WO2018183736A1 - Article abrasif et son procédé de formation - Google Patents

Article abrasif et son procédé de formation Download PDF

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Publication number
WO2018183736A1
WO2018183736A1 PCT/US2018/025236 US2018025236W WO2018183736A1 WO 2018183736 A1 WO2018183736 A1 WO 2018183736A1 US 2018025236 W US2018025236 W US 2018025236W WO 2018183736 A1 WO2018183736 A1 WO 2018183736A1
Authority
WO
WIPO (PCT)
Prior art keywords
microns
bond material
abrasive particles
abrasive
content
Prior art date
Application number
PCT/US2018/025236
Other languages
English (en)
Inventor
Jiashu LI
Kelley Mcneal
Srinivasan Ramanath
Cecile O. MEJEAN
Ji Wang
Original Assignee
Saint-Gobain Abrasives, Inc.
Saint-Gobain Abrasifs
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint-Gobain Abrasives, Inc., Saint-Gobain Abrasifs filed Critical Saint-Gobain Abrasives, Inc.
Priority to EP18776324.8A priority Critical patent/EP3600769A4/fr
Priority to BR112019020399A priority patent/BR112019020399A2/pt
Priority to KR1020197031413A priority patent/KR20200006044A/ko
Priority to CN201880022620.1A priority patent/CN110799306A/zh
Publication of WO2018183736A1 publication Critical patent/WO2018183736A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/02—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent
    • B24D3/04—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic
    • B24D3/06—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements
    • B24D3/10—Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents the constituent being used as bonding agent and being essentially inorganic metallic or mixture of metals with ceramic materials, e.g. hard metals, "cermets", cements for porous or cellular structure, e.g. for use with diamonds as abrasives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/06—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental
    • B24D5/063—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor with inserted abrasive blocks, e.g. segmental with segments embedded in a matrix which is rubbed away during the grinding process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0009—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using moulds or presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D18/00—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for
    • B24D18/0072—Manufacture of grinding tools or other grinding devices, e.g. wheels, not otherwise provided for using adhesives for bonding abrasive particles or grinding elements to a support, e.g. by gluing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
    • B24D5/14—Zonally-graded wheels; Composite wheels comprising different abrasives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1409—Abrasive particles per se
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K3/00—Materials not provided for elsewhere
    • C09K3/14—Anti-slip materials; Abrasives
    • C09K3/1436—Composite particles, e.g. coated particles

Definitions

  • the present disclosure relates to abrasive articles, and in particular, bonded abrasive articles including abrasive particles contained within a bond material including a metal or metal alloy.
  • Abrasives used in machining applications typically include bonded abrasive articles and coated abrasive articles.
  • Coated abrasive articles are generally layered articles having a backing and an adhesive coat to fix abrasive particles to the backing, the most common example of which is sandpaper.
  • Bonded abrasi ve tools consist of rigid, and typically monolithic, three-dimensional, abrasive composites in the form of wheels, discs, segments, mounted points, hones and other tool shapes, which can be mounted onto a machining apparatus, such as a grinding or polishing apparatus.
  • Bonded abrasive tools usually have at least two phases including abrasive particles and bond material. Certain bonded abrasive articles can have an additional phase in the form of porosity. Bonded abrasive tools can be manufactured in a variety of 'grades' and 'structures' that have been defined according to practice in the art by the relative hardness and density of the abrasive composite (grade) and by the volume percentage of abrasive grain, bond, and porosity within the composite (structure).
  • Some bonded abrasive tools may be particularly usef ul in grinding and shaping certain types of workpieces, including for example, metals, ceramics and crystalline materials, used in the electronics and optics industries. In other instances, certain bonded abrasive tools may be used in shaping of superabrasive materials for use in industrial applications.
  • the process involves a significant amount of time and labor directed to maintaining the bonded abrasive article. 'That is, generally, metal-bonded abrasive articles require regular truing and dressing operations to maintain the grinding capabilities of the abrasive article.
  • FIG. 1A includes a cross-sectional illustration of an abrasive article according to an embodiment.
  • FIG. IB includes a cross-sectional illustration of an abrasive article according to an embodiment.
  • FIG. 2 includes a scanning electron microscope (SEM) image of a portion of a conventional abrasive article
  • FIG. 3 includes a SEM image of a portion of an abrasive article according to an example.
  • FIG. 4 includes a plot of current versus number of workpieces for samples described herein.
  • FIG. 5 includes a plot of current versus number of workpieces for samples described herein.
  • FIG. 6 includes a SEM image of a portion of Sample S5 according to an embodiment.
  • FIG. 7 includes a graph of run lengths for samples disclosed herein.
  • FIG. 8 includes a plot of coolant flow rates versus dressing frequencies for samples disclosed herein.
  • An abrasive article can be formed according to the following method.
  • a mixture is formed including abrasive particles in a precursor bond material.
  • the precursor bond material can include a raw material powder including a metal, metal alloy, or metal forming material or compound, in one embodiment, the precursor bond material, which may be a powder material, can have an average particle size (D50) of not greater than 25 microns or not greater than 10 microns or not greater than 1 micron or not greater than 0.75 microns or not greater than 0.5 microns or not greater than 0.25 microns or not greater than 0.1 microns.
  • D50 average particle size
  • the precursor bond material may have an average particle size of at least 0.001 microns, such as at least 0.01 microns or at least 0.1 microns or even at least 0.5 microns. It will be appreciated that the average particles size of the precursor bond material can be within a range including any of the minimum and maximum values noted above.
  • the mixture can include a precursor bond material, which may be formed of one or more powdered metal materials.
  • the precursor bond material which forms the bond material of the body of the abrasive article, can include at least one of cobalt, tin, tungsten, copper, or any combination thereof.
  • the precursor bond material can include cobalt, tin and tungs en.
  • the precursor bond material may have a particular content of cobalt and tin that may facilitate improved formation and/or
  • the precursor bond material can include cobalt (CCo) and tin (CSn) in a ratio [CSn/CCo] of not greater than 0.2, wherein CCo is the weight percent of cobalt for the entire weight of the precursor bond material and CSn is the weight percent of tin for the entire weight of the precursor bond material.
  • the ratio [CSn/CCo] can be not greater than 0.19, such as not greater than 0.18 or not greater than 0.17 or not greater than 0.16 or not greater than 0.15 or not greater than 0.14 or not greater than 0.
  • the ratio [CSn/CCo] can be at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1. It will be appreciated that the ratio [CSn/CCo] can be within a range including any of the minimum and maximum values noted above.
  • the precursor bond material may have a particular content of cobalt and tungsten that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can include cobalt (CCo) and tungsten (CW) in a ratio [CW/CCo] of not greater than 0.9, wherein CCo is the weight percent of cobalt for the entire weight of the precursor bond material and CW is the weight percent of tungsten for the entire weight of the precursor bond material, in another embodiment, the ratio [CW/CCo] can be not greater than 0.8, such as not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.10 or not greater than 0.09 or not greater than 0.08 or not greater than 0.07 or not greater than 0.06 or not greater than 0.05 or not greater than 0.04 or not greater than 0.03 or not greater than 0.02 or not greater than 0.0 .
  • the ratio [CW/CCo] can be at least about 0.001 , such as at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7. It will be appreciated that the ratio [CW/CCo] can be within a range including any of the minimum and maximum values noted above.
  • the precursor bond material may have a particular content of tungsten and tin that may facilitate impro ved formation and/or performance of the abrasive article.
  • the precursor bond material can include tin (CSn) and tungsten (CW) in a ratio [CSn/CW] of not greater than 1, wherein CW is the weight percent of tungsten for the entire weight of the precursor bond material and CSn is the weight percent of tin for the entire weight of the precursor bond material.
  • the ratio [CSn/CW] can be not greater than 0.9, such as not greater than 0.8 or not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.1.
  • the ratio [CSn/CW] can be at least 0.01, such as at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9. It will be appreciated that the ratio [CSn/CW ] can be within a range including any of the minimum and maximum values noted above.
  • the prec rsor bond material may have a partic lar content of cobalt that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material may include at least 40 wt% cobalt for a total weight of the precursor bond material, such as at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least 54 wt% or at least 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt or at least 59 wt or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt
  • the precursor bond material can include a content of cobalt of not greater than 99 wt% for the total weight of the precursor bond material, such as not greater than 98 wt% or not greater than 97 wt% or not greater than 96 wt% or not greater than 95 wt or not greater than 94 wt% or not greater than 93 wt% or not greater than 92 wt% or not greater than 91 wt% or not greater than 90 wt% or not greater than 89 wt% or not greater than 88 wt% or not greater than 87 wt% or not greater than 86 wt% or not greater than 85 wt% or not greater than 84 wt% or not greater than 83 wt% or not greater than 82 wt% or not greater than 81 wt% or not greater than 80 wt% or not greater than 79 wt% or not greater than 78 wt% or not greater than 77 wt%
  • the content of cobalt in the precursor bond material can be within a range including any of the minimum and maximum values noted above.
  • the precursor bond material may have a particular content of tin that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material may include at least 0.1 wt% tin for a total weight of the precursor bond material or at least 0.2 wt% or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least
  • the precursor bond material can include a content of tin of not greater than 15 wt% for a total weight of the precursor bond material or not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 wt% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater man 5.5 wt% or not greater than 5 wt% or not greater than 4.5 wt% or not greater than 4 wi% or not greater than 3.5 wt% or not greater than 3 wt or not greater than 2.5 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% or not greater than 0.5 wt% tin for the total weight of the precursor bond material. It will be appreciated that the content of tin in the precursor bond material can be within
  • the precursor bond material may have a particular content of tungsten that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material may include at least 1 wt% tungsten for a total weight of the precursor bond material, such as at least 0.1 wt or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1 wt
  • the precursor bond material may include greater than 20 wt% tungsten for a total weight of the precursor bond material, such as not greater than 18 wt% or not greater than 16 wt% or not greater than 14 wt% or not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% or not greater than 5 wt% or not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt% tungsten for the total weight of the precursor bond material. It will be appreciated that the content of tungsten in the precursor bond material can be within a range including any of the minimum and maximum values noted above. In at least one embodiment, the precursor bond material may be essentially free of tungsten.
  • the mixture may include a particular content of iron that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can include a content of iron of at least 0.05 wt% for a total weight of the precursor bond material, such as at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 wt% or at least 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt iron for a total weight of the precursor bond material.
  • the precursor bond material can include a content of iron of not greater than 5 wt% for a total weight of the precursor bond material, such as not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt%.
  • the content of iron in the precursor bond material can be within a range including any of the minimum and maximum values noted above. Still, in one embodiment, the precursor bond material may be essentially free of iron.
  • the mixture may include a particular content of aluminum that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can include a content of aluminum of not greater than 1 wt% for a total weight of the precursor bond material, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • the precursor bond material can include a content of aluminum of at least 0.001 wt% or at least 0.01 wt% for the total weight of the precursor bond material. It will be appreciated that the content of aluminum in the precursor bond material can be within a range including any of the minimum and maximum values noted abo ve. Still, in one embodiment, the precursor bond material may be essentially free of aluminum.
  • the mixture may include a particular content of copper that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can include a content of copper of not greater than 20 wt% for a total weight of the precursor bond material, such as not greater than 1 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • the precursor bond materiai can include a content of copper of at least 0.001 wt% or at least 0.01 wt% for the total weight of the precursor bond material. It will be appreciated that the content of copper in the precursor bond material can be within a range including any of the minimum and maximum values noted above. Still, in one embodiment, the precursor bond material may be essentially free of copper.
  • the mixture may include a particular content of manganese that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can include a content of manganese of not greater than 1 wt% for a total weight of the precursor bond materiai, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt or not greater than 0.2 wt or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • the precursor bond material can include a content of manganese of at least 0.001 wt or at least 0.01 wt% for the total weight of the precursor bond material. It will be appreciated that the content of manganese in the precursor bond material can be within a range including any of the minimum and maximum values noted abo ve. Still, in one embodiment, the precursor bond material may be essentially free of manganese.
  • the mixture may include a particular content of titanium that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can include a content of titanium of not greater than 1 wt% for a total weight of the precursor bond material, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt%.
  • the precursor bond material can include a content of titanium of at least 0.001 wt or at least 0.01 wt% for the total weight of the precursor bond material. It will be appreciated that the content of titanium in the precursor bond material can be within a range including any of the minimum and maximum values noted above. Still, in one embodiment, the precursor bond material may be essentially free of titanium.
  • the precursor bond material may have a particular content of certain metals that may facilitate improved formation and/or performance of the abrasive article.
  • the precursor bond material can have a total content of aluminum, copper, manganese, lead, silicon, and titanium (i.e., sum total of weight percent for each of the listed elements) of not greater than 20 wt% for a total weight of the precursor bond material, such as not greater than 15 wt% or not greater than 10 wt% or not greater than 5 wt or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt%.
  • the precursor bond material can include a total content of aluminum, copper, manganese, lead, silicon, and titanium of at least 0.001 wt% or at least 0.01 wt% for the total weight of the precursor bond material, it will be appreciated that the total content of aluminum, copper, manganese, lead, silicon, and titanium in the precursor bond material can be within a range including any of the minimum and maximum values noted above.
  • the precursor bond material can be essentially free of aluminum, copper, manganese, lead, silicon, and/or titanium.
  • the term essentially free is intended to include minimum amounts of the material limited to impurity contents, including for example, but not necessarily limited to, contents of not greater than 0.01 wt%.
  • the composition should be interpreted as including components X, Y, and Z and only impurity amounts of other components or such minimal amounts of said other components, that said other components do not affect the properties or performance of the composition. Such statements are applicable to the description of any of the embodimen s herein.
  • the precursor bond material can be formed to include at least 95 wt% of cobalt, tin and tungsten for the total weight of the precursor bond material.
  • not greater than 5 wt% of the precursor bond material can include secondary elements selected from the group consisting of including aluminum, copper, manganese, lead, silicon, and titanium.
  • the precursor bond material can be formed to include at least 95 wt% of cobalt and tin, such as at least 96 wt% or at least 97 wt% or at least 98 wt% or even at least 99 wt% cobalt and tin for the total weight of the precursor bond material.
  • the mixture may include one or more other additives, including for example, fillers that may be present in the final abrasive article and facilitate improved operations of the abrasive article.
  • suitable fillers can include those known in the art, including for example, pore formers and the like.
  • Some additives may be included in the mixture and may be consumed or removed during processing. Such additives may be added to the mixture to improve processing of the abrasive article.
  • Some exemplary additives can include mixing agents (e.g., dispersants, surfactants, etc.).
  • the abrasive particles can include a material selected from the group consisting of oxides, carbides, nitrides, borides, or any combination thereof.
  • the abrasive particles can include a superabrasive material, such as diamond, in one particular instance, the abrasive particles can consist essentially of diamond.
  • the abrasive particles can include a mixture of abrasive particles, which may differ from each other based on at least one characteristic selected from the group consisting of average particle size, average toughness, hardness, ellipticity, composition, or any combination thereof.
  • the abrasive particles can include a blend of two different types of diamond particles including a first type of diamond particles and a second type of diamond particles, wherein the first type of diamond particles are different from the second type of diamond particles based on average particle size, average toughness, hardness, ellipticity, or any combination thereof.
  • the abrasive particles can have a coating overlying the exterior surface. The coating may facilitate improved formation and performance of the abrasive article.
  • the coating can include a material that reduces chemical changes to the abrasive particles during formation, such as oxidation of the abrasive particles.
  • the coating may limit the chemical interactions between the abrasive particle and the bond material during forming.
  • the coating can include a metal or metal alloy. Some suitable metal materials can include one or more transition metal elements.
  • the coating can include titanium, and may consist essentially of titanium.
  • the weight and/or thickness of the coating can be varied to facilitate suitable processing and/or performance of the abrasive article.
  • the coating can be formed such that it overlies a majority of the exterior surfaces of the abrasive particles, such as at least 60% or at least 70% or at least 80% or at least 90% or at least 95% of the exterior surfaces of the abrasive particles.
  • the abrasive particles may have a particular particle size distribution that can facilitate improved performance of the abrasive article.
  • the abrasive particles can have a median particle size (D50), which may also be referred to herein as the average particle size, of at least 65 microns, such as at least 75 microns or at least 90 microns or at least 95 microns or at least 97 microns or at least 100 microns or at least 105 microns or at least 1 10 microns or at least 120 microns.
  • D50 median particle size
  • the abrasive particles can have a median particle size (D50) of not greater than 50 microns or not greater than 140 microns or not greater than 130 microns or not greater than 120 microns or not greater than 1 10 microns or not greater than 105 microns or not greater than 100 microns. It will be appreciated that the abrasive particles can have a median particle size within a range including any of the minimum and maximum values noted above.
  • the abrasive particles may also have a particular D10 that may define the maximum particle size of the particles in the lowest 10% of the distribution (i.e., the particle size of the abrasive particles in the 10 th percentile of the distribution).
  • the abrasive particles can have a D10 of at least 57 microns, such as at least 60 microns or at least 65 microns or at least 70 microns or at least 75 microns or at least 77 microns or at least 80 microns or at least 83 microns or at least 85 microns or at least 87 microns or at least 90 microns or at least 93 microns or at least 95 microns.
  • the abrasive particles can have a D10 of not greater than 127 microns or not greater than 120 microns or not greater than 110 microns or not greater than 100 microns or not greater than 95 microns or not greater than 93 microns or not greater than 90 microns or not greater than 87 microns or not greater than 85 microns or not greater than 83 microns or not greater than 80 microns. It will be appreciated that the abrasive particles can have a D10 within a range including any of the minimum and maximum values noted above.
  • the abrasive particles may also have a particular D90 that may define the minimum particle size of the particles in the greatest 10% of the distribution (i.e., the particle size for the abrasive particles in the 90 Ul percentile of the distribution).
  • the abrasive particles can have a D90 of at least 97 microns, such as at least 100 microns or at least 103 microns or at least 105 microns or at least 108 microns or at least 110 microns or at least 113 microns or at least 115 microns or at least 118 microns or at least 120 microns or at least 123 microns or at least 125 microns or at least 128 microns or at least 130 microns or at least 133 microns or at least 135 microns or at least 138 microns.
  • the abrasive particles can have a D90 of not greater than 165 microns, such as not greater than 160 microns or not greater than 155 microns or not greater than 150 microns or not greater than 145 microns or not greater than 140 microns or not greater than 135 microns or not greater than 133 microns or not greater than 130 microns or not greater than 128 microns or not greater than 125 microns or not greater than 123 or not greater than 120 microns or not greater than 118 microns or not greater than 115 microns or not greater than 113 microns or not greater than 110 microns or not greater than 108 microns or not greater than 105 microns. It will be appreciated that the abrasive particles can have a D90 within a range including any of the minimum, and maximum values noted above.
  • the abrasive particles may also define a particle size distribution having a particularly limited size of particles greater than 120 microns.
  • the abrasive particles define a particle size distribution having not greater than 10 vol% of abrasive particles with a particle size greater than 120 microns for the total volume of abrasive particles in the distribution, such as not greater than 9 vol% or not greater than 8 vol% or not greater than 7 vol% or not greater than 6 vol% or not greater than 5 vol% or not greater than 4 vol% or not greater than 3 vol% or not greater than 2 vol% or not greater than 1.8 vol% or not greater than 1.5 vol% of abrasive particles with a particle size greater than 120 microns for the total volume of abrasive particles in the distribution.
  • the content of abrasive particles with a particle size greater than 120 microns for the total volume of abrasive particles in the distribution may be at least 0.1 vol% or at least 0.5 vol% or even at least 0.8 vol%. It will be appreciated that the content of abrasive particles with a particle size greater than 120 microns for the total volume of abrasive particles in the distribution can be within a range including any of the minimum and maximum percentages noted above.
  • the abrasive particles may have a particular Vickers hardness that may facilitate improved performance of the abrasive article.
  • the abrasive particles can have a Vickers hardness of at least 2000 kg/mm" 1 or at least 3000 kg/mm z or at least 4000 kg/mm 2 or at least 5000 kg/mm 2 .
  • the abrasive particles can have a Vickers hardness of not greater than 12,000 kg/mm'. It will be appreciated that the abrasive particles can have a Vickers hardness within a range including any of the minimum and maximum values noted above.
  • the abrasive particles can have a particular average toughness that may facilitate improved performance of the abrasive article.
  • Toughness of the abrasive particles is measured according to ANSIB74.23 on abrasive grains as obtained from the supplier under the ambient condition without subjecting the grains to processing or treatment, such as heating, prior to the measurement.
  • Average toughness is to be appreciated as an average calculated based upon the toughness test data that appears to have a variation of 5% or less.
  • the abrasive particles can have an average toughness of 11257 cycles, which may include a variation of up to ⁇ 563.
  • the average toughness can be at least 1 1850 cycles or at least 11900 or at least 12000 cycles or at least 12100 cycles or at least 12200 cycles or at least 12300 cycles or at least 12400 cycles or at least 12500 cycles or at least 12600 cycles or at least 12700 cycles or at least 12800 cycles or at least 12900 cycles or at least 13000 cycles or at least 13100 cycles or at least 13200 cycles.
  • the abrasive particles can have an average toughness of not greater than 16000 cycles or not greater than 15000 cycles or not greater than 14500 cycles or not greater than 14000 cycles or not greater than 13900 cycles or not greater than 13800 cycles or not greater than 13700 cycles or not greater than 13600 cycles or not greater than 13500 cycles or not greater than 13400 cycles or not greater than 13300 cycles. It will be appreciated that the abrasive particles can have an average toughness within a range including any of the minimum and maximum values noted above.
  • the abrasive particles may have a particular shape, as measured by ellipticity that may facilitate improved performance of the abrasive article.
  • the abrasive particles can have an ellipticity of not greater than 1.18, such as not greater than 1.17 or not greater than 1.16 or not greater than 1.15 or not greater than 1.14 or not greater than 1.13 or not greater than 1.12 or not greater than 1.11 or not greater than 1.10.
  • the abrasive particles can have an ellipticity of at least 1.01 or at least 1.02 or at least 01.03 or at least 1.04 or at least 1.05 or at least 1.06 or at least 1.07 or at least 1.08 or at least 1.09 or at least 1.10 or at least 1.11 or at least 1.12 or at least 1.13 or at least 1.14 or at least 1.15 or at least 1.16. It will be appreciated that the abrasive particles can have an ellipticity within a range including any of the minimum and maximum values noted above.
  • the ellipticity is measured using imaging analysis of a suitable number of randomly sampled particles.
  • a random sampling of at least 2000 discrete abrasive particles is obtained and placed onto an adhesive side of a tape. Care should be taken to distribute the particles uniformly across the tape and avoid clumping of the particles.
  • the tape may be attached to a slide or other surface that can facilitate imaging of the particles contained on the tape.
  • Using a Pro-scanner 7200 commercially available from Refiecta, GmbH scan the diamonds contained on the tape of the slide. Multiple scans may be required until the scanner produces a clear image of each of the particles.
  • Diashape software the image is analyzed. Care should be taken to ensure that the number of particles identified by the software is the same as the number of particles originally sampled.
  • the Diashape software calculates the ellipticity of each of the particles and then calculates and average ellipticity for the sample of particles.
  • the mixture may be formed to include a particular content of the abrasive particles, which may facilitate formation and performance of the abrasive article.
  • the mixture can include at least 2 wt% abrasive particles for a total weight of the mixture or at least 2.5 wt% or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt% for the total weight of the mixture.
  • the mixture may include not greater than 10 wt% abrasive particles for a total weight of the mixture, such as not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 wt% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater than 5.5 wt% or not greater than 5 wt% or not greater than 4.5 wt% or not greater than 4 wt% or not greater than 3.5 wt% or not greater than 3 wt% or not greater than 2.5 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% for the total weight of the mixture.
  • the mixture can include a content of abrasive particles within a range including any of the minimum and maximum values noted above.
  • the mixture may he formed to include a particular content of the bond material or precursor bond material, which may facilitate formation and performance of the abrasive article.
  • the mixture can include at least at least 20 wt% bond material or precursor bond material for a total weight of the mixture, such as at least 25 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt or at least 80 wt% or at least 90 wt% or at least 95 wt% for the total weight of the mixture, in one non-limiting embodiment, the mixture may include not greater than 99 wt% bond material or precursor bond material for a total weight of the mixture, such as not greater than 95 wt% or not greater than 90 wt% or not greater than 80 wt% or not greater than 70 wt% or not greater than 60 wt% or not greater than 50 wt% or not greater than 40 wt% or not greater than 30 wt% or not greater than 25 wt% for the total weight of the mixture.
  • the mixture can include a content of bond material or precursor bond material within a range including any of the minimum and maximum percentages noted above. It will also be appreciated that the bond material or precursor bond material may be a total content of raw material powder particulate that will for the bond material.
  • the mixture can be shaped into a green body.
  • suitable processes for shaping of the green body from the mixture can include molding, pressing, casting, punching, cutting, printing, spraying, depositing, or any combination thereof.
  • the body may undergo treatment to form the finally-formed abrasive article.
  • suitable treatments can include drying, curing, heating, sintering, or any combination thereof.
  • the mixture is placed into a mold and subject to a suitable pressure and temperature to facilitate formation of the finally-formed abrasive article.
  • the process of forming the abrasive article can include heating of the mixture to form the body of the finally-formed abrasive article.
  • Heating may be conducted at a particular temperature to ensure suitable formation of a microstructure that may facilitate improved performance.
  • heating the mixture can be conducted at a temperature of at least 700°C or at least 725 °C or at least 750°C or at least 775 °C or at least 800°C or at least 825°C or at least 850°C or at least 875°C or at least 900°C or at least 925°C or at least 950°C or at least 975°C or at least 1000°C.
  • heating of the mixture can be conducted at a temperature of not greater than 1100°C or not greater than 1050°C or not greater than 1000°C or not greater than 975°C or not greater than 950°C or not greater than 925°C or not greater than 900°C. It will be appreciated that the heating can be completed at a temperature within a range including any of the minimum and maximum values noted above.
  • the heating temperature noted above may be the maximum temperature at which the mixture is sintered to facilitate formation of the abrasive article.
  • the heating temperature may also be the maximum temperature that coincides with a maximum pressure applied to the mixture, in those instances where a combination of heat and pressure are applied to the mixture to facilitate formation of the abrasive article.
  • the process for forming the body of the finally- formed abrasive article can include hot pressing the mixture, wherein a combination of pressure and temperature are applied to the mixture to facilitate formation.
  • the hot pressing operation can be conducted at a temperature within a range for any of the temperatures noted above.
  • the process for forming the body can include hot pressing the mixture at a pressure of at least 1000 psi, such as at least 1500 psi or at least 2000 psi or at least 2200 psi.
  • hot pressing can be conducted at a pressure of not greater than 5000 psi, such as not greater than 4000 psi or not greater than 3000 psi or not greater than 2750 psi.
  • the pressure can be within a range including any of the minimum and maximum values noted above.
  • the pressure noted above may be the maximum pressure applied to the mixture during forming.
  • the pressure noted above may also be the maximum pressure that coincides with a maximum temperature applied to the mixture during the forming process.
  • the hot pressing can be unidirectional or isostatic pressing.
  • the resulting abrasive article can be a bonded abrasive body including a three dimensional body including a three-dimensional bond of the bond material defining a matrix of material as a continuous phase and containing abrasive particles therein.
  • the body of the abrasive article may include some phase or porosity.
  • the body may have a particular content of porosity that may facilitate improved performance of the abrasive article.
  • the body can include a content of porosity of at least 0.5 vol% for a total volume of the body, such as at least 1 vol% or at least 1.5 vol% or at least 2 vol% or at least 2.5 vol% or at least 3 vol% or at least 3.5 vol% or at least 4 vol or at least 4.5 vol or at least 5 vol% or at least 5.5 vol% or at least 6 vol or at least 7 vol% or at least 8 vol% or at least 9 vol or at least 10 vol%.
  • the content of porosity in the body can be not greater than 50 vol% for a total volume of the body or not greater than 30 vol% or not greater than 20 vol% or not greater than 15 wt% or not greater than 12 wt% or not greater than 10 vol% or not greater than 9 vol% or not greater than 8 vol% or not greater than 7 vol% or not greater than 6 vol% or not greater than 5 vol% or not greater than 4 vol or not greater than 3 vol or not greater than 2 vol% or not greater than 1 vol%. It will be appreciated that the content of porosity within the body can be within a range including any of the minimum and maximum values noted above.
  • the body of the abrasive article may be formed to include a particular content of the abrasive particles, which may facilitate improved performance of the abrasive article.
  • the body can include at least 2 wt% abrasive particles for a total weight of the body or at least 2.5 wt% or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt% for the total weight of the mixture.
  • the body may include not greater than 10 wt% abrasive particles for a total weight of the body, such as not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 t% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater than 5.5 wt or not greater than 5 wt% or not greater than 4.5 wt% or not greater than 4 wt% or not greater than 3.5 wt% or not greater than 3 wt% or not greater than 2.5 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% for the total weight of the body. It will be appreciated that the body can include a content of abrasive particles within a range including any of the minimum, and maximum values noted above.
  • the body may be formed to include a particular content of the bond material, which may facilitate improved performance of the abrasive article.
  • the body can include at least at least 20 wt% bond material or material for a total weight of the body, such as at least 25 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt% or at least 95 wt% for the total weight of the body.
  • the body may include not greater than 99 wt% bond material for a total weight of the body, such as not greater than 95 wt% or not greater than 90 wt% or not greater than 80 wt% or not greater than 70 wt% or not greater than 60 wt% or not greater than 50 wt% or not greater than 40 wt% or not greater than 30 wt or not greater than 25 wt for the total weight of the body. It will be appreciated that the body can include a content of bond material within a range including any of the minimum and maximum values noted above.
  • the abrasive particles contained in the body can have any of the features described in the embodiments herein with respect to the abrasive particles included in the mixture used to form the abrasive article.
  • the abrasive particles of the finally- formed abrasive article can have any of the same features of composition, coaling, coating composition, coating content, particle size distribution (i.e., DIO, D50, D90, and percent volume greater than 120 microns), Vickers hardness, average toughness, and/or ellipticity as noted herein.
  • the bond material contained in the body can ha ve any of the features described in the embodiments herein with respect to the bond material or precursor bond material included in the mixture used to form the abrasive article.
  • the bond material may have a particular content of cobalt and tin that may facilitate improved performance of the abrasive article.
  • the bond material can include cobalt (CCo) and tin (CSn) in a ratio [CSn/CCo] of not greater than 0.2, wherein CCo is the weight percent of cobalt for the entire weight of the bond material and CSn is the weight percent of tin for the entire weight of the bond material.
  • the ratio [CSn/CCo] can be not greater than 0.19, such as not greater than 0.18 or not greater than 0.17 or not greater than 0.16 or not greater than 0.15 or not greater than 0.14 or not greater than 0.13 or not greater than 0.12 or not greater than 0.11 or not greater than 0.10 or not greater than 0.09 or not greater than 0.08 or not greater than 0.07 or not greater than 0.06 or not greater than 0.05 or not greater than 0.04 or not greater than 0.03 or not greater than 0.02 or not greater than 0.01.
  • the ratio [CSn/CCo] can be at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1. It will be appreciated that the ratio [CSn/CCo] can be within a range including any of the minimum and maximum values noted above.
  • the bond material may have a particular content of cobalt and tungsten that may facilitate improved formation and/or performance of the abrasive article.
  • the bond material can include cobalt (CCo) and tungsten (CW) in a ratio [CW/CCo] of not greater than 0.9, wherein CCo is the weight percent of cobalt for the entire weight of the bond material and CW is the weight percent of tungsten for the entire weight of the bond material.
  • the ratio [CW/CCo] can be not greater than 0.8, such as not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.10 or not greater than 0.09 or not greater than 0.08 or not greater than 0.07 or not greater than 0.06 or not greater than 0.05 or not greater than 0.04 or not greater than 0.03 or not greater than 0.02 or not greater than 0.01.
  • the ratio [CW/CCo] can be at least about 0.001, such as at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7. It will be appreciated that the ratio [CW/CCo] can be within a range including any of the minimum and maximum values noted above.
  • the bond material may have a particular content of tungsten and tin that may facilitate improved formation and/or performance of the abrasive article.
  • the bond material can include tin (CSn) and tungsten (CW) in a ratio [CSn CWJ of not greater than 1, wherein CW is the weight percent of tungsten for the entire weight of the bond material and CSn is the weight percent of tin for the entire weight of the bond material.
  • the ratio [CSn/CW] can be not greater than 0.9, such as not greater than 0.8 or not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.1.
  • the ratio [CSn/CW] can be at least 0.01, such as at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9. It will be appreciated that the ratio [CSn/CW] can be within a range including any of the minimum and maximum values noted abo ve.
  • the bond material may have a particular content of cobalt that may facilitate improved performance of the abrasive article.
  • the bond material may include at least 40 wt% cobalt for a total weight of the bond material, such as at least 50 wt% or at least 1 wt% or at least 52 wt% or at least 53 wt or at least 54 wt% or at least 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt% or at least 72 wt% or at least 73
  • the bond material can include a content of cobalt of not greater than 99 wt% for the total weight of the bond material, such as not greater than 98 wt% or not greater than 97 wt% or not greater than 96 wt% or not greater than 95 wt% or not greater than 94 wi% or not greater than 93 wt% or not greater than 92 wt% or not greater than 91 wt% or not greater than 90 wt% or not greater than 89 wt% or not greater than 88 wt% or not greater than 87 wt% or not greater than 86 wt% or not greater than 85 wt% or not greater than 84 wt% or not greater than 83 wt% or not greater than 82 wt% or not greater than 81 wt% or not greater than 80 wt% or not greater than 79 wt% or not greater than 78 wt% or not greater than 77 wt% or not greater
  • the bond material of the finally formed abrasive article may have a particular content of tin that may facilitate improved performance of the abrasive article.
  • the bond material may include at least 0.1 wt% tin for a total weight of the bond material or at least 0.2 wt% or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt or at least 0.9 wt% or at least 1 wt% or at least 1,1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3
  • the bond material can include a content of tin of not greater than 15 wt% for a total weight of the bond material or not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 wt% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater than 5.5 wt% or not greater than 5 wt% or not greater man 4.5 wt% or not greater than 4 wt% or not greater than 3.5 wt% or not greater than 3 wi% or not greater than 2.5 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% or not greater than 0.5 wt% tin for the total weight of the bond material. It will be appreciated that the content of tin in the bond material can be within a range
  • the bond material of the finally-formed abrasive article may have a particular content of tungsten that may facilitate improved performance of the abrasive article.
  • the bond material may include at least 1 wi% tungsten for a total weight of the bond material, such as at least 0.1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 wt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5 wt% or at least 2.6 wt% or at least 2.7 wt% or at least 2.8 wt% or at least 2.9 wt% or at least 3 wt% or at least 3.1
  • the bond material may include greater than 20 wt% tungsten for a total weight of the bond material, such as not greater than 18 wt% or not greater than 16 wt% or not greater than 14 wt% or not greater than 12 wt% or not greater than 10 wt or not greater than 9 wt or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% or not greater than 5 wt% or not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt% tungsten for the total weight of the bond material. It will be appreciated that the content of tungsten in the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material can be essentially free of tungsten.
  • the bond material of the finally-formed abrasive article may include a particular content of iron that may facilitate improved performance of the abrasive article.
  • the bond material can include a content of iron of at least 0.05 wt% for a total weight of the bond material, such as at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 wt% or at least 0.15 wt% or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 t% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% iron for a total weight of the bond material.
  • the bond material can include a content of iron of not greater than 5 wt% for a total weight of the bond material, such as not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt%.
  • the content of iron in the bond material can be within a range including any of the minimum and maximum values noted abo ve.
  • the bond material of the finally-formed abrasive article may include a particular content of aluminum that may facilitate improved performance of the abrasive article.
  • the bond material can include a content of aluminum of not greater than 1 wt% for a total weight of the bond material, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • the bond material can include a content of aluminum of at least 0.001 wt% or at least 0.01 wt% for the total weight of the bond material. It will be appreciated that the content of aluminum in the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material can be essentially free of aluminum.
  • the bond material of the finally-formed abrasive may include a particular content of copper that may facilitate improved performance of the abrasive article.
  • the bond material can include a content of copper of not greater than 20 wt% for a total weight of the bond material, such as not greater than 15 wt% or not greater than 10 wi% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • the bond material can include a content of copper of at least 0.001 wt% or at least 0.01 wt% for the total weight of the bond material. It will be appreciated that the content of copper in the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material can be essentially free of copper.
  • the bond material of the finally-formed abrasive may include a particular content of manganese that may facilitate improved performance of the abrasive article.
  • the bond material can include a content of manganese of not greater than 1 wt% for a total weight of the bond material, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • the bond material can include a content of manganese of at least 0.001 wt% or at least 0.01 wt% for the total weight of the bond material. It will be appreciated that the content of manganese in the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material can be essentially free of manganese.
  • the bond material of the finally-formed abrasive may include a particular content of titanium that may facilitate improved performance of the abrasive article.
  • the bond material can include a content of titanium of not greater than 1 wt% for a total weight of the bond material, such as not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt%.
  • the bond material can include a content of titanium of at least 0.001 wt% or at least 0.01 wt% for the total weight of the bond material. It will be appreciated that the content of titanium in the bond material can be within a range including any of the minimum and maximum values noted above. In at least one non-limiting embodiment, the bond material can be essentially free of titanium.
  • the bond material of the finally-formed abrasive may have a particular content of certain metals that may facilitate improved performance of the abrasi ve article.
  • the bond material can have a total content of aluminum, copper, manganese, lead, silicon, and titanium (i.e., sum total of weight percent for each of the listed elements) of not greater than 20 wt% for a total weight of the bond material, such as not greater than 15 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than I wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt or not greater than 0.2 wt% or not greater than 0.1 wt%.
  • the bond material can include a total content of aluminum, copper, manganese, lead, silicon, and titanium of at least 0.001 wt% or at least 0.01 wt% for the total weight of the bond material. It will be appreciated that the total content of aluminum, copper, manganese, lead, silicon, and titanium in the bond material can be within a range including any of the minimum and maximum values noted above, in at least one embodiment, the bond material can be essentially free of aluminum, copper, manganese, lead, silicon, and/or titanium.
  • the bond material of the finally-formed abrasive can be formed to include at least 95 wt% of cobalt, tin and tungsten.
  • not greater than 5 wt% of the bond material can include secondary elements selected from the group consisting of including aluminum, copper, manganese, lead, silicon, and titanium.
  • the bond material can be formed to include at least 95 wt% of cobalt and tin, such as at least 96 wt% or at least 97 wt% or at least 98 wt% or even at least 99 wt% cobalt and tin for the total weight of the precursor bond material.
  • the finally-formed body of the abrasive article may have a particular microstructure that can facilitate improved performance.
  • the body may have micro-porosity that includes discontinuous porosity in the shape of isolated pores contained within the bond material.
  • the micro-porosity may consist essentially of discontinuous porosity.
  • the entire body can include micro-porosity, and in certain instances, the body may include only micro-porosity having the features described herein. That is, in one
  • all of the porosity of the body is micro-porosity having the features described herein.
  • the micro-porosity can have a particular pore size distribution that may facilitate improved performance of the abrasive article.
  • the micro-porosity can have an average pore size (D50) of at least 0.01 microns or at least 0.05 microns or at least 0.1 microns or at least 0.2 microns or at least 0. 25 microns or at least 0.3 microns or at least 0.35 microns or at least 0.4 microns or at least 0.45 microns or at least 0.5 microns.
  • D50 average pore size
  • the micro-porosity can have an average pore size (D50) of not greater than 9 microns or not greater than 8 microns or not greater than 7 microns or not greater than 6 microns or not greater than 5 microns or not greater than 4 microns or not greater than 4 microns or not greater than 3 microns or not greater than 2 microns or not greater than 1 micron or not greater than 0.9 microns or not greater than 0.8 microns or not greater than 0.7 microns or not greater than 0.6 microns or not greater than 0.5 microns.
  • the micro-porosity may also have a particular standard deviation, which is the first standard deviation of the distribution of porosity within the body as calculated from a distribution of porosity as measured from images taken from samples of the finally-formed abrasive article.
  • a finally-formed sample of an abrasive article is obtained, and four cubic samples having dimensions of 0.3 inches per side are removed from the abrasive article. The samples are taken from random locations of the abrasive article.
  • the cube samples are mounted in epoxy and polished to reveal the surface of the abrasive for image analysis.
  • a portion of the sample having an area of at least 50x40 microns is identified that does not include abrasive particles.
  • Several images of the representative area is obtained and then analyzed further using suitable imaging processing software (e.g., ImageJ) to create a binary image of the representative area.
  • imaging processing software e.g., ImageJ
  • the imaging software is used to identify the number and sizes of the pores and create a pore size distribution plot. The average pore size and standard deviation of the pore size is then calculated from the pore size distribution plot.
  • the micro-porosity can have a pore size standard deviation of at least 0.2 microns, such as at least 0.22 microns or at least 0.24 microns or at least 0.26 microns or at least 0.28 microns or at least 0.3 microns or at least 0.32 microns or at least 0.34 microns or at least 0.36 microns or at least 0.38 microns or at least 0.4 microns or at least 0.42 microns or at least 0.44 microns.
  • the micro- porosity can have a pore size standard deviation of not greater than 2 microns, such as not greater than 1.8 microns or not greater than 1.6 microns or not greater than 1.4 microns or not greater than 1.2 microns or not greater than 1 microns or not greater than 0.8 microns or not greater than 0.6 microns or not greater than 0.5 microns. It will be appreciated that the micro-porosity can have a pores size standard deviation within a range including any of the minimum and maximum values noted above.
  • the abrasive particles may have a particular particle size distribution that can facilitate improved performance of the abrasive article.
  • the abrasive particles can have a median particle size (D50), which may also be referred to herein as the average particle size, of at least 65 microns, such as at least 75 microns or at least 90 microns at least 95 microns, such as at least 97 microns or at least 100 microns or at least 105 microns or at least 1 10 microns or at least 120 microns.
  • D50 median particle size
  • the abrasive particles can have a median particle size (D50) of not greater than 150 microns or not greater than 140 microns or not greater than 130 microns or not greater than 120 microns or not greater than 110 microns or not greater than 105 microns or not greater than 100 microns. It will be appreciated that the abrasive particles can have a median particle size within a range including any of the minimum and maximum values noted above.
  • the abrasive particles of the abrasive article may also have a particular D10 corresponding to any of the D10 values of the abrasive particles in the mixture used to form the abrasive article as described in other embodiments herein.
  • the abrasive particles in the abrasive body may have a D90 corresponding to any of the D90 values of the abrasive particles included in the mixture used to form the abrasive article.
  • FIG. 1A includes a cross-sectional illustration of an abrasive article according to an embodiment.
  • the abrasive article 100 formed by the above-described method comprises a core 101 and an abrasive body 103 disposed on a peripheral surface of the core 101.
  • the abrasive body 103 may be disposed within an interior recess of a peripheral surface of the core 101.
  • the core 101 may further include an opening 107, which can be configured to engage a spindle and facilitate rotation of the abrasive article 100.
  • the abrasive body 103 may include a profiled surface 105, which may have a particular shape suitable for grinding the edges of workpieces. While the profiled surface 105 of FIG. 1 A is shown as generally having or U- shaped contour or concave contour, other shapes can be used, including for example, but not limited to a planar profile, V-shaped profile, and the like.
  • the core 101 may include various materials, including but not limited to inorganic materials (e.g., metal, metal alloy, ceramic, etc.), organic materials or a combination thereof.
  • the core 101 may include an organic material that may facilitate improved performance of the bonded abrasive body, including but not limited to, aspects of strength, wear resistance, vibration damping, and manufacturability.
  • the core 101 can include a polymer material selected from the group of a polyamide (PA), a polybutylene terephthalate (PBT), a polyphenylene sulfide (PPS), ethylene tetrafluoroethylene (ETFE), a polyetherketone (PEEK), a polyester (PEj, a polyethyleneimine (PEI), a polyethersulfone (PESU), a polyethylene terephthalate (PET), a polyphthalamide (PPA), a poly (p-phenylene sulfide), a polycarbonate (PC), acrylonitrile- butadiene-styrene (ABS), PC-ABS, or any combination thereof.
  • PA polyamide
  • PBT polybutylene terephthalate
  • PPS polyphenylene sulfide
  • ETFE ethylene tetrafluoroethylene
  • PEEK polyetherketone
  • PET polyethylene terephthalate
  • PPA polyphthalamide
  • the polymer material may be a nylon, a PBT, a PPS, or a PC-ABS.
  • the nylon may be, for example, nylon 6, nylon 66, nylon 610, nylon 612, nylon 66/6, nylon 410, or nylon 46.
  • the polymer material of the core may consist essentially of PPS.
  • the polymer material of the core may consist essentially of PC-ABS. in another embodiment, the polymer material of the core may be essentially free of nylon.
  • the core 101 may further contain reinforcing fibers and/or a powder distributed within the polymer material.
  • the reinforcing fibers may include, for example, glass fibers, carbon fibers, ceramic fibers, organic fibers, mineral fibers, or combinations thereof.
  • Suitable powders may be, for example, calcium carbonate, glass powder, mineral powder, or talc.
  • FIG. IB includes a cross-sectional illustration of a portion of an abrasive article according to an embodiment.
  • the portion of the abrasive article of FIG. IB includes a core 101 and an abrasive body 103 disposed on a peripheral surface of the core 101.
  • the abrasive body 103 may include a profiled surface 105, which may have a particular shape suitable for grinding the edges of workpieces.
  • the abrasive body 103 includes a first region
  • the embodiment of FIG. IB includes three regions, but other abrasive bodies may be formed to have a fewer or greater number of regions.
  • the grade and/or structure of the regions may differ from each other.
  • the regions may have different contents of abrasive particles, different sizes (e.g., D10, D50 and/or D90) of abrasive particles, different compositions of the abrasive particles, different content of bond material, different composition of bond material, different porosity, different microstructural features, or any combination thereof. It is thought that such controlled differences between the regions may facilitate improved operations of the abrasive article. Any one of the regions can have one or more of the features of any of the embodiments herein.
  • the first region 1 1 can have a first content of abrasive particles 153 contained within a bond material 152 and the second region 161 can have a second content of abrasive particles 163 contained within a bond material 162, and further the first content and second content can be different compared to each other.
  • the second content can be greater than the first content
  • the content of abrasive particles may be measured as the volume percent or weight percent of abrasive particles in a given region. If the distinction between the regions is not clearly visible, at least three random samplings of material may be selected from portions of the body suspected as being part of different regions, the content of abrasive particles can be measured and averaged. The average content can he representative of the content for a given region.
  • the volume percent or weight percent may be based on the weight or volume sampled from the region.
  • the abrasive body 103 with the first and second regions 151 and 161 may define a ratio (C1/C2) of not greater than 0.97, wherein CI represents the first content of abrasive particles in the first region (vol% or wt%) and C2 represents the second content (vol% or wt%) of abrasive particles in the second region.
  • the ratio (C1/C2) can be not greater than 0.95, such as not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • the ratio (CI VC2) can be at least 0.1 , such as at least 0.1 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It will be appreciated that the ratio (C1/C2) can be within a range including any of the minimum and maximum values noted above.
  • the abrasive particles 153 of the first region 151 can be the same type of abrasive particles 163 contained in the second region 161.
  • Reference herein to the type of abrasive particle can be reference to at least one characteristic selected from the group of median particle size (D50), D10, D90, Vickers hardness, ellipticity, average toughness, composition, or any combination thereof.
  • the abrasive particles 153 and 163 can have the same composition relative to each other.
  • the composition of the abrasive particles 153 can be different compared to the composition of the abrasive particles 163.
  • the abrasive particles 153 of the first region 151 can be the same size (e.g., DIO, D50, and/or D90) as the abrasive particles 163 contained in the second region 161.
  • the abrasive particles 153 and 163 can have the average particle size (i.e., D50) relative to each other.
  • the composition of the abrasive particles 153 can have a different average particle size (i.e., D50) compared to the abrasive particles 163. Irs certain instances, and as illustrated in FIG.
  • the first region 151 can be in the form of a layer that extends radially between an inner wall 112 of the cavity and the profiled surface 105.
  • the second region 161 can be in the form of a layer, such as a layer extending radially between the inner wall 112 and the profiled surface 105.
  • the second region 161 can be in direct contact with the first region 151, such that there are no intervening layers or objects positioned between the first and second regions 151 and 161.
  • the first region 151 can have a first content of a first bond materia] 152 and the second region 161 can have a second content of a second bond material 162.
  • the second content of the second bond material 162 can be different than the first content of the first bond material 152.
  • the second content of the second bond material 162 can be the same as the first content of the first bond material 152.
  • the first bond material 152 of the first region 151 can have the same composition as the second bond material 162 of the second region 161.
  • the first and second bond materials 152 and 162 can have any of the compositions for bond materials as noted in the embodiments herein.
  • the first and second bond materials 152 and 162 can be an inorganic material, such as a metal, metal alloy, amorphous material, glass, ceramic, or a combination thereof.
  • the first and second bond materials 152 and 162 can have different compositions compared to each other. Compositions may be considered different from each other when at least one component (e.g., element, compound or complex) differs by at least 5% between the two compositions.
  • certain abrasive bodies may include a third region 171 having a third content of abrasive particles 173.
  • the second region 161 can be disposed between the first region 151 and the third region 171.
  • the third content of abrasive particles 173, as measured in volume percent or weight percent can be different compared to the second content of abrasive particles 163 contained within the second region 161.
  • the first content of abrasive particles 153 and the third content of abrasive particles 173 may be the same with respect to each other.
  • the second content of abrasive particles 163 in the second region 161 may be greater than the third content of abrasive particles 173 in the third region 171. This may be advantageous as the second region 161 may conduct the majority of the material removal operations compared to the third region 171. Moreover, the second content of abrasive particles 163 in the second region 61 can be greater than the first content of abrasive particles 153 in the first region 151.
  • the abrasive body 103 may include a ratio (C3/C2) of not greater than 0.97, wherein C3 represents the third content of abrasive particles 173 in the third region 171 and C2 represents the second content of abrasive particles 163 in the second region 161.
  • the ratio (C3/C2) may be not greater than 0.95, such as not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • the ratio (C3/C2) may be at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It will be appreciated that the ratio (C3/C2) can be within a range including any of the minimum and maximum values noted above.
  • the abrasive particles 173 of the third region 171 can be the same type of abrasive particles 163 as contained in the second region 1.61.
  • Reference herein to a type in the context of abrasive particles is reference to at least one characteristic selected from the group of median particle size (D50), D10, D90, Vickers hardness, ellipticity, average toughness, composition, or any combination thereof.
  • the abrasive particles 173 and 163 can have the same composition relative to each other.
  • the abrasive particles 163 and 173 can be different types compared to each other.
  • the composition of the abrasive particles 173 can be different compared to the composition of the abrasive particles 163.
  • the abrasive particles 173 of the third region 171 can be the same size (e.g., D10, D50, and/or D90) as the abrasive particles 163 contained in the second region 161.
  • the abrasive particles 173 and 163 can have the average particle size (i.e., D50) relative to each other.
  • the composition of the abrasive particles 173 can have a different average particle size (i.e., D50) compared to the abrasive particles 163.
  • the third region 171 can be in the form of a layer that extends radially between the inner wall 1.12 and the profiled surface 105. Additionally, the second region 161 may be in the form of a layer. The second region 161 can be in direct contact with the third region 171, such that there are no intervening layers or objects positioned between the third and second regions 171 and 161.
  • the third region 171 can have a third content of a third bond material 172 and the second region 161 can have a second content of a second bond material 162.
  • the second content of the second bond material 162 can be different than the third content of the third bond material 172.
  • the second content of the second bond material 162 can be the same as the third content of the third bond material 172.
  • the first content of the first bond material 152 can be the same as the third content of the third bond material 172.
  • the second content of the second bond material 162 can be the same as the third content of the third bond material 172.
  • the third bond material 172 of the third region 171 can have the same composition as the second bond material 162 of the second region 161.
  • the second and third bond materials 162 and 172 can have any of the compositions for bond materials as noted in the embodiments herein.
  • the second and third bond materials 162 and 172 can be an inorganic material, such as a metal, metal alloy, amorphous material, glass, ceramic, or a combination thereof.
  • the second and third bond materials 162 and 172 can have different compositions compared to each other. Compositions may be considered different from each other when at least one component (e.g., element, compound or complex) differs by at least 5% between the two compositions.
  • the first region 151 includes a first type of abrasive particle having a first median particle size (D5Q
  • the first median particle size (D50i) can be different than the second median particle size (D50 2 ).
  • the second type of abrasive particles have a greater median particle size (050?) compare to the first type of abrasive particles (D50i).
  • the abrasive body can have a ratio (D50i/D50 2 ) of not greater than 0.97, such as not greater than 0.95 or not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • a ratio (D50i/D50 2 ) of not greater than 0.97 such as not greater than 0.95 or not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater
  • the ratio (D50i/D50 2 ) can be at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It will be appreciated that the ratio (D50i/D50 2 ) can be within a range including any of the minimum and maximum values provided above.
  • the third region 171 may include a third type of abrasive particle 173.
  • the third type of abrasive particle 173 can be different from the second type of abrasive particle 163 in the second region 161.
  • the abrasive body 103 can have a ratio (D5O 3 /D5O 2 ) of not greater than 0.97, wherein D50 3 represents the median particle size of the third type of abrasive particles 173 and D50 2 represents the median particle size of the second type of abrasive particles 163.
  • the ratio (D50 3 D50 2 ) can be not greater than 0.95, such as not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • the ratio (D50 3 /D50 2 ) can be at least 0.1, such as at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95. It will be appreciated that the ratio (D5O 3 /D5O 2 ) can be within a range including any of the minimum and maximum values provided above.
  • the third type of abrasive particles 173 and the first type of abrasive particles 153 may be the same type of abrasive particles. Accordingly, the first type of abrasive particles 153 and the third type of abrasive particles 173 may have the same median particle size (D50), D10, D90, Vickers hardness, ellipticity, average toughness, and composition.
  • Embodiment 1 An abrasive article comprising:
  • a body comprising: a bond material comprising metal and further comprising micro-porosity within the bond material, the micro-porosity comprising an average pore size (D50) of not greater than 10 microns and a pore size standard deviation of at least 0.2 microns;
  • D50 average pore size
  • abrasive particles contained within bond material and further comprising at least one of:
  • Embodiment 2 The abrasive article of embodiment 1, wherein the abrasive particles comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, or any combination thereof.
  • Embodiment 3 The abrasive article of embodiment 1, wherein the abrasive particles comprise a superabrasive material.
  • Embodiment 4 The abrasive article of embodiment 1, wherein the abrasive particles comprise diamond.
  • Embodiment 5 The abrasive article of embodiment 1, wherein the abrasive particles consist essentially of diamond.
  • Embodiment 6 The abrasive article of embodiment 1, wherein the abrasive particles comprise a coating.
  • Embodiment 7 The abrasive article of embodiment 6, wherein the coating comprises a metal or metal alloy including a transition metal element.
  • Embodiment 8 The abrasive article of embodiment 6, wherein the coating comprises titanium.
  • Embodiment 9 The abrasive article of embodiment 6, wherein the coating overlies a majority of the exterior surfaces of the abrasive particles or at least 60% or at least 70% or at least 80% or at least 90% or at least 95%.
  • Embodiment 10 The abrasive article of embodiment 1, wherein the abrasive particles comprise a median particle size (D50) of at least 65 microns or at least 75 microns or at least 90 microns or at least 95 microns or at least 97 microns or at least 100 microns or at least 105 microns or at least 110 microns or at least 120 microns.
  • D50 median particle size
  • Embodiment 11 The abrasive article of embodiment 1, wherein the abrasive particles comprise a median particle size (D50) of not greater than 150 microns or not greater than 140 microns or not greater than 130 microns or not greater than 120 microns or not greater than 110 microns or not greater than 105 microns or not greater than 100 microns.
  • D50 median particle size
  • Embodiment 13 The abrasive article of embodiment 1, wherein the abrasive particles comprise a D10 of not greater than 127 microns or not greater than 120 microns or not greater than 110 microns or not greater than 100 microns or not greater than 95 microns or not greater than 93 microns or not greater than 90 microns or not greater than 87 microns or not greater than 85 microns or not greater than 83 microns or not greater than 80 microns.
  • Embodiment 14 The abrasive article of embodiment 1, wherein the abrasive particles comprise a D90 of at least 97 microns or at least 100 microns or at least 103 microns or at least 105 microns or at least 108 microns or at least 110 microns or at least 113 microns or at least 115 microns or at least 118 microns or at least 120 microns or at least 123 microns or at least 125 microns or at least 128 microns or at least 130 microns or at least 133 microns or at least 135 microns or at least 138 microns.
  • Embodiment 15 The abrasive article of embodiment 1, wherein the abrasive particles comprise a D90 of not greater than 165 microns or not greater than 160 microns or not greater than 155 microns or not greater than 150 microns or not greater than 145 microns or not greater than 140 microns or not greater than 135 microns or not greater than 133 microns or not greater than 130 microns or not greater than 128 microns or not greater than 125 microns or not greater than 123 or not greater than 120 microns or not greater than 1 18 microns or not greater than 115 microns or not greater than 113 microns or not greater than 110 microns or not greater than 108 microns or not greater than 105 microns.
  • Embodiment 16 The abrasive article of embodiment 1, wherein the abrasive particles comprise a Vickers hardness of at least 2000 kg/mm2 or at least 3000 kg/mm2 or at least 4000 kg/mm2 or at least 5000 kg/mm2.
  • Embodiment 17 The abrasive article of embodiment 16, wherein the abrasive particles comprise diamond.
  • Embodiment 18 The abrasive article of embodiment 1, wherein the abrasive particles have an average toughness of at least 11900 cycles or at least 12000 cycles at least 12100 cycles or at least 12200 cycles or at least 12300 cycles or at least 12400 cycles or at least 12500 cycles or at least 12600 cycles or at least 12700 cycles or at least 12800 cycles or at least 12900 cycles or at least 13000 cycles or at least 13100 cycles or at least 13200 cycles.
  • Embodiment 19 Embodiment 19.
  • Embodiment 20 The abrasive article of embodiment 1, wherein the abrasive particles have an ellipticity of not greater than 1.17 or not greater than 1.16 or not greater than 1.15 or not greater than 1.14 or not greater than 1.13 or not greater than 1.12 or not greater than 1.11 or not greater than 1.10.
  • Embodiment 21 The abrasive article of embodiment 20, wherein the abrasive particles comprise an ellipticity of at least 1.01 or at least 1.02 or at least 01.03 or at least
  • Embodiment 22 The abrasive article of embodiment 1, wherein the body comprises a content of the abrasive particles of at least 2 wt% or at least 2.5 wt or at least 3 wt% or at least 3.5 wt% or at least 4 wt% or at least 4.5 wt% or at least 5 wt% or at least 5.5 wt% or at least 6 wt% or at least 6.5 wt% or at least 7 wt% or at least 7.5 wt% or at least 8 wt% or at least 8.5 wt% or at least 9 wt% or at least 9.5 wt% or at least 10 wt%.
  • Embodiment 23 The abrasive article of embodiment 1, wherein the body comprises a content of abrasive particles of not greater than 10 wt% or not greater than 9 wt% or not greater than 8.5 wt% or not greater than 8 wt% or not greater than 7.5 wt% or not greater than 7 wt% or not greater than 6.5 wt% or not greater than 6 wt% or not greater than
  • Embodiment 24 The abrasive article of embodiment 1, wherein the body comprises a content of the bond material of at least 20 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% or at least 90 wt% or at least 95 wt%.
  • Embodiment 25 The abrasive article of embodiment 1, wherein the body comprises a content of bond material of not greater than 99 wt% for a total weight of the body or not greater than 95 wt% or not greater than 90 wt% or not greater than 80 wt% or not greater than 70 wt or not greater than 60 wt% or not greater than 50 wt% or not greater than 40 wt% or not greater than 30 wt% or not greater than 25 wt%
  • Embodiment 26 The abrasive article of embodiment 1, wherein the bond material comprises at least one of cobalt, Lin, tungsten, copper, or any combination thereof.
  • Embodiment 27 The abrasive article of embodiment 1, wherein the bond material comprises cobalt (CCo) and tin (CSn) in a ratio [CSn/CCo] of not greater than 0.2, wherein CCo is the weight percent of cobalt for the entire weight of the body and CSn is the weight percent of tin for the entire weight of the body or not greater than 0.19 or not greater than 0.18 or not greater than 0.17 or not greater than 0.16 or not greater than 0.15 or not greater than 0.14 or not greater than 0.13 or not greater than 0.12 or not greater than 0.11 or not greater than 0.10 or not greater than 0.09 or not greater than 0.08 or not greater than 0.07 or not greater than 0.06 or not greater than 0.05 or not greater than 0.04 or not greater than 0.03 or not greater than 0.02 or not greater than 0.01.
  • CCo cobalt
  • CSn tin
  • Embodiment 28 The abrasive article of embodiment 27, wherein the bond materia] comprises a ratio [CSn/CCo] of at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1.
  • the bond materia] comprises a ratio [CSn/CCo] of at least 0.001 or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at
  • Embodiment 29 The abrasive article of embodiment 1, wherein the bond material comprises a ratio [CW/CCo] of not greater than 0.9, wherein CCo is the weight percent of cobalt for the entire weight of the body and CW is the weight percent of tungsten for the entire weight of the body or not greater than 0.8 or not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.10 or not greater than 0.09 or not greater than 0.08 or not greater than 0.07 or not greater than 0.06 or not greater than 0.05 or not greater than 0.04 or not greater than 0.03 or not greater than 0.02 or not greater than 0.01.
  • Embodiment 30 The abrasive article of embodiment 1, wherein the bond material comprises a ratio [CW/CCo J of at least about 0.001, wherein CCo is the weight percent of cobalt for the entire weight of the body and CW is the weight percent of tungsten for the entire weight of the body or at least 0.002 or at least 0.003 or at least 0.004 or at least 0.005 or at least 0.006 or at least 0.007 or at least 0.008 or at least 0.009 or at least 0.01 or at least 0.015 or at least 0.02 or at least 0.03 or at least 0.04 or at least 0.05 or at least 0.06 or at least 0.07 or at least 0.08 or at least 0.09 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7.
  • CCo is the weight percent of cobalt for the entire weight of the body
  • CW is the weight percent of tungsten for the entire weight of the body or at least 0.00
  • Embodiment 31 The abrasive article of embodiment 1, wherein the bond material comprises tungsten (CW) and tin (CSn) in a ratio [CSn/CW] of not greater than 1, wherein CW is the weight percent of tungsten for the entire weight of the body and CSn is the weight percent of tin for the entire weight of the bond, or not greater than 0.9 or not greater than 0.8 or not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.1.
  • CW is the weight percent of tungsten for the entire weight of the body
  • CSn is the weight percent of tin for the entire weight of the bond, or not greater than 0.9 or not greater than 0.8 or not greater than 0.7 or not greater than 0.6 or not greater than 0.5 or not greater than 0.4 or not greater than 0.3 or not greater than 0.2 or not greater than 0.1.
  • Embodiment 32 The abrasive article of embodiment 1, wherein the bond material comprises tungsten (CW) and tin (CSn) in a ratio [CSn/CW] of at least 0.01, wherein CW is the weight percent of tungsten for the entire weight of the body and CSn is the weight percent of tin for the entire weight of the body, or at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9.
  • CW is the weight percent of tungsten for the entire weight of the body
  • CSn is the weight percent of tin for the entire weight of the body, or at least 0.02 or at least 0.05 or at least 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9.
  • Embodiment 33 The abrasive article of embodiment 1, wherein the bond material comprises cobalt in a content of at least 40 wt% for a total weight of the body or at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt or at least 54 wt% or at least 55 wt% or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% or at least 60 wt% or at least 61 wt% or at least 62 wt% or at least 63 wt% or at least 64 wt% or at least 65 wt% or at least 66 wt% or at least 67 wt% or at least 68 wt% or at least 69 wt% or at least 70 wt% or at least 71 wt% or at least 72 wt% or at least 73 wt% or at least 74 w
  • Embodiment 34 The abrasive article of embodiment 1, wherein the bond material comprises cobalt in a content of not greater than 99 wt% or not greater than 98 wt% or not greater than 97 wt% or not greater than 96 wt% or not greater than 95 wt% or not greater than 94 wt% or not greater than 93 wt% or not greater than 92 wt% or not greater than 91 wt% or not greater than 90 wt% or not greater than 89 wt% or not greater than 88 wt% or not greater than 87 wt% or not greater than 86 wt% or not greater than 85 wt% or not greater than 84 wt% or not greater than 83 wt% or not greater than 82 wt% or not greater than 81 wt% or not greater than 80 wt% or not greater than 79 wt% or not greater than 78 wt% or not greater than 77 wt% or
  • Embodiment 35 The abrasive article of embodiment 1, wherein the bond material comprises tin in a content of at least 0.1 wt% for a total weight of the body or at least 0.2 wt or at least 0.3 wt% or at least 0.4 wt% or at least 0.5 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt% or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt% or at least 1.6 vvt% or at least 1.7 wt% or at least 1.8 wt% or at least 1.9 wt% or at least 2 wt% or at least 2.1 wt% or at least 2.2 wt% or at least 2.3 wt% or at least 2.4 wt% or at least 2.5
  • Embodiment 36 The abrasive article of embodiment 1, wherein the bond material comprises tin in a content of not greater than 15 wt% for a total weight of the body or not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than
  • Embodiment 37 The abrasive article of embodiment 1, wherein the bond material comprises tungsten in a content of at least 1 wt% for a total weight of the body or at least 1.1 wt% or at least 1.2 wt% or at least 1.3 wt% or at least 1.4 wt% or at least 1.5 wt or at least
  • Embodiment 38 The abrasive article of embodiment 1, wherein the bond material comprises tungsten in a content of not greater than 20 wt% for a total weight of the body or not greater than 18 wt% or not greater than 16 wt or not greater than 14 wt% or not greater than 12 wt% or not greater than 10 wt% or not greater than 9 wt% or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% or not greater than 5 wt% or not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt%.
  • Embodiment 39 The abrasive article of embodiment 1, wherein the bond material comprises iron in a content of at least 0.05 wt% for a total weight of the body or at least 0.06 wt% or at least 0.07 wt% or at least 0.08 wt% or at least 0.09 wt% or at least 0.1 t% or at least 0.15 wt or at least 0.2 wt% or at least 0.25 wt% or at least 0.3 wt% or at least 0.35 wt% or at least 0.4 wt% or at least 0.45 wt% or at least 0.5 wt% or at least 0.55 wt% or at least 0.6 wt% or at least 0.7 wt% or at least 0.8 wt% or at least 0.9 wt% or at least 1 wt%.
  • Embodiment 40 The abrasive article of embodiment 1, wherein the bond material comprises iron in a content of not greater than 5 wt% for a total weight of the body or not greater than 4 wt% or not greater than 3 wt% or not greater than 2 wt% or not greater than 1.5 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt%.
  • Embodiment 41 The abrasive article of embodiment 1, wherein the bond material comprises aluminum in a content of not greater than 1 wt% for a total weight of the body or not greater than 0.9 wt% or not greater than 0.8 wt or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%
  • Embodiment 42 The abrasive article of embodiment 1, wherein the bond material comprises copper in a content of not greater than 20 wt% for a total weight of the body or not greater than 15 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%.
  • Embodiment 43 The abrasive article of embodiment 1, wherein the bond material comprises manganese in a content of not greater than 1 wt% for a total weight of the body or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt or not greater than 0.2 wt or not greater than 0.1 wt or not greater than 0.09 wt% or not greater than 0.05 wt% or not greater than 0.01 wt%
  • Embodiment 44 The abrasive article of embodiment 1, wherein the bond material comprises titanium in a content of not greater than 1 wt% for a total weigh of the body or not greater than 0.9 wt% or not greater than 0.8 wt% or not greater than 0.7 wt% or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt% or not greater than 0.09 wt%.
  • Embodiment 45 The abrasive article of embodiment 1, wherein the body comprises a total content of aluminum, copper, manganese, lead, silicon, and titanium not greater than 20 wt% for a total weight of the body or not greater than 1 wt% or not greater than 10 wt% or not greater than 5 wt% or not greater than 2 wt% or not greater than 1 wt% or not greater than 0.9 wt% or not greater than 0.8 wt or not greater than 0.7 wt or not greater than 0.6 wt% or not greater than 0.5 wt% or not greater than 0.4 wt% or not greater than 0.3 wt% or not greater than 0.2 wt% or not greater than 0.1 wt%.
  • Embodiment 46 The abrasive article of embodiment 1, wherein at least 95 wt% of the bond material comprises cobalt, tin and tungsten, and not greater than 5 wt% of the bond material comprises secondary elements selected from the group consisting of including aluminum, copper, manganese, lead, silicon, and titanium.
  • Embodiment 47 The abrasive article of embodiment 1, wherein the micro- porosity comprises an average pore size (D50) of not greater than 9 microns or not greater than 8 microns or not greater than 7 microns or not greater than 6 microns or not greater than 5 microns or not greater than 4 microns or not greater than 4 microns or not greater than 3 microns or not greater than 2 microns or not greater than 1 micron or not greater than 0.9 microns or not greater than 0.8 microns or not greater than 0.7 microns or not greater than 0.6 microns or not greater than 0.5 microns.
  • D50 average pore size
  • Embodiment 48 The abrasive article of embodiment 1, wherein the micro- porosity comprises an average pore size (D50) of at least 0.01 microns or at least 0.05 microns or at least 0.1 microns or at least 0.2 microns or at least 0. 25 microns or at least 0.3 microns or at least 0.35 microns or at least 0.4 microns or at least 0.45 microns or at least 0.5 microns.
  • D50 average pore size
  • micro- porosity comprises a pore size standard deviation of at least 0.2 microns or at least 0.22 microns or at least 0.24 microns or at least 0.26 microns or at least 0.28 microns or at least 0.3 microns or at least 0.32 microns or at least 0.34 microns or at least 0.36 microns or at least 0.38 microns or at least 0.4 microns or at least 0.42 microns or at least 0.44 microns.
  • Embodiment 50 The abrasive article of embodiment 1, wherein the micro- porosity comprises a pore size standard deviation of not greater than 2 microns or not greater than 1.8 microns or not greater than 1.6 microns or not greater than 1.4 microns or not greater than 1.2 microns or not greater than 1 microns or not greater than 0.8 microns or not greater than 0.6 microns or not greater than 0.5 microns.
  • Embodiment 51 The abrasive article of embodiment 1, wherein the body comprises a content of porosity of at least 0.5 vol% for a total volume of the body or at least 1 vol% or at least 1.5 vol% or at least 2 vol% or at least 2.5 vol% or at least 3 vol% or at least 3.5 vol% or at least 4 vol% or at least 4.5 vol% or at least 5 vol% or at least 5.5 vol% or at least 6 vol or at least 7 vol% or at least 8 vol% or at least 9 vol% or at least 10 vol%.
  • Embodiment 52 The abrasive article of embodiment 1, wherein the body comprises a content of porosity of not greater than 50 vol% for a total volume of the body or not greater than 30 vol% or not greater than 20 vol% or not greater than 15 wt% or not greater than 12 wt% or not greater than 10 vol% or not greater than 9 vol% or not greater than 8 vol% or not greater than 7 vo!% or not greater than 6 vol% or not greater than 5 vo!% or not greater than 4 vol% or not greater than 3 vol% or not greater than 2 vol% or not greater than 1 vol%.
  • Embodiment 53 The abrasive article of embodiment 1, wherein the body comprises a first region comprising a first content of abrasive particles and a second region comprising a second content of abrasive particles, wherein the first content and second content are different compared to each other.
  • Embodiment 54 The abrasive article of embodiment 53, wherein the second content is greater than the first content.
  • Embodiment 55 The abrasive article of embodiment 53, further comprising a ratio (C1./C2) of not greater than 0.97, wherein CI represents the first content and C2 represents the second content, and wherein the ratio (C1/C2) is not greater than 0.95 or not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • a ratio (C1./C2) of not greater than 0.97, wherein CI represents the first content and C2 represents the second content, and wherein the ratio (C1/C2) is not greater than 0.95 or not greater than
  • Embodiment 56 The abrasive article of embodiment 53, further comprising a ratio (C1/C2) of at least 0.1, wherein CI represents the first content and C2 represents the second content, and wherein the ratio (C1/C2) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95.
  • a ratio (C1/C2) of at least 0.1, wherein CI represents the first content and C2 represents the second content, and wherein the ratio (C1/C2) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at
  • Embodiment 57 The abrasive article of embodiment 53, wherein the abrasive particles of the first region and the abrasive particles of the second region are the same type of abrasive particles.
  • Embodiment 58 The abrasive article of embodiment 53, wherein the abrasive particles of the first region and the abrasive particles of the second region are different types of abrasive particles.
  • Embodiment 59 The abrasive article of embodiment 53, wherein the first region is in the form of a layer.
  • Embodiment 60 The abrasive article of embodiment 53, wherein the second region is in the form of a layer.
  • Embodiment 61 The abrasive article of embodiment 53, wherein the second region is directly contacting the first region.
  • Embodiment 62 The abrasive article of embodiment 53, wherein the first region comprises a first content of a first bond material, and wherein the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the first content of the first bond material.
  • Embodiment 63 The abrasive article of embodiment 62, wherein the first bond material and second bond material have the same composition.
  • Embodiment 64 The abrasive article of embodiment 62, wherein the first bond material and second bond material have a different composition compared to each other.
  • Embodiment 65 The abrasive article of embodiment 62, further comprising a third region comprising a third content of abrasive particles, wherein the third content is different than the second content.
  • Embodiment 66 The abrasive article of embodiment 65, wherein the second region is disposed between the first region and the third region.
  • Embodiment 67 The abrasive article of embodiment 65, wherein the first content and the third content are the same with respect to each other.
  • Embodiment 68 The abrasive article of embodiment 65, wherein the second content is greater than the third content.
  • Embodiment 69 The abrasive article of embodiment 65, further comprising a ratio (C3/C2) of not greater than 0.97, wherein C3 represents the third content and C2 represents the second content, and wherein the ratio (C3/C2) is not greater than 0.95 or not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • Embodiment 70 The abrasive article of embodiment 65, further comprising a ratio (C3/C2) of at least 0.1 , wherein C3 represents the third content and C2 represents the second content, and wherein the ratio (C3/C2) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95.
  • a ratio (C3/C2) of at least 0.1 , wherein C3 represents the third content and C2 represents the second content, and wherein the ratio (C3/C2) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7
  • Embodiment 71 The abrasive article of embodiment 65, wherein the abrasive particles of the third region and the abrasive particles of the second region are the same type of abrasive particles.
  • Embodiment 72 The abrasive article of embodiment 65, wherein the abrasive particles of the third region and the abrasive particles of the second region are different types of abrasive particles.
  • Embodiment 73 The abrasive article of embodiment 65, wherein the abrasive particles of the third region and the abrasive particles of the first region are the same type of abrasive particles.
  • Embodiment 74 The abrasive article of embodiment 65, wherein the third region is in the form of a layer.
  • Embodiment 75 The abrasive article of embodiment 65, wherein the second region is in the form of a layer and is directly contacting the third region.
  • Embodiment 76 The abrasive article of embodiment 65, wherein the third region comprises a third content of a third bond material, and the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the third content of the third bond material.
  • Embodiment 77 The abrasive article of embodiment 76, wherein the third bond material and second bond material have the same composition.
  • Embodiment 78 The abrasive article of embodiment 76, wherein the third bond material and second bond material have a different composition compared to each other.
  • Embodiment 79 The abrasive article of embodiment i, wherein the body comprises a first region comprising a first type of abrasive particles and a second region comprising a second type of abrasive particles, wherein the first type and second type of abrasive particles are different compared to each other.
  • Embodiment 80 The abrasive article of embodiment 79, wherein the first type and second type are different compared to each other based on at least one characteris ic selected from the group of median particle size (D50), D10, D90, Vickers hardness, ellipticity, average toughness, composition, or any combination thereof.
  • D50 median particle size
  • D10 D10
  • D90 Vickers hardness
  • ellipticity average toughness
  • composition or any combination thereof.
  • Embodiment 81 The abrasive article of embodiment 79, wherein the first type and second type are different compared to each other based on median particle size.
  • Embodiment 82 The abrasive article of embodiment 79, wherein the second type of abrasive particles have a greater median particle size compare to the first type of abrasive particles.
  • Embodiment 83 The abrasive article of embodiment 79, further comprising a ratio (D501/D502) of not greater than 0.97, wherein D501 represents the median particle size of the first type of abrasive particles and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D501/D502) is not greater than 0.95 or not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • Embodiment 84 The abrasive article of embodiment 79, further comprising a ratio (D501/D502) of at least 0.1, wherein D501 represents the median particle size of the first type of abrasive particles and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D501/D502) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95.
  • D501 represents the median particle size of the first type of abrasive particles
  • D502 represents the median particle size of the second type of abrasive particles
  • the ratio (D501/D502) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or
  • Embodiment 85 The abrasive article of embodiment 79, wherein the first region comprises a first content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the first content and second content are different compared to each other.
  • Embodiment 86 The abrasive article of embodiment 79, wherein the first region comprises a first content of abrasive particles and the second region comprises a second content of abrasive particles, wherein the first content and second content are the same compared to each other.
  • Embodiment 87 The abrasive article of embodiment 79, wherein the first region is in the form of a layer.
  • Embodiment 88 The abrasive article of embodiment 79, wherein the second region is in the form of a layer.
  • Embodiment 89 The abrasive article of embodiment 79, wherein the second region is directly contacting the first region.
  • Embodiment 90 The abrasive article of embodiment 79, wherein the first region comprises a first content of a first bond material, and wherein the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the first content of the first bond material.
  • Embodiment 91 The abrasive article of embodiment 90, wherein the first bond material and second bond material have the same composition.
  • Embodiment 92 The abrasive article of embodiment 90, wherein the first bond material and second bond material have a different composition compared to each other.
  • Embodiment 93 The abrasive article of embodiment 79, further comprising a third region comprising a third type of abrasive particles, wherein the third type is different than the second type.
  • Embodiment 94 The abrasive article of embodiment 93, wherein the second region is disposed between the first region and the third region.
  • Embodiment 95 The abrasive article of embodiment 93, wherein the first type and the third type are the same with respect to each other.
  • Embodiment 96 The abrasive article of embodiment 93, further comprising a ratio (D503/D502) of not greater than 0.97, wherein D503 represents the median particle size of the third type of abrasive particles and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D503/D502) is not greater than 0.95 or not greater than 0.93 or not greater than 0.90 or not greater than 0.87 or not greater than 0.85 or not greater than 0.83 or not greater than 0.80 or not greater than 0.77 or not greater than 0.75 or not greater than 0.73 or not greater than 0.70 or not greater than 0.67 or not greater than 0.65 or not greater than 0.63 or not greater than 0.60 or not greater than 0.57 or not greater than 0.55 or not greater than 0.53 or not greater than 0.50 or not greater than 0.47 or not greater than 0.45 or not greater than 0.43 or not greater than 0.40.
  • a ratio (D503/D502) is not greater than 0.95 or not greater than 0.
  • Embodiment 97 The abrasive article of embodiment 93, further comprising a ratio (D503/D502) of at least 0.1, wherein D503 represents the median particle size of the third type of abrasive particles and D502 represents the median particle size of the second type of abrasive particles, and wherein the ratio (D503/D502) is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.75 or at least 0.8 or at least 0.85 or at least 0.9 or at least 0.93 or at least 0.95.
  • D503/D502 is at least 0.15 or at least 0.2 or at least 0.25 or at least 0.3 or at least 0.35 or at least 0.4 or at least 0.45 or at least 0.5 or at least 0.55 or at least 0.6 or at least 0.65 or at least 0.7 or at least 0.
  • Embodiment 98 The abrasive article of embodiment 93, wherein the third region is in the form of a layer.
  • Embodiment 99 The abrasive article of embodiment 93, wherein the second region is in the form of a layer and is directly contacting the third region.
  • Embodiment 100 The abrasive article of embodiment 93, wherein the third region comprises a third content of a third bond material, and the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the third content of the third bond material.
  • Embodiment 101 The abrasive article of embodiment 100, wherein the third bond material and second bond material have the same composition.
  • Embodiment 102 The abrasive article of embodiment 100, wherein the third bond material and second bond material have a different composition compared to each other.
  • Embodiment 103 The abrasive article of embodiment 93, wherein the third region comprises a third content of abrasive particles, and the second region comprises a second content of abrasive particles, and wherein the third content is different than the second content.
  • Embodiment 104 A method for forming an abrasive article including forming a mixture including precursor bond material and abrasive particles; and heating the mixture to form a body comprising: a bond material comprising metal and further comprising micro-porosity within the bond material, the micro-porosity comprising an average pore size (D50) of not greater than 10 microns and a pore size standard deviation of at least 0.2 microns;
  • D50 average pore size
  • abrasive particles contained within bond material and further comprising at least one of:
  • Embodiment 105 The method of embodiment 104, wherein the mixture includes a precursor bond material having an average particle size of not greater than 25 microns or not greater than 10 microns or not greater than 1 micron or not greater than 0.75 microns or not greater than 0.5 microns or not greater than 0.25 microns or not greater than 0.1 microns.
  • Embodiment 106 The method of embodiment 104, wherein the mixture includes a precursor bond material having an average particles size of at least 0.001 microns, such as at least 0.01 microns or even at least 0.1 microns.
  • Embodiment 107 The method of embodiment 104, wherein heating the mixture is conducted at a temperature of at least 700°C or at least 725 °C or at least 750°C or at least 775°C or at least 800°C or at least 825°C or at least 850°C or at least 875 °C or at least 900°C or at least 925 °C or at least 950°C or at least 975 °C or at least 1000°C.
  • Embodiment 108 The method of embodiment 104, wherein heating mixture is conducted at a temperature of not greater than 1100°C or not greater than 1050°C or not greater than 1000°C or not greater than 975 °C or not greater than 950°C or not greater than 925 °C or not greater than 900°C.
  • Embodiment 109 The method of embodiment 104, wherein forming comprises hot pressing the mixture.
  • Embodiment 1 10. The method of embodiment 104, wherein forming comprises hot pressing the mixture at a pressure of at least 1000 psi or at least 1500 psi or at least 2000 psi or at least 2200 psi.
  • Embodiment 111 The method of embodiment 104, wherein forming comprises hot pressing the mixture at a pressure of not greater than 5000 psi or not greater than 4000 psi or not greater than 3000 psi or not greater than 2750 psi.
  • a first sample, Sample CI, is a commercially available glass grinding wheel having
  • the abrasive article of Sample CI also includes approximately 16 vol% diamond abrasive particles having a D50 of approximately 93 microns, a DIG of 76 microns, a D90 of 113 micron, an ellipticity of 1.19, an average toughness of approximately 11676 cycles, and 3 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the porosity of Sample CI is approximately 1 vol for the total volume of the body, and has an average pore size (D50) of 0.38 microns with a standard deviation of 0.19 microns.
  • FIG. 2 includes a scanning electron microscope (SEM) image of a portion of the abrasive article of Sample CI without the abrasive particles.
  • a second sample, Sample S2 is formed by creating a mixture of abrasive particles, precursor bond material, and additives.
  • the abrasive particles are titanium-coated diamond particles available as from ILJIN.
  • the abrasive particles have D50 of approximately 104 microns, a D90 of 113 microns, a D10 of 88 microns, and 1.5 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 13135 cycles and an ellipticity of approximately 1.17.
  • the precursor bond material includes cobalt powder commercially available as
  • Extra Cobalt from Umicore and further includes tin commercially available as Tin201 from ACupowder.
  • the mixture was uniaxially hot pressed at a temperature of 975 °C for a duration of approximately 5 minutes under a pressure of 2500 psi.
  • the finally-formed abrasive article of Sample S2 includes approximately 16% vol% abrasive particles and approximately 81 vol% bond material.
  • the bond material includes approximately 97 wt% cobalt and 3 wt% tin.
  • the body further includes approximately 3 vol% porosity, which is micro-porosity having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of 0.42 microns.
  • D50 average pore size
  • Sample S3 is formed using the same process disclosed for making
  • Sample S2 except the abrasive particles are titanium-coated diamond particles available as IMD-F from ILJIN.
  • the abrasive particles have D50 of approximately 97 microns, a D90 of 113 microns, a D10 of 84 microns, and 6 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 10683 cycles and an ellipticity of approximately 1.15.
  • the abrasive article of Sample S3 is formed via hot pressing at a temperature of 975 °C for a duration of approximately 5 minutes under a pressure of 2500 psi.
  • the finally formed abrasi ve article of Sample S3 includes approximately 16 vol% abrasive particles and approximately 81 vol% bond material.
  • the bond material includes approximately 97 wt% cobalt and 3 wt% tin.
  • the body includes approximately 3 voI% porosity, which is micro- porosity having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of approximately 0.42 microns.
  • a fourth sample, Sample S4 is formed using the same process disclosed for making Sample S2, except the abrasive particles are titanium-coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 101 microns, a D90 of 113, a D 10 of 88, and 1.5 vo1% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15.
  • the abrasive article of Sample S4 is formed via hot pressing at a temperature of 975 °C for a duration of approximately 5 minutes under a pressure of 2500 psi.
  • the finally formed abrasive article of Sample S4 includes approximately 14 vol% abrasive particles and approximately 83 vol% bond material.
  • the bond material includes 97 wt% cobalt and 3 wt% tin.
  • the body includes approximately 3 vol% porosity.
  • Each of the samples was used to grind the edge of a glass workpiece of white tempered glass.
  • the length of the worked surface was approximately 4 linear meters for each glass workpiece sample.
  • the samples were operated at a traverse speed of 15 m/min and a spindle speed of 45 m/s.
  • FIGs. 4 and 5 include plots of current versus number of glass workpieces finished for each of the samples for two different dressing cycles, respectively.
  • samples S2 and S3 had the lowest current.
  • Sample S3 finished the most glass samples before the current peaked to an undesirable level and the sample required dressing.
  • Each of the samples were dressed according to the same conditions and tested again to generate the date provided in FIG. 5.
  • Sample S2 and S3 had notably lower current requirements and finished more glass workpieces than Samples CI and S4.
  • Sample S2 demonstrated a notable improvement in the number of glass workpieces finished.
  • sample S5 is formed according to the process disclosed for Sample S2, except that the diamonds were sub-sieved using a stack of four screens having approximate micron sized openings of 106 microns, 97 microns, 90 microns, and 75 microns. All abrasive particles above the 106 micron screen and below the 75 microns screen were discarded.
  • the abrasive particles are titanium-coated diamond particles available as IMD-Mc from ILJIN.
  • the abrasive particles have a D50 of approximately 95 microns, a D90 of approximately 103 microns, a D10 of approximately 80 microns, and approximately 0.1 vol% of the abrasive particles have a particle size greater than 120 microns.
  • FIG. 6 includes a SEM image of a portion of sample S5 according to an embodiment.
  • sample S6 is formed according to the process disclosed for Sample
  • the abrasive particles are titanium-coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 104 microns, a D90 of approximately 1 13 microns, a D10 of approximately 88 microns, and approximately 1.5 vo1% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 13135 cycles and an ellipticity of approximately 1.17.
  • the finally formed abrasive article of Sample S6 includes approximately 14 vol% abrasive particles and approximately 83 vol% bond material.
  • the bond material includes
  • the body includes
  • micro-porosity which is micro-porosity having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of approximately 0.42 microns.
  • D50 average pore size
  • sample S7 is formed according to the process disclosed for Sample
  • the abrasive particles are titanium-coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 97 microns, a D90 of approximately 1 13 microns, a DIO of approximately 84 microns, and approximately 6 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 10683 cycles and an ellipticity of approximately 1.15.
  • the finally formed abrasive article of Sample S7 includes approximately 14.5 vol% abrasive particles and approximately 82.5 vo1% bond material.
  • the bond material includes approximately 97 wt% cobalt and approximately 3 wt% tin.
  • the body includes approximately 3 vol% porosity, which is micro-porosity having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of approximately 0.42 microns.
  • D50 average pore size
  • sample S8 is formed according to the process disclosed for Sample
  • the abrasive particles are titanium-coaled diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 101 microns, a D90 of approximately 3, a D10 of approximately 88, and approximately 1.5 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 11939 cycles and an ellipiicity of approximately 1.15.
  • the finally formed abrasive article of Sample S8 includes approximately 11 vol abrasive particles and approximately 86 vol% bond material.
  • the bond material includes approximately 97 wt% cobalt and approximately 3 wt% tin.
  • the body includes approximately 3 vol% porosity.
  • a sample (Sample S9) is formed according to the process disclosed for Sample S2, except for a difference in the content of abrasive particles and bond material.
  • the abrasive particles are titanium-coaled diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 104 microns, a D90 of approximately 113 microns, a D10 of approximately 88 microns, and approximately 1.5 voi% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 13135 cycles and an ellipticity of approximately 1.17.
  • the finally-formed abrasive article of Sample S9 includes approximately 14.5% vo!% abrasive particles and approximately 82.5vol% bond material.
  • the bond material includes approximately 97 wt% cobalt and approximately 3 wt% tin.
  • sample S10 is formed according to the process disclosed for Sample
  • the abrasive particles are titanium-coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 101 microns, a D90 of approximately 113, a D 10 of approximately 88, and approximately 1.5 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15.
  • the finally-formed abrasive article of Sample S10 includes approximately 1 1 % vol% abrasive particles and approximately 86 vol% bond material.
  • the bond material includes
  • a sample (Sample SI 1) is formed according to the process disclosed for Sample S2, except for a difference in the size and content of abrasive particles and the content of the bond material.
  • the abrasive particles are titanium-coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 101 microns, a D90 of approximately 113, a DIO of approximately 88, and approximately 1.5 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15.
  • the finally-formed abrasive article of Sample SI 1 includes approximately 11% vol% abrasive particles and approximately 86 vol% bond material.
  • the bond material includes approximately 97 wt% cobalt and approximately 3 wt% tin.
  • a sample (Sample S12) is formed according to the process disclosed for Sample S2, except for a difference in the size and content of abrasive particles and the content of the bond material.
  • the abrasive particles are titanium-coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 106 microns, a D90 of approximately 115 microns, a D10 of approxima ely 92 microns, and approximately 2 vol% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15.
  • the finally -formed abrasive article of Sample S12 includes approximately 15 vol% abrasive particles and approximately 85 vol bond material.
  • the bond material includes approximately 97 wt% cobalt and approximately 3 wt% tin.
  • a sample (Sample SI 3) is made from multiple layers of abrasive material, which are sintered together according to the conditions provided in Sample S2.
  • the abrasive region is made of three layers, including a first layer, a third layer, and a second layer disposed between the first and third layers.
  • Each of the layers are created separately as green (i.e., unsintered) layers and combined prior to final sintering and formation of the abrasive body.
  • the first layer includes titanium- coated diamond particles available as from ILJIN.
  • the abrasive particles have D50 of approximately 97 microns, a D90 of
  • the first layer is formed to include approximately 14 vol% abrasive particles and approximately 86 vo1% bond material.
  • the bond material includes approximately 97 wt% cobalt and approximately 3 wt% tin.
  • the second layer includes titanium- coated diamond particles available from ILJIN.
  • the abrasive particles have D50 of approximately 104 microns, a D90 of approximately 1 13 microns, a D10 of approximately 88 microns, and approximately 1.5 vo1% of the abrasive particles have a particle size greater than 120 microns.
  • the abrasive particles have an average toughness of approximately 11939 cycles and an ellipticity of approximately 1.15.
  • the second layer is formed to include approximately 14 vol% abrasive particles and approximately 83 vol% bond material.
  • the bond material includes 97 wt% cobalt and approximately 3 wt% tin.
  • the third layer was formed to have the same construction as the first layer.
  • the three layers were co-sintered together according to the conditions provided in Sample S2.
  • the finally formed abrasive body included approximately 3 vol% porosity for the total volume of the body.
  • Samples S2 and S6, and a conventional sample C2 obtained from 3MTM under the commercial name K20P were subjected to a grinding tested on a laminated glass workpiece having a thickness of 2.1 mm using a Bystronic® grinding machine.
  • the samples were operated at the traverse speed of 18 m/min and spindle speed of 38 m/s.
  • the same dressing was applied at the same frequency to the samples.
  • the run lengths for the samples are illustrated in FIG. 7. Comparing to C2, Samples S2 and S6 was able to grind longer linear lengths.
  • Sample S2 was able to grind at a faster speed and finish grinding a similar linear length, as compared to C3.
  • Sample S2 was able to grind a longer linear distance at a faster traverse speed, as compared to C4 (Table 2).
  • Sample S14 is formed using the same process disclosed for making Sample S2, except the abrasive particles are titanium coated diamond particles (200/230 mesh size) available from Warren Amplex Superahrasives.
  • the abrasive particles have an average toughness of approximately 12392 cycles and an eUipticity of approximately 1.1176.
  • the finally formed abrasive article of Sample S 14 includes approximately 16 vol% diamond abrasive particles and approximately 81 vol% bond material.
  • the bond material includes approximately 97 wt% cobalt and 3 wt% tin.
  • the body further includes approximately 3 vo!% porosity, which is micro-porosity having an average pore size (D50) of approximately 0.51 microns, a D10 of approximately 0.25 microns, a D90 of approximately 1.25 microns, and a standard deviation of 0.42 microns.
  • D50 average pore size
  • Samples S6 and SI 4 were tested on glass workpieces under optimal and low coolant flow conditions.
  • the coolant flow rate was 67 1/min
  • Sample S6 was operated at the traverse speed of 15 m/min and spindle speed of 30 m/s
  • Sample S 14 was operated at the same traverse speed as S6 and the wheel speed of 37.5 m/s.
  • the flow rale was 40 1/min
  • Samples S6 and S14 were operated at the traverse speed of 12 m/min and wheel speed of 53 m/s.

Abstract

La présente invention concerne un article abrasif comprenant un corps ayant un matériau de liaison comprenant du métal et une microporosité dans le matériau de liaison présentant une taille de pore moyenne (D50) inférieure ou égale à 10 micromètres et un écart-type de taille de pore d'au moins 0,2 micromètre, et le corps comprenant en outre des particules abrasives contenues dans le matériau de liaison et ayant une ellipticité inférieure ou égale à 1,18 ou une ténacité moyenne d'au moins 11 257 cycles.
PCT/US2018/025236 2017-03-29 2018-03-29 Article abrasif et son procédé de formation WO2018183736A1 (fr)

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EP18776324.8A EP3600769A4 (fr) 2017-03-29 2018-03-29 Article abrasif et son procédé de formation
BR112019020399A BR112019020399A2 (pt) 2017-03-29 2018-03-29 artigo abrasivo e método para formar o mesmo
KR1020197031413A KR20200006044A (ko) 2017-03-29 2018-03-29 연마재 물품 및 이를 형성하는 방법
CN201880022620.1A CN110799306A (zh) 2017-03-29 2018-03-29 磨料制品及其形成方法

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KR102188525B1 (ko) * 2019-10-29 2020-12-08 에스케이씨 주식회사 연마패드, 이의 제조방법, 및 이를 이용한 반도체 소자의 제조방법
KR102421888B1 (ko) * 2020-09-29 2022-07-15 에스케이씨솔믹스 주식회사 연마 패드, 연마 패드의 제조 방법 및 이를 이용한 반도체 소자의 제조 방법
KR102512675B1 (ko) * 2020-12-30 2023-03-21 에스케이엔펄스 주식회사 연마 패드, 연마 패드의 제조 방법 및 이를 이용한 반도체 소자의 제조 방법

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US20180281153A1 (en) 2018-10-04
EP3600769A1 (fr) 2020-02-05
BR112019020399A2 (pt) 2020-04-22

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