Abstract: The present invention addresses problems in the diamond saw blade and segment art. One aspect of the invention comprises a method for making handleable, strong, discrete, metal-clad abrasive pellets. This method comprises the steps of:(a) spraying onto a bed of gas-fluidized abrasive particles a slurry of metallic powder, a binding agent, and a volatile solvent until substantially all the abrasive particles are coated with at least about 20 wt-% of the metallic powder;(b) recovering the metal powder coated abrasive particles; and(c) heating said recovered coated particles under conditions to form a sintered continuous metal coating enveloping said abrasive particles. The resulting sintered metal-clad pellets form another aspect of the invention.

Abstract: One aspect of the present invention is a method for making metal-clad particle pellets which comprises the steps of:(a) coating diamond particles with a carbide-forming metal;(b) spraying onto a bed of gas-fluidized coated abrasive particles of step (a) a slurry of metallic powder, a binding agent, and a volatile solvent, for a time until each abrasive particle is outer coated with at least about 20 wt-% of said metallic powder, said metallic powder having a sintering temperature that is at least about 50.degree. C. lower than the melting point temperature of said carbide-forming metal;(c) recovering said metal powder-coated abrasive pellets of step (b) substantially devoid of said volatile solvent;(d) heating said recovered coated abrasive pellets under conditions to form a sintered continuous outer metal coating on said abrasive pellets; and(e) heating said pellets of step (d) at a second higher temperature to liquefy said carbide-forming metal for forming some metal carbide from said diamond particle.