Abstract: Methods of making polymer bond abrasive articles and their precursors using powder bed jetting are disclosed. Polymer bond abrasive articles prepared by the method include abrasive articles having arcuate or tortuous cooling channels, unitary structured abrasive discs, abrasive segments, shaped abrasive particles, and abrasive wheels.

Abstract: Various embodiments disclosed relate to an abrasive article. The abrasive article includes a metallic matrix component, an abrasive particle component dispersed within the metallic matrix component; and a filler particle component dispersed within the metallic matrix component. A portion of the filler particle component is at least partially coated by a first metallic layer.

Abstract: A shaped abrasive agglomerate particle includes a shaped abrasive particle bonded in a vitreous matrix. The shaped abrasive particles have a longest particle lineal dimension on a surface and a shortest particle dimension perpendicular to the longest particle lineal dimension, and the longest particle lineal dimension is at least twice the shortest particle dimension. The shaped abrasive agglomerate particle has a longest agglomerate lineal dimension on a surface and a shortest agglomerate dimension perpendicular to the longest agglomerate lineal dimension, and the longest agglomerate lineal dimension is at least twice the shortest agglomerate dimension. The abrasive agglomerate particles are useful in abrasive articles. Methods of making the shaped abrasive agglomerate particle and abrading a workpiece are also described.

Abstract: The present disclosure provides bonded abrasive articles including abrasive particles retained in a binder. The abrasive particles are oriented at a predetermined angle greater than 0 degrees and less than 90 degrees with respect to a longitudinal axis of the bonded abrasive article. Fifty percent or more of the abrasive particles are oriented within 15 degrees above or below the angle, as measured using microscopy image analysis under magnification. The present disclosure further provides a method of making a bonded abrasive article, the method comprising sequential steps.

Abstract: Metal bond abrasive articles and methods of making metal bond abrasive articles via a focused beam are disclosed. In an aspect, a metal bond abrasive article includes a metallic binder material having abrasive particles retained therein, where the abrasive particles have at least one coating disposed thereon. The coating includes a metal, a metal oxide, a metal carbide, a metal nitride, a metalloid, or combinations thereof, and the at least one coating has an average thickness of 0.5 micrometers or greater. The metal bond abrasive article includes a number of layers directly bonded to each other. Metal bond abrasive articles prepared by the method can include abrasive articles having arcuate or tortuous cooling channels, abrasive segments, abrasive wheels, and rotary dental tools.

Abstract: An abrasive agglomerate particle includes fused aluminum oxide mineral bonded in a vitreous matrix. The fused aluminum oxide mineral is present in a range from 70 percent by weight to 95 percent by weight and the vitreous matrix is present at least at five percent by weight, based on the weight of the abrasive agglomerate particle. The fused aluminum oxide mineral has an average particle size of up to 300 micrometers, and the abrasive agglomerate particle has a frusto-pyramidal shape with side walls having a taper angle in a range from 2 to 15 degrees and a dimension of at least 400 micrometers. The abrasive agglomerate particles are useful in abrasive articles. The method includes contacting the workpiece with an abrasive article and moving the workpiece and the abrasive article relative to each other to abrade the workpiece.

Abstract: An abrasive disc for use with a sanding tool having a plurality of dust collection holes includes a hole pattern consisting of six openings arranged for substantial alignment with the dust collection holes provided in the sanding tool.

Abstract: A method of shape sorting abrasive particles involves disposing initial crushed abrasive particles with agitation against the surface of a tool, the surface defining a plurality of shaped cavities having an average aspect ratio of at least 1.2, thereby causing a first portion of the initial crushed abrasive particles to become retained within at least some of the shaped cavities, and causing a second portion of the initial crushed abrasive particles to remain as loose particles on the surface. Substantially all of the shaped cavities contain at most one abrasive particle. The second portion of the initial crushed abrasive particles is separated from the tool. The first portion of the initial crushed abrasive particles is then separated from the tool and isolated as loose sorted crushed abrasive particles. The average aspect ratio of the loose sorted crushed abrasive particles is greater than that of the initial crushed abrasive particles.

Abstract: Various embodiments disclosed relate to pore inducers and porous abrasive forms made using the same. In various embodiments, the present invention provides a method of forming a porous abrasive form including heating an abrasive composition including pore inducers to form the porous abrasive form. During the heating the pore inducers in the porous abrasive form reduce in volume to form induced pores in the porous abrasive form.

Abstract: Methods of making abrasive articles involve adhering shaped abrasive particles to a reinforcing member according to a predetermined pattern and optionally orientation, and depositing a space-filling binder precursor on the reinforcing member and shaped abrasive particles to provide a filled abrasive preform, disposing another reinforcing member onto the filled abrasive preform, and curing the abrasive article precursor to form the abrasive articles. In some aspects, multiple abrasive preforms are stacked on each other. Bonded abrasive wheels preparable according to the methods are also disclosed.

Abstract: Abrasive preforms include a frame having first and second opposed parallel major surfaces. The first major surface has a plurality of first cavities formed therein. The second major surface optionally has a plurality of second cavities formed therein. The frame comprises a binder precursor material. Abrasive particles are disposed in at least a portion of the plurality of first cavities and optional plurality of second cavities. Methods of making abrasive articles using the abrasive preforms and bonded abrasive articles preparable thereby are also disclosed.

Abstract: The present disclosure provides methods of making a vitreous bond abrasive article and a metal bond abrasive article. An abrasive article preform is produced by an additive manufacturing sub-process comprising the deposition of a layer of loose powder particles in a confined region and selective heating via conduction or irradiation to heat treat an area of the layer of loose powder particles. The loose powder particles include abrasive particles and organic compound particles, as well as vitreous bond precursor particles or metal particles. The abrasive article preform produced by additive manufacturing is subsequently heated to provide the vitreous bond abrasive article comprising the abrasive particles retained in a vitreous bond material, or to provide the metal bond abrasive article. Also, the methods include receiving, by an additive manufacturing device having a processor, a digital object specifying data for an abrasive article, and generating the abrasive article with the manufacturing device.

Abstract: The present disclosure provides methods of making a vitreous bond abrasive article and a metal bond abrasive article. The methods include sequential steps. Step a) includes a subprocess including sequentially: i) depositing a layer of loose powder particles in a confined region; and ii) selectively applying heat via conduction or irradiation, to heat treat an area of the layer of loose powder particles. The loose powder particles include abrasive particles and organic compound particles, as well as vitreous bond precursor particles or metal particles. The layer of loose powder particles has substantially uniform thickness. Step b) includes independently carrying out step a) a number of times to generate an abrasive article preform comprising the bonded powder particles and remaining loose powder particles. Step c) includes separating remaining loose powder particles from the abrasive article preform.

Abstract: An abrasive disc for use with a sanding tool having a plurality of dust collection holes includes a hole pattern consisting of six openings arranged for substantial alignment with the dust collection holes provided in the sanding tool.

Abstract: A method of making a bonded abrasive article comprises urging crushed abrasive particles with agitation against the surface of a tool, thereby causing a first portion of crushed abrasive particles to become retained within horizontally-oriented precisely-shaped cavities at predetermined locations with respect to the surface of the tool, and causing a second portion of the crushed abrasive particles to remain as loose particles on the surface of the tool. The loose particles are separated from the tool. The tool is positioned within a mold containing a curable binder material precursor. The crushed abrasive particles retained in the precisely-shaped cavities into the mold are released, and the tool is removed from the mold. The crushed abrasive particles and the curable binder material precursor are shaped and cured to form the bonded abrasive article. A bonded abrasive article preparable by the method is also disclosed.

Abstract: A method of shape sorting abrasive particles involves disposing initial crushed abrasive particles with agitation against the surface of a tool, the surface defining a plurality of shaped cavities having an average aspect ratio of at least 1.2, thereby causing a first portion of the initial crushed abrasive particles to become retained within at least some of the shaped cavities, and causing a second portion of the initial crushed abrasive particles to remain as loose particles on the surface. Substantially all of the shaped cavities contain at most one abrasive particle. The second portion of the initial crushed abrasive particles is separated from the tool. The first portion of the initial crushed abrasive particles is then separated from the tool and isolated as loose sorted crushed abrasive particles. The average aspect ratio of the loose sorted crushed abrasive particles is greater than that of the initial crushed abrasive particles.

Abstract: An abrasive disc for use with a sanding tool having a plurality of dust collection holes includes a hole pattern consisting of six openings arranged for substantial alignment with the dust collection holes provided in the sanding tool.

Abstract: Methods of making metal bond abrasive articles via powder bed jetting are disclosed. Metal bond abrasive articles prepared by the method include abrasive articles having arcuate or tortuous cooling channels, abrasive segments, abrasive wheels, and rotary dental tools.

Abstract: Methods of making vitreous bond abrasive articles and their precursors using powder bed jetting are disclosed. Vitreous bond abrasive articles prepared by the method include abrasive articles having arcuate or tortuous cooling channels, unitary structured abrasive discs, abrasive segments, shaped abrasive particles, and abrasive wheels.

Abstract: Methods of making abrasive articles involve adhering shaped abrasive particles to a reinforcing member according to a predetermined pattern and optionally orientation, and depositing a space-filling binder precursor on the reinforcing member and shaped abrasive particles to provide a filled abrasive preform, disposing another reinforcing member onto the filled abrasive preform, and curing the abrasive article precursor to form the abrasive articles. In some aspects, multiple abrasive preforms are stacked on each other. Bonded abrasive wheels preparable according to the methods are also disclosed.