Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K3/00—Materials not provided for elsewhere
  • C09K3/14—Anti-slip materials; Abrasives
  • C09K3/1436—Composite particles, e.g. coated particles
  • C09K3/1445—Composite particles, e.g. coated particles the coating consisting exclusively of metals
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
  • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
  • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
  • B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
  • B24D3/14—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic ceramic, i.e. vitrified bondings
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B32/00—Carbon; Compounds thereof
  • C01B32/25—Diamond
  • C01B32/28—After-treatment, e.g. purification, irradiation, separation or recovery
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B32/00—Carbon; Compounds thereof
  • C01B32/90—Carbides
  • C01B32/914—Carbides of single elements
  • C01B32/991—Boron carbide
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
  • C09K3/00—Materials not provided for elsewhere
  • C09K3/14—Anti-slip materials; Abrasives
  • C09K3/1436—Composite particles, e.g. coated particles

Definitions

• the present invention relates to vitreous bond grinding elements containing metal coated superabrasive particles or grit and more particularly to the use of functionally graded coatings for improved wetting of the coated particles by the vitreous bond matrices.
• Refractory metal oxides titanium, zirconia, alumina, silica coatings on diamond, CBN, and silicon carbides for use in grinding elements have been proposed (see U.S. Patents Nos. 4,951,427 and 5,104,422). Processing of these coatings includes deposition of an elemental metal (Ti, Zr, Al) on the abrasive particle surface followed by oxidizing the sample at an appropriate temperature to convert the metal to an oxide.
• elemental metal Ti, Zr, Al
• these coatings often crack do to inherent brittleness of the oxide layer and residual stresses developed from the mismatch in thermal expansion coefficients between the oxide and abrasive particle. In practice, these abrasive particles pull out of the matrix during grinding when the interface between the coating and abrasive particle is weak.
• Coated crystals pulling out from the vitreous bond during grinding is one of the major failure modes of grinding wheels.
• coated abrasive crystals which provide improved retention in vitreous bonds.
• the retention of metal oxide coated superabrasive particles in a vitreous bond matrix is improved by incorporating functionally graded coated abrasive particles in the vitreous bond matrix.
• Diamond, cubic boron nitride, silicon carbide, and like abrasive particles are useful for this purpose.
• the novel functionally graded coated abrasive particles have an outer oxide phase coating layer derived from a metal carbide, nitride, and/or boride, which forms an imier coating layer. The coating provides improved adhesion of the abrasive particles in the matrix and protection against chemical attack during tool fabrication and processing.
• the invention is directed to coated abrasive particles for use in vitreous bond matrices.
• the particles are coated with between 1 and about 50 coating layers.
• Each coating layer ranges in thickness from between about 0.1 and 50 microns.
• Each layer has the composition, MC ⁇ N ⁇ BzOw, where, M represents one or more of Ti, Si, V, Cr, Zr, Nb, Mo, Hf, Ta, W, Re or a rare earth metal, and w, x, y, and z, each range from between 0 and 3.
• the outermost coating layer has a concentration of oxygen that is higher by a factor of at least about 2 than the layer in direct contact with the abrasive particle.
• the coating layers can be formed by depositing between 1 and about 50 layers of a coating of the composition, MC ⁇ N ⁇ B z .
• An outermost layer(s) enriched in oxygen by a factor of at least about 2 compared to the coating layer in direct contact with the abrasive particle is formed by reaction of oxygen with the carbide/nitride/boride coated abrasive particles.
• the functionally graded coated abrasive particles can be incorporated with matrix materials for forming a vitreous bond grinding element.
• Matrix materials include vitreous bond material, SiO 2 , B 2 O 3 , Na 2 O, CaO, MgO, or other similar glass forming materials.
• Conventional processing common in the art is used to form the vitreous bond grinding elements. Improved grinding performance results from using such grinding elements
• Fig. 1 displays x-ray diffraction analysis results on SiC coated diamond abrasive particles of Example 1;
• Fig. 2 provides thermogravimetric analysis (TGA) results of oxidized SiC coated diamond abrasive particles of Example 1;
• Fig. 3 displays x-ray diffraction analysis results on SiC coated diamond abrasive particles of Example 1, which have an outer oxidized layer;
• Fig. 4 provides thermogravimetric analysis (TGA) results of functionally graded SiC coated diamond abrasive particles of Example 1 compared to uncoated diamond crystals;
• Figs. 5 and 6 are photomicrographs from scanning electron microscopy (SEM) of uncoated diamond crystals that were blended with a borosilicate glass to form a vitreous element (62 and 110 magnification, respectively); and Figs. 7 and 8 are photomicrographs from scanning electron microscopy (SEM) of SiC ⁇ O coated diamond crystals that were blended with a borosilicate glass to form a vitreous element (78 and 101 magnification, respectively).
• SEM scanning electron microscopy
• the diamond particles can be natural or synthetic. Synthetic diamond most often is used in grinding operations. Synthetic diamond can be made by high pressure/high temperature (HP/HT) processes, which are well known in the art.
• the particle size of the diamond is conventional in size for vitreous-bond grinding elements. Generally, the diamond grit can range in particle size from about 1 micron to about 10 mm, advantageously from about 10 to 1000 microns, and preferably from about 37 microns (400 mesh) upward to 425 microns (40 mesh). Narrow particle size distributions can be preferred according to conventional grinding technology. Cubic boron nitride (CBN) also can be coated in accordance with the precepts of the present invention, as can SiC or other abrasive particles, especially those that are not wetted by the vitreous bond matrix.
• CBN Cubic boron nitride
• the abrasive particles are coated with at least one layer of a material of the composition, where, M represents one or more of Ti, Si, V, Cr, Zr, Nb, Mo, Hf, Ta, W, Re or a rare earth metal, and w, x, y, and z, each range from between 0 and 3.
• the coating thickness of each layer is between about 0.1 and 50 microns and the number of layers is between 1 and about 50.
• the outermost layer has a concentration of oxygen that is higher by a factor of at least about 2 than that in the layer in direct contact with the abrasive particle and advantageously by a factor of at least about 5.
• the initial step in forming the functionally graded abrasive particles is to deposit layers of material, MC ⁇ N ⁇ B z , by chemical vapor deposition (CND), pack cementation, metal deposition followed by carburization, nitridation, boridation, or other methods practiced in this art, or combinations of such methods.
• the thickness of each layer ranges from between about 0.1 to about 50 ⁇ with the number of layers ranging from 1 to about 50.
• a single layer, especially if relatively thick, can have its outer surface oxidized to form a functionally graded abrasive particle according to the precepts of the present invention.
• a chemically bonded oxide coating is formed by reaction of oxygen with the carbide/nitride/boride coated abrasive particles by high temperature annealing in air, oxygen, or an oxygen-containing gas, sintering in a glassy matrix, CVD processing, sol-gel techniques, fusion treatments in oxygen-containing molten salts, such as at least one of the alkali nitrates, alkali hydroxides, or alkali carbonates, or by other methods practiced in the art for oxidizing metal carbide/nitride/boride coatings.
• the glass matrix can comprise the vitreous bond itself, so that formation of the outermost oxide layer and sintering of the vitreous matrix composite occurs in a single processing step.
• the thus-formed oxide layer has the composition, where M represents the metal or alloy found in the outermost layer and x, y, z, and w, range from between 0 and 3.
• the oxide-rich surface layer is deposited directly, rather than by oxidation of the outermost portion of the MO ⁇ N ⁇ Bz layer.
• Deposition of the oxide-rich surface layer may be performed by CVD, pack cementation, or other methods that are practiced in the art.
• the thus-formed oxide layer has the composition, MC ⁇ N ⁇ BzOw, where M represents the metal or alloy found in the outermost layer and x, y, z, and w, range from between 0 and 3.
• the novel functionally graded abrasive particles then can be combined with vitreous matrix composite materials.
• the mixture then can be sintered or hot-pressed following procedures common in the vitreous bond art.
• the functionally graded abrasive particles are mixed with SiO 2 , B 2 O 3 , Na 2 O, CaO, MgO, or other similar glass forming material(s), and hot pressed.
• the concentration of functionally coated diamond and fabrication of such wheels is conventional and well known in that art. Broadly, such concentrations range from about 25 to 200 (100 concentration conventionally being defined in the art as 4.4 carats/cm 3 with 1 carat equal to 0.2 g, wherein the concentration of diamond grains is linearly related to its carat per unit volume concentration).
• Diamond particles (500/425 ⁇ or 35/40 mesh) were coated with SiC to an average weight percent coating of about 2.7 using a CND process.
• X-ray diffraction analysis of the coatings was conducted.
• the coating was confirmed to be SiC, as evidenced in Fig. 1, which displays the x-ray diffraction results.
• the oxidation properties of the coated diamond were determined using thermogravimetric analysis (TGA).
• TGA thermogravimetric analysis
• the temperature of the TGA furnace was ramped from 25° C to 1100° C at a rate of 10° C per minute in static air.
• the weight gain of the particles, as measured by TGA indicated the development of an oxide layer layer on the outermost portion of the coating at temperatures below 980° C.
• vitreous elements were fabricated using uncoated and SiC ⁇ Ow coated diamond crystals and borosilicate glass.
• Uncoated and SiC coated diamond crystals and glass were placed in a graphite mold and heated in static air using a standard laboratory box furnace. The temperature of the furnace was ramped from room temperature to 850° C over a 2 hour time period. As shown in Fig. 3, an oxycarbide outer layer forms during the heating step on the surface of the diamond particles initially coated with SiC. The furnace was held at 850° C for 1 hour and then allowed to cool for approximately 4 hours. The samples then were removed from the furnace once the temperature was less than 50° C.
• the diamond-glass interface was analyzed by fracturing the vitreous elements and examining the fracture surfaces using scanning electron microscopy (SEM).
• Figs. 5 and 6 show that the glass matrix did not wet the uncoated crystals. Furthermore, the diamond crystal surface is smooth and free from glass residue.
• the SiC ⁇ O coated diamond crystals were wet by the glass matrix, as shown in Fig. 7 and 8. A continuous interface is present between the SiC ⁇ Ow coated diamond crystals and the glass matrix.

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

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• 2001
  • 2001-11-16 US US09/987,863 patent/US6475254B1/en not_active Expired - Lifetime
• 2002
  • 2002-06-19 US US10/174,914 patent/US6596040B2/en not_active Expired - Lifetime
  • 2002-10-30 AU AU2002350066A patent/AU2002350066A1/en not_active Abandoned
  • 2002-10-30 WO PCT/US2002/034795 patent/WO2003044121A1/en not_active Ceased
  • 2002-10-30 KR KR1020047007505A patent/KR20050042071A/ko not_active Ceased
  • 2002-10-30 CN CNB028228154A patent/CN100429289C/zh not_active Expired - Lifetime
  • 2002-10-30 JP JP2003545748A patent/JP2005509724A/ja active Pending
  • 2002-10-30 DE DE10297443.8T patent/DE10297443B4/de not_active Expired - Lifetime

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