% Relative to the total volume of the binding component.

Description

Abrasive article and method of forming the same

The following relates to an abrasive article and a method of forming an abrasive article. More particularly, the following relates to an abrasive article comprising abrasive particles in the bonding material.

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. Bonded abrasive articles are hard, typically monolithic, three-dimensional, abrasive composites in the form of wheels, disks, segments, mounted points, horns and other articles, which are machined devices, such as polishing, polishing or cutting devices. It can be mounted on. Some bonded abrasive articles may be particularly useful in the polishing, forming and cutting of certain types of products, including, for example, ceramics used in refractory products.

Accordingly, the art continues to require improved bonded abrasive articles and methods for their use.

summary

According to the first aspect, the abrasive article may comprise a body. The body may comprise a bonding component and abrasive particles in the bonding component. The coupling component may include a Fe-Co-Cu-Ni-Sn-based coupling material and a performance improving material. The performance enhancing material may comprise hexagonal boron nitride. The content of the performance enhancing material may be at least about 6 vol.% And at most about 14 vol.% Relative to the total volume of the binding component.

According to another aspect, the abrasive article may comprise a body. The body may comprise a bonding component and abrasive particles in the bonding component. The coupling component may include a Fe-Co-Cu-Ni-Sn-based coupling material and a performance improving material. The performance enhancing material may comprise hexagonal boron nitride. The body may comprise a hardness of at least about 50 HRB and up to about 85 HRB.

According to yet another aspect, the abrasive article comprises a body. The body may comprise a continuous bonding material phase, abrasive particles in the continuous bonding material phase, and a discontinuous performance enhancing material phase dispersed within the continuous bonding material phase. The bonding material phase may comprise a Fe—Co—Cu—Ni—Sn based bonding material. The hardness H _PEMP on the performance enhancing material may be less than the hardness H _BMP on the bonding material.

According to yet another aspect, a method of forming an abrasive article may include providing an abrasive article forming mixture and forming the abrasive article forming mixture into an abrasive article. The abrasive article forming mixture may comprise a bond forming mixture, and abrasive particles. The bond forming mixture may comprise a raw bond material and a raw performance enhancing material. The unprocessed bonding material may include a Fe—Co—Cu—Ni—Sn based bonding material. The unprocessed performance enhancing material may comprise hexagonal boron nitride. The content of the raw performance enhancing material in the abrasive article forming mixture is at least about 6 vol.% And at most about 14 vol.% Relative to the total volume of the bond forming mixture.

According to yet another aspect, a method of forming an abrasive article includes providing an abrasive article forming mixture; And forming a mixture into the abrasive article. The bond forming mixture may comprise a raw bond material and a raw performance enhancing material. The unprocessed bonding material may include a Fe—Co—Cu—Ni—Sn based bonding material. The unprocessed performance enhancing material may comprise hexagonal boron nitride. The abrasive article may comprise a body and the body may have a hardness of at least about 50 HRB and at most about 85 HRB.

According to yet another aspect, a method of forming an abrasive article may include providing an abrasive article forming mixture and forming the mixture into an abrasive article. The abrasive article may comprise a continuous bonding material phase, abrasive particles in the continuous bonding material phase, and a discontinuous performance enhancing material phase dispersed in the continuous bonding material phase. The bonding material phase may comprise a Fe—Co—Cu—Ni—Sn based bonding material. The hardness H _PEMP on the performance enhancing material may be less than the hardness H _BMP on the bonding material.

By referring to the accompanying drawings, those skilled in the art can better understand the present disclosure, and numerous features and advantages thereof are clarified.
1 includes a flowchart illustrating a process for forming an abrasive article in accordance with embodiments described herein;
2 includes a plot showing the performance of an abrasive article formed in accordance with an embodiment described herein compared to the performance of a comparative sample abrasive article;
3 includes a plot showing the performance of an abrasive article formed in accordance with an embodiment described herein compared to the performance of a comparative sample abrasive article;
4 includes a plot showing the performance of an abrasive article formed in accordance with an embodiment described herein compared to the performance of a comparative sample abrasive article;
5A and 5B include images of the microstructure of an abrasive article formed in accordance with an embodiment described herein; And
6A and 6B include images of the microstructure of a comparative abrasive article.
Use of the same reference numerals in different drawings denotes similar or identical items.

For example, abrasive articles and techniques are disclosed that can be used for polishing, including polishing of various materials, such as ceramics and glass. According to certain embodiments, the abrasive articles described herein can be used for abrasive refractory materials and have been demonstrated to have improved performance, life, and efficiency over conventional abrasive tools used in abrasive refractory materials.

According to certain embodiments, the abrasive article as described herein may comprise abrasive particles in the binding component. The coupling component may include a Fe-Co-Cu-Ni-Sn-based coupling material and a performance improving material.

According to certain embodiments, the Fe—Co—Cu—Ni—Sn based binding material comprises iron (Fe), which accounts for most of the total volume of the binding material, such as at least about 50 vol.% Relative to the total volume of the binding material. ), Cobalt (Co), copper (Cu), nickel (Ni) and tin (Sn).

According to yet another embodiment, the performance enhancing material may comprise hexagonal boron nitride (hBN). Yet in accordance with another embodiment, the performance enhancing material may be constructed with essentially hexagonal boron nitride.

1 includes a flowchart illustrating a method of forming an abrasive article in accordance with embodiments described herein. As illustrated in FIG. 1, process 100 may be initiated in step 101 by providing an abrasive article forming mixture containing abrasive particles and a bond forming mixture. The bond forming mixture may comprise a raw bond material and a raw performance enhancing material. Reference to "unprocessed" materials refers to starting materials that may or may not necessarily encounter chemical or physical changes during processing.

According to yet another embodiment, the abrasive article forming mixture may comprise a particular content of the abrasive particles. For example, the abrasive article forming mixture may comprise at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.%, Relative to the total volume of the abrasive article forming mixture, or At least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or at least about 12 vol.% Or at least about 13 vol.% Or even at least about 14 vol.% Abrasive particle content. have. According to yet another embodiment, the abrasive article forming mixture is at most about 25 vol.%, Such as at most about 24 vol.% Or at most about 23 vol.% Or at most about 22 vol.% Or at most about 21 vol.% Or up to about 20 vol.% Or up to about 19 vol.% Or up to about 18 vol.% Or up to about 17 vol.% Or up to about 16 vol.% Or even up to about 15 vol.%. Can be. It will be appreciated that the abrasive article forming mixture may comprise an abrasive particle content of any value between any of the minimum and maximum values noted above. It will also be appreciated that the abrasive article forming mixture may comprise any value of abrasive particle content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the abrasive particles may comprise inorganic materials, such as naturally occurring materials (eg minerals) or synthetically formed compositions. Suitable inorganic materials may include oxides, carbides, nitrides, oxycarbide, oxynitrides, diamonds, other natural minerals or combinations thereof. In certain, non-limiting embodiments, the abrasive particles can be cubic boron nitride (cBN), molten alumina, calcined alumina, silicon carbide, or mixtures thereof.

According to yet another embodiment, the abrasive particles can be a super abrasive material. In particular in other embodiments, the abrasive material may comprise a material selected from the group consisting of diamond, cubed boron nitride, and combinations thereof. In yet another embodiment, the superabrasive material may be constructed with diamond as essential. In yet another embodiment, the superabrasive material may be constructed with cube boron nitride as essential. In yet another embodiment the superabrasive material may have a Mohs hardness of at least about 8, such as at least about 8.5 or even at least about 9.

According to yet another embodiment, the abrasive particles can have a particular average particle size. For example, the abrasive particles can be at least about 100 microns, such as at least about 150 microns or at least about 200 microns or at least about 250 microns or at least about 300 microns or at least about 350 microns or at least about 400 microns or even at least about 450 microns. It can have an average particle size of. According to yet another embodiment, the abrasive particles can be up to about 1000 microns, such as up to about 950 microns or up to about 900 microns or up to about 850 microns or up to about 800 microns or up to about 750 microns or up to about 700 microns or up to about It may have an average particle size of 650 microns or up to about 600 microns or even up to about 550 microns. It will be appreciated that the abrasive particles may have an average particle size of any value between any of the minimum and maximum values noted above. It will also be appreciated that the abrasive particles may have an average particle size of any value within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the abrasive particles may comprise a coating capable of promoting the formation and performance of the abrasive article. In certain embodiments, the coating can be a metal coating, for example nickel. According to yet another embodiment, the coating may be iron oxide, silane, such as gamma amino propyl triethoxy silane, or even silica.

According to yet another embodiment, the coating of abrasive particles may have a certain thickness. For example, the average thickness of the coating of abrasive particles may be at least about 1.25 microns, such as at least about 1.5 microns, at least about 1.75 microns, at least about 2.0 microns, at least about 2.25 microns, at least about 2.5 microns, or at least about 3.0 microns. Can be. However, the average thickness can be limited to, for example, up to about 8.0 microns, up to about 7.5 microns, up to 7.0 microns, up to 6.5 microns, up to 6.0 microns, up to 5.5 microns, up to 5.0 microns, up to 4.5 microns, or up to 4.0 microns. It will be appreciated that the average thickness of the coating can be any value between any of the minimum and maximum values noted above. It will also be appreciated that the average thickness of the coating can be any value within the range between any of the minimum and maximum values noted above.

According to another embodiment, the coating of abrasive particles may be formed to cover a particular portion of the outer surface of the abrasive particles. For example, the coating may comprise at least about 50% of the outer surface area of the abrasive particles, such as at least about 60%, at least about 70%, at least about 80%, at least about 90%, even at least about 95%, or essentially The entire outer surface of the abrasive particles may be covered. In yet another non-limiting embodiment, the coating can contain up to about 99% of the outer surface area of the abrasive particles, such as up to about 95%, up to about 90%, up to about 80%, up to about 70% of the outer surface of the abrasive particles. Or even up to about 60%. It will be appreciated that the coating may cover any percentage of the abrasive particles between any of the minimum and maximum values noted above. It will also be appreciated that the coating may cover any percentage of the abrasive particles within a range between any of the minimum and maximum values noted above.

Further with respect to the abrasive particles, the morphology of the abrasive particles can be described in terms of aspect ratio, which is the ratio between the length to width size. It will be appreciated that the length is the longest size of the abrasive particles and the width is the second longest size of a given abrasive particle. According to an embodiment herein, the abrasive particles may have an aspect ratio (length: width) of up to about 2: 1 or even up to about 1.5: 1. In certain cases, the abrasive particles are essentially isotropic so that they have an aspect ratio of approximately 1: 1.

According to yet another embodiment, the abrasive article forming mixture may comprise a particular content of the bond forming mixture. For example, the abrasive article forming mixture may comprise at least about 55 vol.%, Such as at least about 58 vol.% Or at least about 60 vol.% Or at least about 63 vol.%, Relative to the total volume of the abrasive article forming mixture, or At least about 65 vol.% Or at least about 68 vol.% Or at least about 70 vol.% Or at least about 73 vol.% Or at least about 75 vol.% Or at least about 78 vol.% Or at least about 80 vol.% Or at least And a bond forming mixture content of about 83 vol.% Or at least about 85 vol.% Or at least about 88 vol.% Or even at least about 90 vol.%. According to yet another embodiment, the abrasive article forming mixture is at most about 95 vol.%, Such as at most about 92 vol.% Or at most about 90 vol.% Or at most about 87 vol.% Or at most about 85 vol.% Or up to about 82 vol.% Or up to about 80 vol.% Or up to about 77 vol.% Or up to about 75 vol.% Or up to about 72 vol.% Or up to about 70 vol.% Or up to about 67 vol.% Or Even up to about 65 vol.% Of the bond formation mixture content. It will be appreciated that the abrasive article forming mixture may comprise any value of bond forming mixture content between any of the minimum and maximum values noted above. It will also be appreciated that the abrasive article forming mixture may comprise any value of bond forming mixture content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bond forming mixture may comprise a specific content of the raw bond material. For example, the bond forming mixture may comprise at least about 60 vol.%, Such as at least about 63 vol.% Or at least about 63 vol.% Or at least about 68 vol.% Or at least about the total volume of the bond forming mixture. 70 vol.% Or at least about 73 vol.% Or at least about 75 vol.% Or at least about 78 vol.% Or at least about 80 vol.% Or at least about 83 vol.% Or at least about 85 vol.% Or at least about 88 vol.% or even at least about 90 vol.% of unprocessed binding material content. According to yet another embodiment, the bond forming mixture may be up to about 94 vol.%, Such as up to about 92 vol.% Or up to about 90 vol.% Or up to about 87 vol.% Or up to about 85 vol.% Or Up to about 82 vol.% Or up to about 80 vol.% Or up to about 77 vol.% Or up to about 75 vol.% Or up to about 72 vol.% Or up to about 70 vol.% Or up to about 67 vol.% Or even And up to about 65 vol.% Of unprocessed binding material content. It will be appreciated that the bond forming mixture may comprise any value of raw binder material content between any of the minimum and maximum values noted above. It will also be appreciated that the bond forming mixture may comprise any value of raw binder material content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw bond material may comprise a raw Fe—Co—Cu—Ni—Sn based bonding material. The unprocessed Fe—Co—Cu—Ni—Sn based binding material comprises iron (Fe), cobalt, which accounts for at least about 50 vol.% Of the total volume of the bonding material, such as the total volume of the bonding material. It can be defined as a bonding material having a total content of (Co), copper (Cu), nickel (Ni) and tin (Sn).

According to yet another embodiment, the bond forming mixture may comprise a specific content of iron (Fe). For example, the bond forming mixture may be at least about 30 vol.%, Such as at least about 35 vol.% Or at least about 38 vol.% Or at least about 40 vol.% Or at least about the total volume of the bond forming mixture. Iron (Fe) content of 43 vol.% Or at least about 45 vol.% Or at least about 48 vol.% Or even at least about 50 vol.%. According to yet another embodiment, the bond forming mixture is at most about 70 vol.%, Such as at most about 67 vol.% Or at most about 65 vol.% Or at most about 62 vol.%, Relative to the total volume of the bond forming mixture. Or up to about 60 vol.% Or up to about 57 vol.% Or even up to about 55 vol.% Of iron (Fe) content. It will be appreciated that the bond forming mixture may comprise any value of iron (Fe) content between any of the minimum and maximum values noted above. It will also be appreciated that the bond forming mixture may comprise any value of iron (Fe) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture may comprise a specific content of iron (Fe). For example, the raw Fe-Co-Cu-Ni-Sn based bonding material may be at least about 30 vol.% Relative to the total volume of the raw Fe-Co-Cu-Ni-Sn based bonding material, such as At least about 35 vol.% Or at least about 38 vol.% Or at least about 40 vol.% Or at least about 43 vol.% Or at least about 45 vol.% Or at least about 48 vol.% Or even at least about 50 vol.% It may include the iron (Fe) content of. According to yet another embodiment, the raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture is based on the total volume of the raw Fe-Co-Cu-Ni-Sn based bonding material. Up to about 70 vol.%, Such as up to about 67 vol.% Or up to about 65 vol.% Or up to about 62 vol.% Or up to about 60 vol.% Or up to about 57 vol.% Or even up to about 55 vol. And iron (Fe) content of%. It will be appreciated that the raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may comprise an iron (Fe) content of any value between any of the minimum and maximum values noted above. . The raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may also comprise any value of iron (Fe) content within a range between any of the minimum and maximum values noted above. Will be understood.

According to yet another embodiment, the bond forming mixture may comprise a specific content of cobalt (Co). For example, the bond forming mixture may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about the total volume of the bond forming mixture. Cobalt (Co) content of 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the bond forming mixture is at most about 25 vol.%, Such as at most about 24 vol.% Or at most about 23 vol.% Or at most about 22 vol.%, Relative to the total volume of the bond forming mixture. Or up to about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.% Cobalt (Co) content. It will be appreciated that the bond forming mixture may comprise any value of cobalt (Co) content between any of the minimum and maximum values noted above. It will also be appreciated that the bond forming mixture may comprise any value of cobalt (Co) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture may comprise a specific content of cobalt (Co). For example, the unprocessed Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol, based on the total volume of the bond forming mixture. % Or at least about 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Cobalt (Co) content. According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture is up to about 25 vol.%, Such as up to about 24, based on the total volume of the bond forming mixture. vol.% or up to about 23 vol.% or up to about 22 vol.% or up to about 21 vol.% or up to about 20 vol.% or even up to about 19 vol.% cobalt (Co) content. . It will be appreciated that the raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may comprise any value of cobalt (Co) content between any of the minimum and maximum values noted above. . The raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may also include any value of cobalt (Co) content within a range between any of the minimum and maximum values noted above. Will be understood.

According to yet another embodiment, the bond forming mixture may comprise a specific content of copper (Cu). For example, the bond forming mixture may comprise at least about 20 vol.%, Such as at least about 21 vol.% Or at least about 22 vol.% Or at least about 23 vol.% Or at least about the total volume of the bond forming mixture. 24 vol.% Or at least about 25 vol.% Or at least about 26 vol.% Or at least about 27 vol.% Or at least about 28 vol.% Or at least about 29 vol.% Or even at least about 30 vol.% Copper ( Cu) content. According to yet another embodiment, the bond forming mixture is at most about 50 vol.%, Such as at most about 49 vol.% Or at most about 48 vol.% Or at most about 47 vol.%, Relative to the total volume of the bond forming mixture. Or up to about 46 vol.% Or up to about 45 vol.% Or up to about 44 vol.% Or up to about 43 vol.% Or up to about 42 vol.% Or up to about 41 vol.% Or even up to about 40 vol.% It may comprise a copper (Cu) content of. It will be appreciated that the bond forming mixture may comprise any value of copper (Cu) content between any of the minimum and maximum values noted above. It will also be appreciated that the bond forming mixture may comprise any value of copper (Cu) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based bonding material in the bond forming mixture may comprise a specific content of copper (Cu). For example, the raw Fe-Co-Cu-Ni-Sn based bonding material may be at least about 20 vol.%, Such as at least about 21 vol.% Or at least about 22 vol, relative to the total volume of the bond forming mixture. .% Or at least about 23 vol.% Or at least about 24 vol.% Or at least about 25 vol.% Or at least about 26 vol.% Or at least about 27 vol.% Or at least about 28 vol.% Or at least about 29 vol. % Or even at least about 30 vol.% Copper (Cu) content. According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture is at most about 50 vol.%, Such as at most about 49, relative to the total volume of the bond forming mixture. vol.% or up to about 48 vol.% or up to about 47 vol.% or up to about 46 vol.% or up to about 45 vol.% or up to about 44 vol.% or up to about 43 vol.% or up to about 42 vol Copper (Cu) content of up to about 41 vol.% Or even up to about 40 vol.%. It will be appreciated that the raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may comprise a copper (Cu) content of any value between any of the minimum and maximum values noted above. . The raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may also comprise any value of copper (Cu) content in the range between any of the minimum and maximum values noted above. Will be understood.

According to yet another embodiment, the bond forming mixture may comprise a specific content of nickel (Ni). For example, the bond forming mixture may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about the total volume of the bond forming mixture. Nickel (Ni) content of 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the bond forming mixture is at most about 30 vol.%, Such as at most about 29 vol.% Or at most about 28 vol.% Or at most about 27 vol.%, Relative to the total volume of the bond forming mixture. Or up to about 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or Even up to about 19 vol.% Of nickel (Ni) content. It will be appreciated that the nickel (Ni) content of any value between any of the above minimum and maximum values may be included. It will also be appreciated that it may include any value of nickel (Ni) content within a range between any of the above minimum and maximum values.

According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based bonding material in the bond forming mixture may comprise a specific content of nickel (Ni). For example, the unprocessed Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol, based on the total volume of the bond forming mixture. % Or at least about 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Nickel (Ni) content. According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture is at most about 30 vol.%, Such as at most about 29, relative to the total volume of the bond forming mixture. vol.% or up to about 28 vol.% or up to about 27 vol.% or up to about 26 vol.% or up to about 25 vol.% or up to about 24 vol.% or up to about 23 vol.% or up to about 22 vol Nickel (Ni) content of up to about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may comprise a nickel (Ni) content of any value between any of the minimum and maximum values noted above. . The raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may also comprise any value of nickel (Ni) content within a range between any of the minimum and maximum values noted above. Will be understood.

According to yet another embodiment, the bond forming mixture may comprise a specific content of tin (Sn). For example, the bond forming mixture may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about the total volume of the bond forming mixture. Tin (Sn) content of 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the bond forming mixture is at most about 30 vol.%, Such as at most about 29 vol.% Or at most about 28 vol.% Or at most about 27 vol.%, Relative to the total volume of the bond forming mixture. Or up to about 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or Even up to about 19 vol.% Of tin (Sn) content. It will be appreciated that the bond forming mixture may comprise any value of tin (Sn) content between any of the minimum and maximum values noted above. It will also be appreciated that the bond forming mixture may comprise any value of tin (Sn) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture may comprise a specific content of tin (Sn). For example, the unprocessed Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol, based on the total volume of the bond forming mixture. % Or at least about 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Tin (Sn) content. According to yet another embodiment, the raw Fe—Co—Cu—Ni—Sn based binding material in the bond forming mixture is at most about 30 vol.%, Such as at most about 29, relative to the total volume of the bond forming mixture. vol.% or up to about 28 vol.% or up to about 27 vol.% or up to about 26 vol.% or up to about 25 vol.% or up to about 24 vol.% or up to about 23 vol.% or up to about 22 vol Tin (Sn) content of up to about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may comprise any value of tin (Sn) content between any of the minimum and maximum values noted above. . The raw Fe-Co-Cu-Ni-Sn based bonding material in the bond forming mixture may also include any value of tin (Sn) content within a range between any of the minimum and maximum values noted above. Will be understood.

According to certain embodiments described herein, the raw binder material may be in the form of a binder powder. The unprocessed bond particles in the bond powder may have an average diameter of, for example, 50 microns or less or even 40 microns or less.

According to yet another embodiment, the bond forming mixture may comprise a specific amount of the raw performance enhancing component. For example, the bond forming mixture may comprise at least about 6 vol.%, Such as at least about 6.25 vol.% Or at least about 6.5 vol.% Or at least about 6.75 vol.% Or at least about the total volume of the bond forming mixture. A raw performance enhancing component content of 7.0 vol.% Or at least about 7.25 vol.% Or at least about 7.5 vol.% Or at least about 7.75 vol.% Or even at least about 8.0 vol.%. According to yet another embodiment, the bond forming mixture is at most about 14 vol.%, Such as at most about 13.75 vol.% Or at most about 13.5 vol.% Or at most about 13.25 vol.% Or at most about 13.0 vol.% Or Up to about 12.75 vol.% Or up to about 12.5 vol.% Or up to about 12.25 vol.% Or even up to about 12.0 vol.%. It will be appreciated that the bond forming mixture may comprise any value of the raw performance enhancing component content between any of the minimum and maximum values noted above. It will also be appreciated that the bond forming mixture may comprise any value of the raw performance enhancing component content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw performance enhancing component can have a particular average particle size. For example, the raw performance enhancing component may be at least about 10 microns, such as at least about 10.1 microns or at least about 10.2 microns or at least about 10.3 microns or at least about 10.4 microns or at least about 10.5 microns or at least about 10.6 microns or at least It may have an average particle size of about 10.7 microns or at least about 10.8 microns or at least about 10.9 microns or even at least about 11.0 microns. According to yet another embodiment the micron or up to about said raw performance enhancing component can be up to about 12 microns, such as up to about 11.9 microns or up to about 11.8 microns or up to about 11.7 microns or up to about 11.6 microns or up to about 11.5 microns or It can have an average particle size of up to about 11.4 microns or up to about 11.3 microns or up to about 11.2 or even up to about 11.1 microns. It will be appreciated that the raw performance enhancing component may have an average particle size of any value between any of the minimum and maximum values noted above. It will also be appreciated that the raw performance enhancing component may have an average particle size of any value within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the raw performance enhancing component may comprise particles having a particular shape. For example, the particles of the performance enhancing component can have a spherical shape. Yet according to another embodiment, the particles of the performance enhancing component may have an agglomerate shape. Yet according to another embodiment, the particles of the performance enhancing component may have an irregular shape. Yet according to another embodiment, the particles of the performance enhancing component may have a platelet shape. Yet according to another embodiment, the particles of the performance enhancing component may have a dendritic shape. According to yet another embodiment, the particles of the performance enhancing component can have a rod shape.

 Referring back to FIG. 1, after providing the mixture in step 101, the process may continue in step 102 by forming a bonded abrasive article from the abrasive article forming mixture incorporating abrasive particles in the bond forming mixture. have. The abrasive article forming mixture may be formed into a predetermined three-dimensional shape, of a predetermined size, for example, the mixture may be formed into wheels, disks, segments, mounted points, horns, and other article shapes, It may be mounted in a machining device, such as a polishing or polishing device.

In certain embodiments, the mixture may be formed into a bonded abrasive article using hot-pressing. Hot-pressing of the mixture may be performed at a temperature of at least about 750 ° C., such as at least about 800 ° C., at least about 850 ° C., at least about 900 ° C., at least about 950 ° C. or even at least about 990 ° C. In yet another embodiment, the hot-pressing of the mixture may be at a temperature of up to about 1000 ° C., up to about 950 ° C., up to about 900 ° C., up to about 850 ° C., up to about 800 ° C., up to about 750 ° C. or even up to about 710 ° C. It can be performed in. It will be appreciated that hot-pressing of the mixture may be carried out at any temperature within a range between any of the minimum and maximum values noted above.

According to another embodiment, the hot-pressing of the mixture is at least about 0.5 tons / in ² _, such as at least about 1.0 tons / in ² _, at least about 1.5 tons / in ² _, at least about 2.0 tons / in ² , at least about 2.5 tons / in ² or even at a pressure of at least about 2.9 tons / in ² . In yet another embodiment, the hot-pressing of the mixture is up to about 3 tons / in ² , up to about 2.5 tons / in ² , up to about 2.0 tons / in ² , up to about 1.5 tons / in ² or even up to about 2.0 tons It may be carried out at a temperature of / in ² . It will be appreciated that hot-pressing of the mixture may be carried out at any pressure within a range between any of the minimum and maximum values noted above.

In yet another embodiment, the mixture may be formed into a bonded abrasive article using cold-pressing. Cold-pressing of the mixture may be performed at a temperature of at least about 750 ° C., such as at least about 800 ° C., at least about 850 ° C., at least about 900 ° C., at least about 950 ° C. or even at least about 990 ° C. In yet another embodiment, the cold-pressing of the mixture is at a temperature of up to about 1000 ° C., up to about 950 ° C., up to about 900 ° C., up to about 850 ° C., up to about 800 ° C., up to about 750 ° C. or even up to about 710 ° C. It can be performed in. It will be appreciated that the cold-pressing of the mixture can be carried out at any temperature within a range between any of the minimum and maximum values noted above.

According to another embodiment, the cold-pressing of the mixture is at least about 0.5 tons / in ² _, such as at least about 1.0 tons / in ² _, at least about 1.5 tons / in ² _, at least about 2.0 tons / in ² , at least about 2.5 tons / in ² or even at a pressure of at least about 2.9 tons / in ² . In yet another embodiment, the cold-pressing of the mixture is up to about 3 tons / in ² , up to about 2.5 tons / in ² , up to about 2.0 tons / in ² , up to about 1.5 tons / in ² or even up to about 2.0 tons It may be carried out at a temperature of / in ² . It will be appreciated that the hot-pressing of the mixture can be carried out at any pressure within a range between any of the minimum and maximum values noted above.

According to another embodiment, the formed abrasive article may have a body having certain characteristics. As noted above, according to certain embodiments, the body of the abrasive article may include a bonding component and abrasive particles in the bonding component.

According to yet another embodiment, the body of the abrasive article may comprise a particular content of the abrasive particles. For example, the body of the abrasive article may comprise at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.%, Relative to the total volume of the body of the abrasive article or At least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or at least about 12 vol.% Or at least about 13 vol.% Or even at least about 14 vol.% Abrasive particle content. have. According to yet another embodiment, the body of the abrasive article has a maximum of about 25 vol.%, Such as at most about 24 vol.% Or at most about 23 vol.% Or at most about 22 vol.% Or at most about 21 vol.% Or up to about 20 vol.% Or up to about 19 vol.% Or up to about 18 vol.% Or up to about 17 vol.% Or up to about 16 vol.% Or even up to about 15 vol.%. Can be. It will be appreciated that the body of the abrasive article may comprise an abrasive particle content of any value between any of the minimum and maximum values noted above. It will also be appreciated that the body of the abrasive article may comprise an abrasive particle content of any value within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the abrasive particles may comprise inorganic materials, such as naturally occurring materials (eg minerals) or synthetically formed compositions. Suitable inorganic materials may include oxides, carbides, nitrides, oxycarbide, oxynitrides, diamonds, other natural minerals or combinations thereof. In certain, non-limiting embodiments, the abrasive particles can be cubic boron nitride (cBN), molten alumina, calcined alumina, silicon carbide, or mixtures thereof.

According to yet another embodiment, the abrasive particles can be a super abrasive material. In particular in other embodiments, the abrasive material may comprise a material selected from the group consisting of diamond, cubed boron nitride, and combinations thereof. In yet another embodiment, the superabrasive material may be constructed with diamond as essential. In yet another embodiment, the superabrasive material may be constructed with cube boron nitride as essential. In yet another embodiment the superabrasive material may have a Mohs hardness of at least about 8, such as at least about 8.5 or even at least about 9.

According to yet another embodiment, the abrasive particles can have a particular average particle size. For example, the abrasive particles can be at least about 100 microns, such as at least about 150 microns or at least about 200 microns or at least about 250 microns or at least about 300 microns or at least about 350 microns or at least about 400 microns or even at least about 450 microns. It can have an average particle size of. According to yet another embodiment, the abrasive particles can be up to about 1000 microns, such as up to about 950 microns or up to about 900 microns or up to about 850 microns or up to about 800 microns or up to about 750 microns or up to about 700 microns or up to about It may have an average particle size of 650 microns or up to about 600 microns or even up to about 550 microns. It will be appreciated that the abrasive particles may have an average particle size of any value between any of the minimum and maximum values noted above. It will also be appreciated that the abrasive particles may have any value average particle size within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the abrasive particles may comprise a coating capable of promoting the formation and performance of the abrasive article. In certain embodiments, the coating can be a metal coating, for example nickel. According to yet another embodiment, the coating may be iron oxide, silane, such as gamma amino propyl triethoxy silane, or even silica.

According to yet another embodiment, the coating of abrasive particles may have a certain thickness. For example, the average thickness of the coating of abrasive particles may be at least about 1.25 microns, such as at least about 1.5 microns, at least about 1.75 microns, at least about 2.0 microns, at least about 2.25 microns, at least about 2.5 microns, or at least about 3.0 microns. Can be. However, the average thickness can be limited to, for example, up to about 8.0 microns, up to about 7.5 microns, up to 7.0 microns, up to 6.5 microns, up to 6.0 microns, up to 5.5 microns, up to 5.0 microns, up to 4.5 microns, or up to 4.0 microns. It will be appreciated that the average thickness of the coating can be any value between any of the minimum and maximum values noted above. It will also be appreciated that the average thickness of the coating can be any value within the range between any of the minimum and maximum values noted above.

According to another embodiment, the coating of abrasive particles may be formed to cover a particular portion of the outer surface of the abrasive particles. For example, the coating may comprise at least about 50% of the outer surface area of the abrasive particles, such as at least about 60%, at least about 70%, at least about 80%, at least about 90%, even at least about 95%, or essentially The entire outer surface of the abrasive particles may be covered. In yet another non-limiting embodiment, the coating can contain up to about 99% of the outer surface area of the abrasive particles, such as up to about 95%, up to about 90%, up to about 80%, up to about 70% of the outer surface of the abrasive particles. Or even up to about 60%. It will be appreciated that the coating may cover any percentage of the abrasive particles between any of the minimum and maximum values noted above. It will also be appreciated that the coating may cover any percentage of the abrasive particles within a range between any of the minimum and maximum values noted above.

Further with respect to the abrasive particles, the morphology of the abrasive particles can be described in terms of aspect ratio, which is the ratio between the length to width size. It will be appreciated that the length is the longest size of the abrasive particles and the width is the second longest size of a given abrasive particle. According to an embodiment herein, the abrasive particles may have an aspect ratio (length: width) of up to about 2: 1 or even up to about 1.5: 1. In certain cases, the abrasive particles are essentially isotropic so that they have an aspect ratio of approximately 1: 1.

According to yet another embodiment, the body of the abrasive article may comprise a particular content of the bonding component. For example, the body of the abrasive article may comprise at least about 55 vol.%, Such as at least about 58 vol.% Or at least about 60 vol.% Or at least about 63 vol.%, Relative to the total volume of the body of the abrasive article or At least about 65 vol.% Or at least about 68 vol.% Or at least about 70 vol.% Or at least about 73 vol.% Or at least about 75 vol.% Or at least about 78 vol.% Or at least about 80 vol.% Or at least Binding component content of about 83 vol.% Or at least about 85 vol.% Or at least about 88 vol.% Or even at least about 90 vol.%. According to yet another embodiment, the body of the abrasive article is at most about 95 vol.%, Such as at most about 92 vol.% Or at most about 90 vol.% Or at most about 87 vol.% Or at most about 85 vol.% Or up to about 82 vol.% Or up to about 80 vol.% Or up to about 77 vol.% Or up to about 75 vol.% Or up to about 72 vol.% Or up to about 70 vol.% Or up to about 67 vol.% Or Even up to about 65 vol.% Of the binding component content. It will be appreciated that the body of the abrasive article may comprise a binding component content of any value between any of the minimum and maximum values noted above. It will also be appreciated that the body of the abrasive article may comprise any value of binding component content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the binding component may comprise a specific content of the binding material. For example, the binding component may be at least about 60 vol.%, Such as at least about 63 vol.% Or at least about 63 vol.% Or at least about 68 vol.% Or at least about 70 vol, relative to the total volume of the binding component. .% Or at least about 73 vol.% Or at least about 75 vol.% Or at least about 78 vol.% Or at least about 80 vol.% Or at least about 83 vol.% Or at least about 85 vol.% Or at least about 88 vol. % Or even at least about 90 vol.% Of the binding material content. According to yet another embodiment, the binding component may be up to about 94 vol.%, Such as up to about 92 vol.% Or up to about 90 vol.% Or up to about 87 vol.% Or up to about 85 vol.% Or up to About 82 vol.% Or up to about 80 vol.% Or up to about 77 vol.% Or up to about 75 vol.% Or up to about 72 vol.% Or up to about 70 vol.% Or up to about 67 vol.% Or even up to And a binding material content of about 65 vol.%. It will be appreciated that the binding component may comprise any value of binding material content between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of binding material content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding material may comprise a Fe—Co—Cu—Ni—Sn based bonding material. Fe-Co-Cu-Ni-Sn based binding material comprises iron (Fe), cobalt (Co), which accounts for at least about 50 vol.% Of the total volume of the binding material, such as the total volume of the binding material, It can be defined as a bonding material having a total content of copper (Cu), nickel (Ni) and tin (Sn).

According to yet another embodiment, the binding component may comprise a specific content of iron (Fe). For example, the binding component may be at least about 30 vol.%, Such as at least about 35 vol.% Or at least about 38 vol.% Or at least about 40 vol.% Or at least about 43 vol, relative to the total volume of the binding component. Iron or Fe content of at least about 45 vol.% Or at least about 48 vol.% Or even at least about 50 vol.%. According to yet another embodiment, the binding component is up to about 70 vol.%, Such as up to about 67 vol.% Or up to about 65 vol.% Or up to about 62 vol.% Or up to the total volume of the binding component Iron (Fe) content of about 60 vol.% Or up to about 57 vol.% Or even up to about 55 vol.%. It will be appreciated that the binding component may comprise any value of iron (Fe) content between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of iron (Fe) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise a specific content of iron (Fe). For example, the Fe—Co—Cu—Ni—Sn based binding material may comprise at least about 30 vol.%, Such as at least about 35 vol.%, Relative to the total volume of the Fe—Co—Cu—Ni—Sn based binding material, or An iron (Fe) content of at least about 38 vol.% Or at least about 40 vol.% Or at least about 43 vol.% Or at least about 45 vol.% Or at least about 48 vol.% Or even at least about 50 vol.% can do. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may contain up to about 70 vol.%, Such as, relative to the total volume of the Fe—Co—Cu—Ni—Sn based binding material, Contains iron (Fe) content up to about 67 vol.% Or up to about 65 vol.% Or up to about 62 vol.% Or up to about 60 vol.% Or up to about 57 vol.% Or even up to about 55 vol.% can do. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of iron (Fe) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of iron (Fe) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the binding component may comprise a specific content of cobalt (Co). For example, the binding component may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about 9 vol, relative to the total volume of the binding component. % Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Cobalt (Co) content. According to yet another embodiment, the binding component can be up to about 25 vol.%, Such as up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to the total volume of the binding component And a cobalt (Co) content of about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the binding component may comprise any value of cobalt (Co) content between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of cobalt (Co) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise a specific content of cobalt (Co). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about the total volume of the binding component. Cobalt (Co) content of 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may be up to about 25 vol.%, Such as up to about 24 vol.% Or up to about the total volume of the binding component. Cobalt (Co) content of 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of cobalt (Co) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of cobalt (Co) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding component may comprise a specific content of copper (Cu). For example, the binding component may be at least about 20 vol.%, Such as at least about 21 vol.% Or at least about 22 vol.% Or at least about 23 vol.% Or at least about 24 vol, relative to the total volume of the binding component. % Or at least about 25 vol.% Or at least about 26 vol.% Or at least about 27 vol.% Or at least about 28 vol.% Or at least about 29 vol.% Or even at least about 30 vol.% Copper (Cu) Content may be included. According to yet another embodiment, the binding component can be up to about 50 vol.%, Such as up to about 49 vol.% Or up to about 48 vol.% Or up to about 47 vol.% Or up to the total volume of the binding component About 46 vol.% Or up to about 45 vol.% Or up to about 44 vol.% Or up to about 43 vol.% Or up to about 42 vol.% Or up to about 41 vol.% Or even up to about 40 vol.% Copper (Cu) content. It will be appreciated that the binding component may comprise any value of copper (Cu) content between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of copper (Cu) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise a specific content of copper (Cu). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 20 vol.%, Such as at least about 21 vol.% Or at least about 22 vol.% Or at least about the total volume of the binding component. 23 vol.% Or at least about 24 vol.% Or at least about 25 vol.% Or at least about 26 vol.% Or at least about 27 vol.% Or at least about 28 vol.% Or at least about 29 vol.% Or even at least about Copper (Cu) content of 30 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may be up to about 50 vol.%, Such as up to about 49 vol.% Or up to about the total volume of the binding component. 48 vol.% Or up to about 47 vol.% Or up to about 46 vol.% Or up to about 45 vol.% Or up to about 44 vol.% Or up to about 43 vol.% Or up to about 42 vol.% Or up to about 41 copper (Cu) content of up to about 40 vol.% or even up to about 40 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of copper (Cu) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of copper (Cu) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding component may comprise a specific content of nickel (Ni). For example, the binding component may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about 9 vol, relative to the total volume of the binding component. % Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Nickel (Ni) content. According to yet another embodiment, the binding component can be up to about 30 vol.%, Such as up to about 29 vol.% Or up to about 28 vol.% Or up to about 27 vol.% Or up to the total volume of the binding component About 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or even up to Nickel (Ni) content of about 19 vol.%. It will be appreciated that the binding component may comprise a nickel (Ni) content of any value between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of nickel (Ni) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise a specific content of nickel (Ni). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about the total volume of the binding component. Nickel (Ni) content of 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may be up to about 30 vol.%, Such as up to about 29 vol.% Or up to about the total volume of the binding component. 28 vol.% Or up to about 27 vol.% Or up to about 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 nickel (Ni) content of up to about 20 vol.% or even up to about 19 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise a nickel (Ni) content of any value between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of nickel (Ni) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the binding component may comprise a specific content of tin (Sn). For example, the binding component may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about 9 vol, relative to the total volume of the binding component. Tin (Sn) content of.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the binding component can be up to about 30 vol.%, Such as up to about 29 vol.% Or up to about 28 vol.% Or up to about 27 vol.% Or up to the total volume of the binding component About 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or even up to It will be appreciated that it may comprise a tin (Sn) content of about 19 vol.%. The binding component may comprise any value of tin (Sn) content between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of tin (Sn) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise a specific content of tin (Sn). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about the total volume of the binding component. Tin (Sn) content of 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding component may be up to about 30 vol.%, Such as up to about 29 vol.% Or up to about the total volume of the binding component. 28 vol.% Or up to about 27 vol.% Or up to about 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 tin (Sn) content of up to about 20 vol.% or even up to about 19 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of tin (Sn) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding component may comprise any value of tin (Sn) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the binding component may comprise the content of a particular performance enhancing component. For example, the binding component may be at least about 6 vol.%, Such as at least about 6.25 vol.% Or at least about 6.5 vol.% Or at least about 6.75 vol.% Or at least about 7.0 relative to the total volume of the bond-forming mixture. vol.% or at least about 7.25 vol.% or at least about 7.5 vol.% or at least about 7.75 vol.% or even at least about 8.0 vol.%. According to yet another embodiment, the binding component can be up to about 14 vol.%, Such as up to about 13.75 vol.% Or up to about 13.5 vol.% Or up to about 13.25 vol.% Or up to about 13.0 vol.% Or up Up to about 12.75 vol.% Or up to about 12.5 vol.% Or up to about 12.25 vol.% Or even up to about 12.0 vol.%. It will be appreciated that the binding component may comprise any value of performance enhancing component content between any of the minimum and maximum values noted above. It will also be appreciated that the binding component may comprise any value of the performance enhancing component content within a range between any of the minimum and maximum values noted above.

Yet according to another embodiment, the performance enhancing component can have a particular average particle size. For example, the performance enhancing component may be at least about 10 microns, such as at least about 10.1 microns or at least about 10.2 microns or at least about 10.3 microns or at least about 10.4 microns or at least about 10.5 microns or at least about 10.6 microns or at least about 10.7 microns or It may have an average particle size of at least about 10.8 microns or at least about 10.9 microns or even at least about 11.0 microns. Yet according to another embodiment the micron or maximum about performance enhancing component can be up to about 12 microns, such as up to about 11.9 microns or up to about 11.8 microns or up to about 11.7 microns or up to about 11.6 microns or up to about 11.5 microns or up to about 11.4 microns Or an average particle size of up to about 11.3 microns or up to about 11.2 or even up to about 11.1 microns. It will be appreciated that the performance enhancing component may have an average particle size of any value between any of the above minimum and maximum values. It will also be appreciated that the performance enhancing component may have an average particle size of any value within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the performance enhancing component may comprise particles having a particular shape. For example, the particles of the performance enhancing component can have a spherical shape. Yet according to another embodiment, the particles of the performance enhancing component may have an agglomerate shape. Yet according to another embodiment, the particles of the performance enhancing component may have an irregular shape. Yet according to another embodiment, the particles of the performance enhancing component may have a platelet shape. Yet according to another embodiment, the particles of the performance enhancing component may have a dendritic shape. According to yet another embodiment, the particles of the performance enhancing component can have a rod shape.

According to yet another embodiment, the body may comprise a specific amount of voids that may be present throughout the entire volume of the body of the abrasive article. According to certain embodiments, the pores may be open pores. Yet according to another embodiment, the pores may be closed pores. According to yet another embodiment, the pores may be a combination of open and closed pores. In certain embodiments, the body comprises at least about 2 vol.%, Such as at least about 3 vol.% Or at least about 4 vol.% Or at least about 5 vol.% Or at least about 6 vol. % Or at least about 7 vol.% Or even at least about 8 vol.% Of voids. According to yet another embodiment, the body has up to about 20 vol.% Voids, such as up to about 19 vol.% Or up to about 18 vol.% Or up to about 17 vol.% Or up to about the total volume of the body. It may have a void of 16 vol.% Or up to about 15 vol.% Or up to about 14 vol.% Or up to about 13 vol.% Or even up to about 12 vol.%. It will be appreciated that the body may comprise any value of voids between any of the above minimum and maximum values. It will also be appreciated that the body may comprise any value of voids within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the body may have a specific HRB hardness measured according to ASTM E18-16. For example, the body may have a hardness of at least about 50 HRB, such as at least about 52 HRB or at least about 55 HRB or at least about 58 HRB or at least about 60 HRB or at least about 63 HRB or even at least about 65 HRB. . According to yet another embodiment, the body has a hardness of up to about 85 HRB, such as up to about 82 HRB or up to about 80 HRB or up to about 78 HRB or up to about 75 HRB or up to about 73 HRB or even up to about 70 HRB. Can have. It will be appreciated that the body may have a hardness of any value between any of the minimum and maximum values noted above. It will also be appreciated that the body may have a hardness of any value within a range between any of the minimum and maximum values noted above.

Yet in accordance with yet another embodiment, the body may comprise a phase material portion having a particular phase. For example, the phase material portion of the body may comprise a bonding material phase and a performance enhancing material phase dispersed within the bonding material phase. According to certain embodiments, the bonding material phase may be a continuous phase. For the purposes of the embodiments described herein, a continuous phase may be defined as a defined region of phase material distributed throughout the body and interconnected to at least one other region of the same phase material. According to certain other embodiments, the performance enhancing material phase may be a discontinuous phase. For the purposes of the embodiments described herein, discrete phases may be defined as defined regions of phase material distributed throughout the body and not connected to one another.

According to yet another embodiment, the body of the abrasive article may comprise a particular content of the phase material portion. For example, the body of the abrasive article may comprise at least about 55 vol.%, Such as at least about 58 vol.% Or at least about 60 vol.% Or at least about 63 vol.%, Relative to the total volume of the abrasive article forming mixture or At least about 65 vol.% Or at least about 68 vol.% Or at least about 70 vol.% Or at least about 73 vol.% Or at least about 75 vol.% Or at least about 78 vol.% Or at least about 80 vol.% Or at least Phase material portion content of about 83 vol.% Or at least about 85 vol.% Or at least about 88 vol.% Or even at least about 90 vol.%. According to yet another embodiment, the body of the abrasive article is at most about 95 vol.%, Such as at most about 92 vol.% Or at most about 90 vol.% Or at most about 87 vol.% Or at most about 85 vol.% Or up to about 82 vol.% Or up to about 80 vol.% Or up to about 77 vol.% Or up to about 75 vol.% Or up to about 72 vol.% Or up to about 70 vol.% Or up to about 67 vol.% Or Even up to about 65 vol.% Phase material portion content. It will be appreciated that the body of the abrasive article may comprise any value of phase material portion content between any of the minimum and maximum values noted above. It will also be understood that the body of the abrasive article may comprise any value of phase material portion content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the phase material portion may comprise a particular content of the bonding material phase. For example, the phase material portion may be at least about 60 vol.%, Such as at least about 63 vol.% Or at least about 63 vol.% Or at least about 68 vol.% Or at least about the total volume of the phase material portion. 70 vol.% Or at least about 73 vol.% Or at least about 75 vol.% Or at least about 78 vol.% Or at least about 80 vol.% Or at least about 83 vol.% Or at least about 85 vol.% Or at least about 88 vol.% or even at least about 90 vol.% of the binding material phase content. According to yet another embodiment, the phase material portion can be up to about 94 vol.%, Such as up to about 92 vol.% Or up to about 90 vol.% Or up to about 87 vol.% Or up to about 85 vol.% Or Up to about 82 vol.% Or up to about 80 vol.% Or up to about 77 vol.% Or up to about 75 vol.% Or up to about 72 vol.% Or up to about 70 vol.% Or up to about 67 vol.% Or even And up to about 65 vol.% Of the binding material phase content. It will be appreciated that the phase material portion may comprise any value of binding material phase content between any of the minimum and maximum values noted above. It will also be appreciated that the phase material portion may comprise any value of binding material phase content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding material phase may comprise a Fe—Co—Cu—Ni—Sn based bonding material. Fe-Co-Cu-Ni-Sn based binding material comprises iron (Fe), cobalt (Co), which accounts for at least about 50 vol.% Of the total volume of the binding material, such as the total volume of the binding material, It can be defined as a bonding material having a total content of copper (Cu), nickel (Ni) and tin (Sn).

According to yet another embodiment, the bonding material phase may comprise a specific content of iron (Fe). For example, the bonding material phase may be at least about 30 vol.%, Such as at least about 35 vol.% Or at least about 38 vol.% Or at least about 40 vol.% Or at least about 43 vol, relative to the total volume of the bonding material phase. Iron or Fe content of at least about 45 vol.% Or at least about 48 vol.% Or even at least about 50 vol.%. According to yet another embodiment, the bonding material phase is up to about 70 vol.%, Such as up to about 67 vol.% Or up to about 65 vol.% Or up to about 62 vol.% Or up to the total volume of the binder material Iron (Fe) content of about 60 vol.% Or up to about 57 vol.% Or even up to about 55 vol.%. It will be appreciated that the bonding material phase may comprise any value of iron (Fe) content between any of the minimum and maximum values noted above. It will also be appreciated that the binding material phase may comprise any value of iron (Fe) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise a specific content of iron (Fe). For example, the Fe—Co—Cu—Ni—Sn based binding material may comprise at least about 30 vol.%, Such as at least about 35 vol.%, Relative to the total volume of the Fe—Co—Cu—Ni—Sn based binding material, or An iron (Fe) content of at least about 38 vol.% Or at least about 40 vol.% Or at least about 43 vol.% Or at least about 45 vol.% Or at least about 48 vol.% Or even at least about 50 vol.% can do. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based bonding material in the bonding material phase is up to about 70 vol.% Fe—Co—Cu—Ni—Sn based on the total volume of the bonding material, such as Iron (Fe) content of up to about 67 vol.% Or up to about 65 vol.% Or up to about 62 vol.% Or up to about 60 vol.% Or up to about 57 vol.% Or even up to about 55 vol.% It may include. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise any value of iron (Fe) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may include any value of iron (Fe) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the binding material phase may comprise a specific content of cobalt (Co). For example, the bonding material phase may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about 9 vol, relative to the total volume of the bonding material phase. % Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Cobalt (Co) content. According to yet another embodiment, the binding material phase is at most about 25 vol.%, Such as at most about 24 vol.% Or at most about 23 vol.% Or at most about 22 vol.% Or at a maximum relative to the total volume of the binding material. And a cobalt (Co) content of about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the bonding material phase may comprise any value of cobalt (Co) content between any of the above minimum and maximum values. It will also be appreciated that the bonding material phase may comprise any value of cobalt (Co) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise a specific content of cobalt (Co). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about the total volume of the binding material. Cobalt (Co) content of 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the bonding material phase is at most about 25 vol.%, Such as at most about 24 vol.% Or at a maximum relative to the total volume of the bonding material. Cobalt (Co) content of about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise any value of cobalt (Co) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may include any value of cobalt (Co) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding material phase may comprise a specific content of copper (Cu). For example, the bonding material phase may be at least about 20 vol.%, Such as at least about 21 vol.% Or at least about 22 vol.% Or at least about 23 vol.% Or at least about 24 vol, relative to the total volume of the bonding material. % Or at least about 25 vol.% Or at least about 26 vol.% Or at least about 27 vol.% Or at least about 28 vol.% Or at least about 29 vol.% Or even at least about 30 vol.% Copper (Cu) Content may be included. According to yet another embodiment, the binding material phase is at most about 50 vol.%, Such as at most about 49 vol.% Or at most about 48 vol.% Or at most about 47 vol.% Or at a maximum of the total volume of the binding material. About 46 vol.% Or up to about 45 vol.% Or up to about 44 vol.% Or up to about 43 vol.% Or up to about 42 vol.% Or up to about 41 vol.% Or even up to about 40 vol.% Copper (Cu) content. It will be appreciated that the bonding material phase may comprise any value of copper (Cu) content between any of the minimum and maximum values noted above. It will also be appreciated that the bonding material phase may comprise any value of copper (Cu) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based bonding material in the bonding material may comprise a specific content of copper (Cu). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 20 vol.%, Such as at least about 21 vol.% Or at least about 22 vol.% Or at least about the total volume of the binding material. 23 vol.% Or at least about 24 vol.% Or at least about 25 vol.% Or at least about 26 vol.% Or at least about 27 vol.% Or at least about 28 vol.% Or at least about 29 vol.% Or even at least about Copper (Cu) content of 30 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase is at most about 50 vol.%, Such as at most about 49 vol.% Or at a maximum relative to the total volume of the binding material. About 48 vol.% Or up to about 47 vol.% Or up to about 46 vol.% Or up to about 45 vol.% Or up to about 44 vol.% Or up to about 43 vol.% Or up to about 42 vol.% Or up to about Copper (Cu) content of 41 vol.% Or even up to about 40 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise any value of copper (Cu) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based bonding material in the bonding material may comprise any value of copper (Cu) content in the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding material phase may comprise a specific content of nickel (Ni). For example, the bonding material phase may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about 9 vol, relative to the total volume of the bonding material phase. % Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.% Nickel (Ni) content. According to yet another embodiment, the binding material phase is at most about 30 vol.%, Such as at most about 29 vol.% Or at most about 28 vol.% Or at most about 27 vol.% Or at a maximum relative to the total volume of the binding material phase. About 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or even up to Nickel (Ni) content of about 19 vol.%. It will be appreciated that the bonding material phase may comprise any value of nickel (Ni) content between any of the minimum and maximum values noted above. It will also be appreciated that the bonding material phase may comprise any value of nickel (Ni) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise a specific content of nickel (Ni). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about the total volume of the binding material. Nickel (Ni) content of 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase is up to about 30 vol.%, Such as up to about 29 vol.% Or up to the total volume on the binding material. About 28 vol.% Or up to about 27 vol.% Or up to about 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about Nickel (Ni) content of 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise a nickel (Ni) content of any value between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise any value of nickel (Ni) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding material phase may comprise a specific content of tin (Sn). For example, the bonding material phase may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about 8 vol.% Or at least about 9 vol, relative to the total volume of the bonding material phase. Tin (Sn) content of.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the binding material phase is at most about 30 vol.%, Such as at most about 29 vol.% Or at most about 28 vol.% Or at most about 27 vol.% Or at a maximum relative to the total volume of the binding material phase. About 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about 21 vol.% Or up to about 20 vol.% Or even up to Tin (Sn) content of about 19 vol.%. It will be appreciated that the bonding material phase may comprise any value of tin (Sn) content between any of the minimum and maximum values noted above. It will also be appreciated that the bonding material phase may comprise any value of tin (Sn) content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise a specific content of tin (Sn). For example, the Fe—Co—Cu—Ni—Sn based binding material may be at least about 5 vol.%, Such as at least about 6 vol.% Or at least about 7 vol.% Or at least about the total volume of the binding material. Tin (Sn) content of 8 vol.% Or at least about 9 vol.% Or at least about 10 vol.% Or at least about 11 vol.% Or even at least about 12 vol.%. According to yet another embodiment, the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase is up to about 30 vol.%, Such as up to about 29 vol.% Or up to the total volume on the binding material. About 28 vol.% Or up to about 27 vol.% Or up to about 26 vol.% Or up to about 25 vol.% Or up to about 24 vol.% Or up to about 23 vol.% Or up to about 22 vol.% Or up to about Tin (Sn) content of 21 vol.% Or up to about 20 vol.% Or even up to about 19 vol.%. It will be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may comprise any value of tin (Sn) content between any of the minimum and maximum values noted above. It will also be appreciated that the Fe—Co—Cu—Ni—Sn based binding material in the binding material phase may include any value of tin (Sn) content within a range between any of the minimum and maximum values noted above.

Yet in accordance with another embodiment, the phase material portion may comprise a specific performance enhancing material phase content. For example, the phase material portion may be at least about 6 vol.%, Such as at least about 6.25 vol.% Or at least about 6.5 vol.% Or at least about 6.75 vol.% Or at least about the total volume of the phase material portion. 7.0 vol.% Or at least about 7.25 vol.% Or at least about 7.5 vol.% Or at least about 7.75 vol.% Or even at least about 8.0 vol.%. According to yet another embodiment, the phase material portion can be up to about 14 vol.%, Such as up to about 13.75 vol.% Or up to about 13.5 vol.% Or up to about 13.25 vol.% Or up to about 13.0 vol.% Or Up to about 12.75 vol.% Or up to about 12.5 vol.% Or up to about 12.25 vol.% Or even up to about 12.0 vol.%. It will be appreciated that the phase material portion may comprise any value of performance enhancing material phase content between any of the minimum and maximum values noted above. It will also be appreciated that the phase material portion may comprise any value of the performance enhancing material phase content within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the bonding material phase may have a specific VHN hardness H _BMP measured according to ASTM E384. For example, the bonding material phase may be at least about 100 VHN, such as at least about 102 VHN or at least about 105 VHN or at least about 107 VHN or at least about 110 VHN or at least about 112 VHN or at least about 115 VHN or at least about 117 VHN or It may even have a hardness of at least about 120 VHN. According to yet another embodiment, the binding material phase is at most about 500 VHN, such as at most about 490 VHN or at most about 480 VHN or at most about 475 VHN or at most about 470 VHN or at most about 465 VHN or at most about 460 VHN or at most about It may have a hardness of 455 VHN or even up to about 450 VHN. It will be appreciated that the hardness on the bonding material can be any value between any of the minimum and maximum values noted above. It will also be appreciated that the hardness on the bonding material can be any value within a range between any of the minimum and maximum values noted above.

According to yet another embodiment, the performance enhancing material phase may have a specific VHN hardness H _PEMP measured according to ASTM E384. For example, the performance enhancing material phase may comprise at least about 10 VHN, such as at least about 12 VHN or at least about 15 VHN or at least about 17 VHN or at least about 20 VHN or at least about 22 VHN or at least about 25 VHN or at least about 27 VHN or It may even have a hardness of at least about 30 VHN. According to yet another embodiment, the performance enhancing material phase can be up to about 300 VHN, such as up to about 290 VHN or up to about 280 VHN or up to about 270 VHN or up to about 260 VHN or up to about 250 VHN or up to about 240 VHN or up to about It may have a hardness of 230 VHN or up to about 220 VHN or up to about 210 VHN or even up to about 200 VHN. It will be appreciated that the hardness on the performance enhancing material can be any value between any of the minimum and maximum values noted above. It will also be appreciated that the hardness on the performance enhancing material can be any value within the range between any of the minimum and maximum values noted above.

According to yet another embodiment, the hardness H _PEMP on the performance enhancing material may be less than the hardness H _BMP on the bonding material _.

Many different aspects and embodiments are possible. Some of such aspects and embodiments are described below. After reading this specification, skilled artisans will appreciate that such aspects and embodiments are illustrative only and do not limit the scope of the invention. Embodiments may be in accordance with one or more of the items listed below.

Embodiment 1. An abrasive article comprising a body, wherein the body comprises: a bonding component; And abrasive particles in the bonding component, wherein the bonding component comprises a Fe—Co—Cu—Ni—Sn based bonding material and a performance enhancing material, wherein the performance enhancing material comprises boron hexagonal nitride, and wherein the performance enhancing The content of material is at least about 6 vol.% And at most about 14 vol.% Relative to the total volume of the binding component.

Embodiment 2. An abrasive article comprising a body, wherein the body comprises: a bonding component; And abrasive particles in the bonding component, wherein the bonding component comprises a Fe—Co—Cu—Ni—Sn based bonding material and a performance enhancing material, wherein the performance enhancing material comprises hexagonal boron nitride, and wherein the body Comprises a hardness of at least about 50 HRB and up to about 85 HRB.

Embodiment 3. An abrasive article comprising a body, wherein the body comprises: a continuous bonding material phase; Abrasive particles in the continuous bonding material phase; And a discontinuous performance enhancing material phase dispersed in the continuous bonding material phase, wherein the bonding material phase comprises a Fe—Co—Cu—Ni—Sn based bonding material, wherein hardness H _PEMP on the performance enhancing material is Hardness H is less than _BMP .

Embodiment 4 A method of forming an abrasive article, wherein the method comprises: providing an abrasive article forming mixture, and forming the abrasive article forming mixture into an abrasive article, wherein the abrasive article forming mixture is a bond forming mixture, and Abrasive particles, wherein the bond forming mixture comprises a raw bond material and a raw performance enhancing material, wherein the raw bond material comprises a Fe—Co—Cu—Ni—Sn based bond material Wherein the raw performance enhancing material comprises boron hexagonal nitride, wherein the content of the raw performance enhancing material in the abrasive article forming mixture is at least about 6 vol. Relative to the total volume of the bond forming mixture. % And up to about 14 vol.%.

Embodiment 5. A method of forming an abrasive article, wherein the method comprises: providing an abrasive article forming mixture; And forming the mixture into an abrasive article, wherein the bond forming mixture comprises a raw bond material and a raw performance enhancing material, wherein the raw bond material is a Fe-Co-Cu-Ni-Sn based A binding material, wherein the raw performance enhancing material comprises boron hexagonal nitride, and wherein the abrasive article comprising the body has a hardness of at least about 50 HRB and at most about 85 HRB.

Embodiment 6. A method of forming an abrasive article, wherein the method comprises: providing an abrasive article forming mixture; And formation of the mixture into an abrasive article, wherein the abrasive article comprises: a continuous bonding material phase; Abrasive particles in the continuous bonding material phase; And a discontinuous performance enhancing material phase dispersed in the continuous bonding material phase, wherein the bonding material phase comprises a Fe—Co—Cu—Ni—Sn based bonding material, wherein hardness H _PEMP on the performance enhancing material is Hardness H is less than _BMP .

Embodiment 7 The composite film or method of any one of Embodiments 1, 2, 3, 4, 5, and 6, wherein the performance enhancing component consists of hexagonal boron nitride.

Embodiment 8 The method of any one of Embodiments 4, 5, and 6, wherein the raw performance enhancing component consists of hexagonal boron nitride.

Embodiment 9. The method of any of embodiments 2, 3, 4, 5, and 6, wherein the content of the performance enhancing component in the abrasive article is at least about 6 vol.% And at most about 14 relative to the total volume of the abrasive article. Composite film or method that is vol.%.

Embodiment 10. The process of any of embodiments 4, 5, and 6, wherein the raw performance enhancing component content in the abrasive article forming mixture is at least about 6 vol.% And maximum relative to the total volume of the bond forming mixture. About 14 vol.%.

Embodiment 11. The composite film or method of any one of Embodiments 1, 2, 3, 4, 5, and 6, wherein the performance enhancing component has an average particle size of at least about 10 microns.

Embodiment 12. The method of any one of embodiments 4, 5, and 6, wherein the raw performance enhancing component has an average particle size of at least about 10 microns.

Embodiment 13. The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the performance enhancing component has an average particle size of up to about 12 microns.

Embodiment 14. The method of any one of embodiments 4, 5, and 6, wherein the raw performance enhancing component has an average particle size of up to about 12 microns.

Embodiment 15. The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the body has a hardness of at least about 50 HRB.

Embodiment 16. The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the body has a hardness of up to about 85 HRB.

Embodiment 17. The composite film of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article comprises a binding component content of at least about 55 vol.% Relative to the total volume of the abrasive article. Or the way.

Embodiment 18. The method of any one of embodiments 4, 5, and 6, wherein the abrasive article forming mixture comprises a bond forming mixture content of at least about 55 vol.% Relative to the total volume of the abrasive article forming mixture.

Embodiment 19. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article is at most about 95 relative to the total volume of the abrasive article. Composite films or methods comprising a binding component content of vol.%.

Embodiment 20. The method of any of embodiments 4, 5, and 6, wherein the abrasive article forming mixture comprises a bond forming mixture content of at most about 95 vol.% Relative to the total volume of the abrasive article forming mixture.

Embodiment 21. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article is at least about 5 relative to the total volume of the abrasive article. Composite film or method comprising an abrasive particle content of vol.%.

Embodiment 22. The method of any of embodiments 4, 5, and 6, wherein the abrasive article forming mixture is at least about 5 relative to the total volume of the abrasive article forming mixture. and an abrasive particle content of vol.%.

Embodiment 23. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article is at most about 25 relative to the total volume of the abrasive article. Composite film or method comprising an abrasive particle content of vol.%.

Embodiment 24. The method of any of embodiments 4, 5, and 6, wherein the abrasive article forming mixture is at most about 25 relative to the total volume of the abrasive article forming mixture. and an abrasive particle content of vol.%.

Embodiment 25. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article comprises a void, wherein the void is an interconnected void, wherein the void is a closed void. Composite films or methods.

Embodiment 26. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article is at least about 2 relative to the total volume of the abrasive article. Composite film or method further comprising a void content of vol.%.

Embodiment 27. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive article is at most about 20 relative to the total volume of the abrasive article. Composite film or method further comprising a void content of vol.%.

Embodiment 28. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises an iron (Fe) content of at least about 30 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 29. The method of any of embodiments 4, 5, and 6, wherein the bond forming mixture comprises an iron (Fe) content of at least about 30 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 30. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises an iron (Fe) content of up to about 70 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 31. The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises an iron (Fe) content of up to about 70 vol.% Relative to the total volume of the binding component.

Embodiment 32. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. Composite film or method comprising a Fe content of at least about 30 vol.% Relative to the total volume.

Embodiment 33. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. Composite film or method comprising a Fe content of at least about 70 vol.% Relative to the total volume.

Embodiment 34. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a cobalt (Co) content of at least about 5 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 35. The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a cobalt (Co) content of at least about 5 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 36. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a cobalt (Co) content of up to about 25 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 37 The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a cobalt (Co) content of up to about 25 vol.% Relative to the total volume of the forming mixture.

Embodiment 38. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. Composite film or method comprising a Co content of at least about 5 vol.% Relative to total volume.

Embodiment 39 The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. A composite film or method comprising a Co content of at least about 25 vol.% Relative to the total volume.

Embodiment 40. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a copper (Cu) content of at least about 20 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 41. The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a copper (Cu) content of at least about 20 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 42. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a copper (Cu) content of up to about 50 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 43. The method of any of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a copper (Cu) content of up to about 50 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 44. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. A composite film or method comprising a copper (Cu) content of at least about 20 vol.% Relative to the total volume.

Embodiment 45. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. A composite film or method comprising a copper (Cu) content of at least about 50 vol.% Relative to the total volume.

Embodiment 46. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a nickel (Ni) content of at least about 5 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 47. The method of any of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a nickel (Ni) content of at least about 5 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 48. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a nickel (Ni) content of up to about 30 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 49. The method of any of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a nickel (Ni) content of up to about 30 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 50. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. A composite film or method comprising a nickel (Ni) content of at least about 5 vol.% Relative to the total volume.

Embodiment 51. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. Composite film or method comprising a nickel (Ni) content of at least about 30 vol.% Relative to the total volume.

Embodiment 52. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a tin (Sn) content of at least about 2 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 53. The method of any one of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a tin (Sn) content of at least about 2 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 54. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the binding component comprises a tin (Sn) content of at most about 20 vol.% Relative to the total volume of the binding component. Composite film or method made.

Embodiment 55. The method of any of embodiments 4, 5, and 6, wherein the bond forming mixture comprises a tin (Sn) content of up to about 20 vol.% Relative to the total volume of the bond forming mixture.

Embodiment 56. The method of any of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. Composite film or method comprising a tin (Sn) content of at least about 2 vol.% Relative to total volume.

Embodiment 57. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the Fe—Co—Cu—Ni—Sn based bonding material is selected from the Fe—Co—Cu—Ni—Sn based bonding material. Composite film or method comprising a tin (Sn) content of at least about 20 vol.% Relative to total volume.

Embodiment 58. The method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive particles comprise diamond, wherein the abrasive particles comprise cubed boron nitride (cBN), wherein the The abrasive particle consists of diamond, wherein the abrasive particle consists of a cube boron nitride (cBN).

Embodiment 59. The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive particles have an average particle size of at least about 100 microns.

Embodiment 60. The composite film or method of any one of embodiments 1, 2, 3, 4, 5, and 6, wherein the abrasive particles have an average particle size of up to about 1000 microns.

Example

Example 1

Sample abrasive article S1 was formed according to the embodiments described herein and compared with comparative sample abrasive article CS1. Sample abrasive article S1 and comparative sample abrasive article CS1 were formed from the abrasive article forming mixture provided in Table 1 below.

The mixture described in Table 1 was formed into a sample abrasive article. All sample abrasive articles were tested to compare polishing performance by measuring the power draw of each article of each sample. Polishing tests were performed according to the parameters provided in Table 2 below.

Polishing test parameters machine Vertical rotating surface grinder Wheel diameter: 1100 mm Ambient speed 8 m / s Polishing rate 0.3 mm / min feed  Fireproof surface area Up to 14000 cm ²  Fireproof type Alumina, Alumina Zirconia Composites Coolant flow Flood coolant

2 is a graph showing the average power drawn per polishing cycle for each sample abrasive wheel. As shown in FIG. 2, when compared to Comparative Sample 1 (ie, an abrasive wheel without hBN added as a performance enhancing component), the sample abrasive article S1 formed according to the embodiments described herein exhibited improved power draw.

Example 2

Sample abrasive article S2 was formed according to the embodiments described herein and compared with comparative sample abrasive articles CS2 and CS3. Sample abrasive article S1 and comparative sample abrasive articles CS2 and CS3 were formed from the abrasive article forming mixture provided in Table 3 below.

The mixture described in Table 3 was formed into a sample abrasive article. All sample abrasive articles were tested to compare polishing performance by measuring the power draw of each article of each sample. Polishing tests were performed according to the parameters provided in Table 4 below.

Polishing test parameters machine CNC milling machine Wheel diameter: 40 mm Ambient speed 5 m / s Polishing rate 0.2 mm Glass surface area 500 mm ² Glass type AZS fireproof Coolant flow Pointed Flow

3 is a graph showing normalized average wear for each sample abrasive wheel. As shown in FIG. 3, the average wear rate of each abrasive article increases with increasing hBN concentration (ie, wheel life decreases).

4 is a graph showing the average power drawn over time for each sample abrasive wheel. As shown in FIG. 4, the average power drawn for each abrasive article decreases with increasing hBN concentration (ie, wheel polishing performance is improved).

Example 3

Sample S3 of the binding component was formed according to the embodiment described herein and compared with comparative sample binding component CS4. Sample S3 and Comparative Sample CS4 were formed from the binding component mixtures provided in Table 5 below.

The mixtures described in Table 5 were formed into samples for evaluation. 5 includes multiple images of the microstructure of sample abrasive article S3. 6 includes multiple images of the microstructure of comparative sample abrasive article CS4. As shown in Figures 5 and 6, hBN addition produces microstructures with multiple defects, discontinuities and ruptured sites. Without intending to be bound by any particular theory, the microstructure of sample abrasive article S3 indicates that the presence of hBN makes the bonding matrix more brittle and thus more abrasive, which improves abrasive performance.

This application represents departure from the prior art. Obviously, the embodiments herein demonstrate improved and unexpected performance over abrasive articles formed according to conventional methods. Without intending to be bound by any particular theory, it is suggested that certain combinations of features, including processes, materials, and the like, may facilitate such improvements. The combination of features includes, but is not limited to, a particular concentration of hBN that acts as a performance enhancing component of the abrasive article relative to the hardness performance enhancing component phase of the abrasive article and balances the hardness of the bonding material on the abrasive article. It may include a composition to.

In the foregoing, specific embodiments and certain component related references are exemplary. It will be understood that reference to a component that is coupled or linked is intended to initiate a direct linkage between the components or an indirect linkage through one or more intervening components, as understood to carry out the methods discussed herein. As such, the above-disclosed subject matter should be considered illustrative and not restrictive, and the appended claims are intended to cover all such modifications, improvements, and other embodiments that fall within the true scope of the present invention. Thus, to the maximum extent allowed in the patent, the scope of the present invention should be determined by the maximum allowable interpretation of the following claims and their equivalents, and should not be limited or limited by the foregoing detailed description.

It is submitted with the understanding that it is provided according to patent law and is not used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped or described together in a single embodiment for the purpose of streamlining the disclosure. This disclosure should not be construed as a reflection of the intention that the claimed embodiments require more features than are expressly stated in the respective claims. Rather, the following claims reflect that the subject matter may relate to less than all features of the disclosed embodiments. Accordingly, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as defining a separately claimed subject matter.

Claims (15)

An abrasive article comprising a body, wherein the body includes:
Binding component; And
Abrasive particles in the bonding component,
Wherein the bonding component comprises a Fe-Co-Cu-Ni-Sn-based bonding material and a performance improving material,
Wherein the performance enhancing material comprises hexagonal boron nitride, and
Wherein the content of the performance enhancing material is at least about 6 vol.% And at most about 14 vol.% Relative to the total volume of the binding component. An abrasive article comprising a body, wherein the body includes:
Binding component; And
Abrasive particles in the bonding component,
Wherein the bonding component comprises a Fe-Co-Cu-Ni-Sn-based bonding material and a performance improving material,
Wherein the performance enhancing material comprises hexagonal boron nitride, and
Wherein the body comprises a hardness of at least about 50 HRB and at most about 85 HRB. An abrasive article comprising a body, wherein the body includes:
Continuous bonding material phase;
Abrasive particles in the continuous bonding material phase; And
A discontinuous performance enhancing material phase dispersed in the continuous bonding material phase,
Wherein the bonding material phase comprises a Fe—Co—Cu—Ni—Sn based bonding material, and
Wherein the hardness H _PEMP on the performance enhancing material is less than the hardness H _BMP on the bonding material. The composite film according to any one of claims 1, 2, and 3, wherein the performance enhancing component consists of hexagonal boron nitride. The composite film of claim 2, wherein the content of performance enhancing component in the abrasive article is at least about 6 vol.% And at most about 14 vol.% Relative to the total volume of the abrasive article. The composite film of claim 1, wherein the performance enhancing component has an average particle size of at least about 10 microns. The composite film of claim 1, wherein the performance enhancing component has an average particle size of up to about 12 microns. The composite film of claim 1, wherein the body has a hardness of at least about 50 HRB. The composite film of claim 1, wherein the body has a hardness of up to about 85 HRB. The composite film of claim 1, wherein the abrasive article comprises a binding component content of at least about 55 vol.% Relative to the total volume of the abrasive article. The abrasive article of claim 1, wherein the abrasive article is at most about 95 relative to the total volume of the abrasive article. Composite film comprising a binding component content of vol.%. The abrasive article of claim 1, wherein the abrasive article is at least about 5 relative to the total volume of the abrasive article. Composite film comprising an abrasive particle content of vol.%. The abrasive article of claim 1, wherein the abrasive article is at most about 25 relative to the total volume of the abrasive article. Composite film comprising an abrasive particle content of vol.%. The abrasive article of claim 1, wherein the abrasive article is at least about 2 relative to the total volume of the abrasive article. Composite film further comprising a void content of vol.%. The abrasive article of claim 1, wherein the abrasive article is at most about 20 relative to the total volume of the abrasive article. Composite film further comprising a void content of vol.%.

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