ABRASIVE ARTICLE AND METHOD FOR FORMING SAME

Abstract

The present disclosure relates to an abrasive article including a body having a bond material including metal and a micro-porosity within the bond material with an average pore size (D50) of not greater than 10 microns and a pore size standard deviation of at least 0.2 microns, and the body further includes abrasive particles contained within the bond material and having an ellipticity of not greater than 1.18 or an average toughness of at least 11257 cycles.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 62/478,253, filed Mar. 29, 2017, entitled “ABRASIVE ARTICLE AND METHOD FOR FORMING SAME,” naming as inventors Jiashu Li et al., and claims priority to U.S. Provisional Patent Application No. 62/525,261, filed Jun. 27, 2017, entitled “ABRASIVE ARTICLE AND METHOD FOR FORMING SAME,” naming as inventors Jiashu Li et al., both of which are incorporated by reference herein in their entireties.

FIELD OF THE DISCLOSURE

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.

BACKGROUND

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 abrasive 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 useful 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. In the context of grinding and shaping certain workpieces with metal-bonded abrasive articles, generally 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.

The industry continues to demand improved methods and articles capable of grinding.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited to the accompanying figures.

FIG. 1A includes a cross-sectional illustration of an abrasive article according to an embodiment.

FIG. 1B 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.

Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale.

DETAILED DESCRIPTION

The following discussion will focus on specific implementations and embodiments of the teachings. The detailed description is provided to assist in describing certain embodiments and should not be interpreted as a limitation on the scope or applicability of the disclosure or teachings. It will be appreciated that other embodiments can be used based on the disclosure and teachings as provided herein.

The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one, at least one, or the singular as also including the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

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. Still, in one embodiment, 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.

According to one embodiment, the mixture can include a precursor bond material, which may be formed of one or more powdered metal materials. For example, in one embodiment, 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. In a more particular embodiment, the precursor bond material can include cobalt, tin and tungsten.

According to a particular embodiment, the precursor bond material may have a particular content of cobalt and tin that may facilitate improved formation and/or performance of the abrasive article. For example, 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. In other instances, 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. In one non-limiting embodiment, 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.

According to a particular embodiment, 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. For example, 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 0.01. In another embodiment, 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.

According to a particular embodiment, the precursor bond material may have a particular content of tungsten and tin that may facilitate improved formation and/or performance of the abrasive article. For example, 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. In another embodiment, 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. In one non-limiting embodiment, 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 precursor bond material may have a particular content of cobalt that may facilitate improved formation and/or performance of the abrasive article. For example, 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 % or at least 72 wt % or at least 73 wt % or at least 74 wt % or at least 75 wt % or at least 76 wt % or at least 77 wt % or at least 78 wt % or at least 79 wt % or at least 80 wt % or at least 81 wt % or at least 82 wt % or at least 83 wt % or at least 84 wt % or at least 85 wt % or at least 86 wt % or at least 87 wt % or at least 88 wt % or at least 89 wt % or at least 90 wt % or at least 91 wt % or at least 92 wt % or at least 93 wt % or at least 94 wt % or at least 95 wt % cobalt for the weight of the precursor bond material. In one non-limiting embodiment, 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 % or not greater than 76 wt % or not greater than 75 wt % or not greater than 74 wt % or not greater than 73 wt % or not greater than 72 wt % or not greater than 71 wt % or not greater than 70 wt % or not greater than 69 wt % or not greater than 68 wt % or not greater than 67 wt % or not greater than 66 wt % or not greater than 65 wt % cobalt for the entire weight of the precursor bond material. It will be appreciated that 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. For example, 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 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 % or at least 3.2 wt % or at least 3.3 wt % or at least 3.4 wt % or at least 3.5 wt % or at least 3.6 wt % or at least 3.7 wt % or at least 3.8 wt % or at least 3.9 wt % or at least 4 wt % or at least 4.1 wt % or at least 4.2 wt % or at least 4.3 wt % or at least 4.4 wt % or at least 4.5 wt % or at least 5 wt % tin for the total weight of the precursor bond material. In one non-limiting embodiment, 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 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 % 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 a range including any of the minimum and maximum values noted above.

The precursor bond material may have a particular content of tungsten that may facilitate improved formation and/or performance of the abrasive article. For example, 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 % or at least 3.2 wt % or at least 3.3 wt % or at least 3.4 wt % or at least 3.5 wt % or at least 3.6 wt % or at least 3.7 wt % or at least 3.8 wt % or at least 3.9 wt % or at least 4 wt % or at least 4.1 wt % or at least 4.2 wt % or at least 4.3 wt % or at least 4.4 wt % or at least 4.5 wt % or at least 4.6 wt % or at least 4.7 wt % or at least 4.8 wt % or at least 4.9 wt % or at least 5 wt % or at least 5.1 wt % or at least 5.2 wt % or at least 5.3 wt % or at least 5.4 wt % or at least 5.5 wt % or at least 5.6 wt % or at least 5.7 wt % or at least 5.8 wt % or at least 5.9 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 % tungsten for the total weight of the precursor bond material. Still, in at least one non-limiting embodiment, 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. For example, 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. In another non-limiting embodiment, 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 %. It will be appreciated that 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. For example, 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 %. Still, in another non-limiting embodiment, 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 above. 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. For example, 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 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 %. Still, in another non-limiting embodiment, the precursor 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 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. For example, the precursor bond material can include a content of manganese 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 %. Still, in another non-limiting embodiment, 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 above. 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. For example, 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 %. Still, in another non-limiting embodiment, 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.

In still another embodiment, the precursor bond material may have a particular content of certain metals that may facilitate improved formation and/or performance of the abrasive article. For example, 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 %. Still, in one non-limiting embodiment, 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.

In at least one embodiment, the precursor bond material can be essentially free of aluminum, copper, manganese, lead, silicon, and/or titanium. As used herein 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 %. Correspondingly, if a composition is described as consisting of or consisting essentially of components X, Y, and Z, 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 embodiments herein.

In another embodiment, 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. Moreover, in such an embodiment, 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. In yet embodiment, 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.).

According to one embodiment, the abrasive particles can include a material selected from the group consisting of oxides, carbides, nitrides, borides, or any combination thereof. For example, the abrasive particles can include a superabrasive material, such as diamond. In one particular instance, the abrasive particles can consist essentially of diamond. It will also be appreciated that 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. For example, in one particular embodiment, 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.

In another aspect, the abrasive particles can have a coating overlying the exterior surface. The coating may facilitate improved formation and performance of the abrasive article. In certain instances, the coating can include a material that reduces chemical changes to the abrasive particles during formation, such as oxidation of the abrasive particles. In other instances, 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. In a particular embodiment, 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. Moreover, 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. For example, 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 110 microns or at least 120 microns. Still, in another non-limiting embodiment, 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 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). For example, 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. In one non-limiting embodiment, 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^th percentile of the distribution). For example, 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. In another non-limiting embodiment, 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. For example, in one instance, 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. Still, in at least one instance, 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. For example, the abrasive particles can have 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. In another non-limiting embodiment, the abrasive particles can have a Vickers hardness of not greater than 12,000 kg/mm². 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.

According to another aspect, 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, as used herein, is to be appreciated as an average calculated based upon the toughness test data that appears to have a variation of 5% or less. For example, the abrasive particles can have an average toughness of 11257 cycles, which may include a variation of up to ±563. In another embodiment, the average toughness can be at least 11850 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. In another non-limiting embodiment, 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.

In still another aspect, the abrasive particles may have a particular shape, as measured by ellipticity that may facilitate improved performance of the abrasive article. For example, 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. Still, in one non-limiting embodiment, 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 Reflecta, 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. Using 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. For example, in one instance, 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. In one non-limiting embodiment, 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. It will be appreciated that 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 be formed to include a particular content of the bond material or precursor bond material, which may facilitate formation and performance of the abrasive article. For example, in one instance, 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. It will be appreciated that 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.

After the mixture is created to combine the desired components, the mixture can be shaped into a green body. Some 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.

After or during the process for forming the green body, the body may undergo treatment to form the finally-formed abrasive article. Some suitable treatments can include drying, curing, heating, sintering, or any combination thereof. In at least one embodiment, the mixture is placed into a mold and subject to a suitable pressure and temperature to facilitate formation of the finally-formed abrasive article.

According to one embodiment, 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. For example, 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. Still, in one non-limiting embodiment, 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.

According to one embodiment, 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. In one embodiment, the hot pressing operation can be conducted at a temperature within a range for any of the temperatures noted above. In one embodiment, 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. In another non-limiting embodiment, 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. It will be appreciated that 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. In certain instances, the body of the abrasive article may include some phase or porosity.

According to one embodiment, the body may have a particular content of porosity that may facilitate improved performance of the abrasive article. For example, 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 %. In one non-limiting embodiment, 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. For example, in one instance, 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. In one non-limiting embodiment, 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 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 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. For example, in one instance, 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. In one non-limiting embodiment, 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. Notably, the abrasive particles of the finally-formed abrasive article can have any of the same features of composition, coating, coating composition, coating content, particle size distribution (i.e., D10, 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 have 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. According to a particular embodiment, the bond material may have a particular content of cobalt and tin that may facilitate improved performance of the abrasive article. For example, 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. In other instances, 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. In one non-limiting embodiment, 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.

According to a particular embodiment, the bond material may have a particular content of cobalt and tungsten that may facilitate improved formation and/or performance of the abrasive article. For example, 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. 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 0.01. In another embodiment, 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.

According to a particular embodiment, the bond material may have a particular content of tungsten and tin that may facilitate improved formation and/or performance of the abrasive article. For example, the 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 bond material and CSn is the weight percent of tin for the entire weight of the bond material. In another embodiment, 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. In one non-limiting embodiment, 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 bond material may have a particular content of cobalt that may facilitate improved performance of the abrasive article. For example, 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 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 wt % or at least 75 wt % or at least 76 wt % or at least 77 wt % or at least 78 wt % or at least 79 wt % or at least 80 wt % or at least 81 wt % or at least 82 wt % or at least 83 wt % or at least 84 wt % or at least 85 wt % or at least 86 wt % or at least 87 wt % or at least 88 wt % or at least 89 wt % or at least 90 wt % or at least 91 wt % or at least 92 wt % or at least 93 wt % or at least 94 wt % or at least 95 wt % cobalt for the weight of the bond material. In one non-limiting embodiment, 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 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 not greater than 76 wt % or not greater than 75 wt % or not greater than 74 wt % or not greater than 73 wt % or not greater than 72 wt % or not greater than 71 wt % or not greater than 70 wt % or not greater than 69 wt % or not greater than 68 wt % or not greater than 67 wt % or not greater than 66 wt % or not greater than 65 wt % cobalt for the entire weight of the bond material. It will be appreciated that the content of cobalt in the bond material can be within a range including any of the minimum and maximum values noted above.

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. For example, 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 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 % or at least 3.2 wt % or at least 3.3 wt % or at least 3.4 wt % or at least 3.5 wt % or at least 3.6 wt % or at least 3.7 wt % or at least 3.8 wt % or at least 3.9 wt % or at least 4 wt % or at least 4.1 wt % or at least 4.2 wt % or at least 4.3 wt % or at least 4.4 wt % or at least 4.5 wt % or at least 5 wt % tin for the total weight of the bond material. In one non-limiting embodiment, 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 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 % 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 including any of the minimum and maximum values noted above.

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. For example, the bond material may include at least 1 wt % 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 wt % or at least 3.2 wt % or at least 3.3 wt % or at least 3.4 wt % or at least 3.5 wt % or at least 3.6 wt % or at least 3.7 wt % or at least 3.8 wt % or at least 3.9 wt % or at least 4 wt % or at least 4.1 wt % or at least 4.2 wt % or at least 4.3 wt % or at least 4.4 wt % or at least 4.5 wt % or at least 4.6 wt % or at least 4.7 wt % or at least 4.8 wt % or at least 4.9 wt % or at least 5 wt % or at least 5.1 wt % or at least 5.2 wt % or at least 5.3 wt % or at least 5.4 wt % or at least 5.5 wt % or at least 5.6 wt % or at least 5.7 wt % or at least 5.8 wt % or at least 5.9 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 % tungsten for the total weight of the bond material. Still, in at least one non-limiting embodiment, 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. For example, 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 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 bond material. In another non-limiting embodiment, 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 %. It will be appreciated that the content of iron in the bond material can be within a range including any of the minimum and maximum values noted above.

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. For example, 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 %. Still, in another non-limiting embodiment, 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. For example, 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 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 %. Still, in another non-limiting embodiment, 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. For example, 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 %. Still, in another non-limiting embodiment, 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. For example, 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 %. Still, in another non-limiting embodiment, 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.

In still another embodiment, the bond material of the finally-formed abrasive may have a particular content of certain metals that may facilitate improved performance of the abrasive article. For example, 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 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 %. Still, in one non-limiting embodiment, 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.

According to another aspect, the bond material of the finally-formed abrasive can be formed to include at least 95 wt % of cobalt, tin and tungsten. Moreover, in such an embodiment, 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. In yet embodiment, 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. For example, 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 embodiment, all of the porosity of the body is micro-porosity having the features described herein.

In at least one aspect, the micro-porosity can have a particular pore size distribution that may facilitate improved performance of the abrasive article. For example, 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. Still, in one non-limiting embodiment, 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. It will be appreciated that the average pore size (D50) of the micro-porosity within the body can be within a range including any of the minimum and maximum values noted above.

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. For each cube sample, using a scanning electron microscope in backscatter mode (10 kv), a portion of the sample having an area of at least 50×40 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. 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.

According to one embodiment, 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. In one non-limiting embodiment, 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. For example, 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 110 microns or at least 120 microns. Still, in another non-limiting embodiment, 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. Furthermore, 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. In one particular instance, such as illustrated in FIG. 1A 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.

As also shown in the embodiments of FIG. 1A, 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. 1A 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. In one embodiment, 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.

In one embodiment 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 (PE), 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. In an aspect, 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. In a particular embodiment, the polymer material of the core may consist essentially of PPS. In another particular embodiment, 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.

In another embodiment, 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. 1B includes a cross-sectional illustration of a portion of an abrasive article according to an embodiment. Like the abrasive article illustrated in FIG. 1A, the portion of the abrasive article of FIG. 1B 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.

As further illustrated in FIG. 1B, the abrasive body 103 includes a first region 151, a second region 161 and a third region 171. It will be appreciated that the embodiment of FIG. 1B includes three regions, but other abrasive bodies may be formed to have a fewer or greater number of regions. According to one aspect, the grade and/or structure of the regions may differ from each other. For example, 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.

According to one embodiment, the first region 151 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. In one particular instance, 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 be 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.

In one particular embodiment, 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 C1 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. According to one embodiment, 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. Still, in another non-limiting embodiment, the ratio (C1/C2) 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 (C1/C2) can be within a range including any of the minimum and maximum values noted above.

In certain instances, 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. For example, the abrasive particles 153 and 163 can have the same composition relative to each other. However, it will be appreciated that in other embodiments, the composition of the abrasive particles 153 can be different compared to the composition of the abrasive particles 163. In another aspect, the abrasive particles 153 of the first region 151 can be the same size (e.g., D10, D50, and/or D90) as the abrasive particles 163 contained in the second region 161. For example, the abrasive particles 153 and 163 can have the average particle size (i.e., D50) relative to each other. However, it will be appreciated that in other embodiments, the composition of the abrasive particles 153 can have a different average particle size (i.e., D50) compared to the abrasive particles 163.

In certain instances, and as illustrated in FIG. 1B, 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. Additionally, 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.

In another aspect, the first region 151 can have a first content of a first bond material 152 and the second region 161 can have a second content of a second bond material 162. For certain abrasive articles of the embodiments herein, the second content of the second bond material 162 can be different than the first content of the first bond material 152. Still, in an alternative design, the second content of the second bond material 162 can be the same as the first content of the first bond material 152.

For certain embodiments, 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. In one particular instance, 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. Still, as will be appreciated, in certain instances, 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.

As illustrated in FIG. 1B, certain abrasive bodies may include a third region 171 having a third content of abrasive particles 173. As also illustrated in FIG. 1B, the second region 161 can be disposed between the first region 151 and the third region 171. In at least one embodiment, 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. In still other instances, the first content of abrasive particles 153 and the third content of abrasive particles 173 may be the same with respect to each other.

For one particular embodiment, 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 161 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. In one embodiment, 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. Still, in another non-limiting embodiment, 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.

According to another aspect, the abrasive particles 173 of the third region 171 can be the same type of abrasive particles 163 as contained in the second region 161. 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. For example, the abrasive particles 173 and 163 can have the same composition relative to each other. However, it will be appreciated that in other embodiments, the abrasive particles 163 and 173 can be different types compared to each other. For example, in one embodiment, the composition of the abrasive particles 173 can be different compared to the composition of the abrasive particles 163. In another aspect, 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. For example, the abrasive particles 173 and 163 can have the average particle size (i.e., D50) relative to each other. However, it will be appreciated that in other embodiments, the composition of the abrasive particles 173 can have a different average particle size (i.e., D50) compared to the abrasive particles 163.

Like the first region 151 in certain embodiments, the third region 171 can be in the form of a layer that extends radially between the inner wall 112 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.

In another aspect, 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. For certain abrasive articles of the embodiments herein, the second content of the second bond material 162 can be different than the third content of the third bond material 172. Still, in an alternative design, the second content of the second bond material 162 can be the same as the third content of the third bond material 172. Additionally, the first content of the first bond material 152 can be the same as the third content of the third bond material 172. Still, in a non-limiting embodiment, the second content of the second bond material 162 can be the same as the third content of the third bond material 172.

For certain embodiments, 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. In one particular instance, 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. Still, as will be appreciated, in certain instances, 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.

According to one particular embodiment, the first region 151 includes a first type of abrasive particle having a first median particle size (D50₁) and the second region 161 can include a second type of abrasive particle having a second median particle size (D50₂) In certain instances, the first median particle size (D50₁) can be different than the second median particle size (D50₂). In one particular embodiment, the second type of abrasive particles have a greater median particle size (D50₂) compare to the first type of abrasive particles (D50₁). For one aspect, the abrasive body can have a ratio (D50₁/D50₂) 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. Still, in one non-limiting embodiment, the ratio (D50₁/D50₂) 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 (D50₁/D50₂) can be within a range including any of the minimum and maximum values provided above.

As described in the embodiments herein, the third region 171 may include a third type of abrasive particle 173. In at least one instance, the third type of abrasive particle 173 can be different from the second type of abrasive particle 163 in the second region 161. In particular instances, the abrasive body 103 can have a ratio (D50₃/D50₂) of not greater than 0.97, wherein D50₃ represents the median particle size of the third type of abrasive particles 173 and D50₂ represents the median particle size of the second type of abrasive particles 163. For example, the ratio (D50₃/D50₂) 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. Still, in one non-limiting embodiment, the ratio (D50₃/D50₂) 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 (D50₃/D50₂) can be within a range including any of the minimum and maximum values provided above.

In yet another embodiment, 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.

EMBODIMENTS

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;
abrasive particles contained within bond material and further comprising at least one of: an ellipticity of not greater than 1.18; or
an average toughness of at least 11257 cycles according to ANSIB74.23.

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.

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.

Embodiment 12

The abrasive article of embodiment 1, wherein the abrasive particles comprise a D10 of at least 57 microns or 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.

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 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.

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

The abrasive article of embodiment 18, wherein the abrasive particles have an average toughness of not greater than 16000 or not greater than 15000 or not greater than 14500 or not greater than 14000 or not greater than 13900 or not greater than 13800 or not greater than 13700 or not greater than 13600 or not greater than 13500 or not greater than 13400 or not greater than 13300.

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 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.

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 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 %.

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, tin, 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.

Embodiment 28

The abrasive article of embodiment 27, wherein the bond material 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.

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] 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.

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.

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.

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 wt % or at least 75 wt % or at least 76 wt % or at least 77 wt % or at least 78 wt % or at least 79 wt % or at least 80 wt % or at least 81 wt % or at least 82 wt % or at least 83 wt % or at least 84 wt % or at least 85 wt % or at least 86 wt % or at least 87 wt % or at least 88 wt % or at least 89 wt % or at least 90 wt % or at least 91 wt % or at least 92 wt % or at least 93 wt % or at least 94 wt % or at least 95 wt %.

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 not greater than 76 wt % or not greater than 75 wt % or not greater than 74 wt % or not greater than 73 wt % or not greater than 72 wt % or not greater than 71 wt % or not greater than 70 wt % or not greater than 69 wt % or not greater than 68 wt % or not greater than 67 wt % or not greater than 66 wt % or not greater than 65 wt %.

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 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 % or at least 3.2 wt % or at least 3.3 wt % or at least 3.4 wt % or at least 3.5 wt % or at least 3.6 wt % or at least 3.7 wt % or at least 3.8 wt % or at least 3.9 wt % or at least 4 wt % or at least 4.1 wt % or at least 4.2 wt % or at least 4.3 wt % or at least 4.4 wt % or at least 4.5 wt % or at least 5 wt %.

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 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 % or not greater than 0.5 wt %.

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 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 % or at least 3.2 wt % or at least 3.3 wt % or at least 3.4 wt % or at least 3.5 wt % or at least 3.6 wt % or at least 3.7 wt % or at least 3.8 wt % or at least 3.9 wt % or at least 4 wt % or at least 4.1 wt % or at least 4.2 wt % or at least 4.3 wt % or at least 4.4 wt % or at least 4.5 wt % or at least 4.6 wt % or at least 4.7 wt % or at least 4.8 wt % or at least 4.9 wt % or at least 5 wt % or at least 5.1 wt % or at least 5.2 wt % or at least 5.3 wt % or at least 5.4 wt % or at least 5.5 wt % or at least 5.6 wt % or at least 5.7 wt % or at least 5.8 wt % or at least 5.9 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 %.

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 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 %.

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 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 %.

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 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 %.

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.

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.

Embodiment 49

The abrasive article of embodiment 1, wherein the 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 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 %.

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 C1 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.

Embodiment 56

The abrasive article of embodiment 53, further comprising a ratio (C1/C2) of at least 0.1, wherein C1 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.

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.

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 1, 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 characteristic selected from the group of median particle size (D50), 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.

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.

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.

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;
abrasive particles contained within bond material and further comprising at least one of:
an ellipticity of not greater than 1.18; or
an average toughness of at least 11257 cycles.

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 110

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.

Example 1

The following samples were created and tested for comparison in performance. A first sample, Sample C1, is a commercially available glass grinding wheel having approximately 92 vol % metal bond of approximately 93% cobalt, 2% tin and 5% tungsten. The abrasive article of Sample C1 also includes approximately 16 vol % diamond abrasive particles having a D50 of approximately 93 microns, a D10 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 C1 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 C1 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 “Extrafine 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.

A third sample, 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 abrasive 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 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.

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 D10 of 88, 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 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. As illustrated in FIG. 4, 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. As illustrated in FIG. 5, Sample S2 and S3 had notably lower current requirements and finished more glass workpieces than Samples C1 and S4. Sample S2 demonstrated a notable improvement in the number of glass workpieces finished.

Example 2

A sample (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.

Example 3

A sample (Sample S6) is formed according to the process disclosed for Sample S2. The abrasive particles are titanium-coated 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 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 finally formed abrasive article of Sample S6 includes approximately 14 vol % abrasive particles and approximately 83 vol % 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.

Example 4

A sample (Sample S7) is formed according to the process disclosed for Sample S3, except for a difference in the content of abrasive particles and bond material. The abrasive particles are titanium-coated diamond particles available from ILJIN. The abrasive particles have D50 of approximately 97 microns, a D90 of approximately 113 microns, a D10 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 vol % 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.

Example 5

A sample (Sample S8) is formed according to the process disclosed for Sample S4, except for a difference in the content of abrasive particles and 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 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 ellipticity 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.

Example 6

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-coated 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 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 finally-formed abrasive article of Sample S9 includes approximately 14.5% vol % abrasive particles and approximately 82.5 vol % bond material. The bond material includes approximately 97 wt % cobalt and approximately 3 wt % tin.

Example 7

A sample (Sample S10) 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 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 ellipticity of approximately 1.15. The finally-formed abrasive article of Sample S10 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.

Example 8

A sample (Sample S11) 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 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 ellipticity of approximately 1.15. The finally-formed abrasive article of Sample S11 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.

Example 9

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 approximately 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.

Example 10

A sample (Sample S13) is made from multiple layers of abrasive material, which are sintered together according to the conditions provided in Sample S2. In particular, 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 approximately 105 microns, a D10 of approximately 76 microns, and 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 first layer is formed to include approximately 14 vol % abrasive particles and approximately 86 vol % 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 113 microns, a D10 of approximately 88 microns, 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 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.

Example 11

Samples S2 and S6, and a conventional sample C2 obtained from 3M™ 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.

Example 12

Sample S2 and conventional samples, C3 and C4, obtained from Daotian High Technology Co. Ltd under the commercial name GNAA, and Shanghai Xingsheng Industrial Co., Ltd, were subjected to a grinding test on laminated windshield glass. The test was conducted using a Bystronic grinding machine, and operation parameters and run lengths are included in Tables 1 and 2.

TABLE 1
			Dressing
Sample	traverse speed	spindle speed	frequency	Linear run length
C3	16 m/min	30 m/s	13pcs	8000-11000 m
S2	18 m/min	36 m/s	13pcs	9537 m

TABLE 2
			Dressing	Linear
Sample	traverse speed	spindle speed	frequency	run length
C4	12 m/min	22 m/s	16pcs/2imp	6000-8000 m
S2	16 m/min	22 m/s	16pcs/2imp	9680 m

As disclosed in Table 1, 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).

Example 13

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 Superabrasives. The abrasive particles have an average toughness of approximately 12392 cycles and an ellipticity of approximately 1.1176. The finally formed abrasive article of Sample S14 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 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.

Samples S6 and S14 were tested on glass workpieces under optimal and low coolant flow conditions. For the optimal condition, the coolant flow rate was 67 l/min, and Sample S6 was operated at the traverse speed of 15 m/min and spindle speed of 30 m/s, while Sample S14 was operated at the same traverse speed as S6 and the wheel speed of 37.5 m/s. For the low coolant flow condition, the flow rate was 40 l/min, and Samples S6 and S14 were operated at the traverse speed of 12 m/min and wheel speed of 53 m/s.

Operation at low coolant flow rate can cause a burning effect on glass workpieces (generation of sparkles during grinding), which can be resolved by adjusting the dressing frequency. As illustrated in FIG. 8, under the optimal coolant flow, Samples S6 and S14 were dressed at the similar frequency, while at the low flow rate condition, Sample S6 needed to be dressed more frequently than Sample S14, every 10 glass pieces for S6 versus every 25 pieces for S14, to achieve a desirable grinding result.

Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.

Claims

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; abrasive particles contained within bond material and further comprising at least one of: a) an ellipticity of not greater than 1.18; or b) an average toughness of at least 11257 cycles according to ANSIB74.23.

2. The abrasive article of claim 1, wherein the abrasive particles comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, or any combination thereof.

3. The abrasive article of claim 1, wherein the abrasive particles comprise a superabrasive material.

4. The abrasive article of claim 1, wherein the abrasive particles comprise diamond.

5. The abrasive article of claim 1, wherein the abrasive particles consist essentially of diamond.

6. The abrasive article of claim 1, wherein the abrasive particles comprise a coating.

7. The abrasive article of claim 6, wherein the coating comprises a metal or metal alloy including a transition metal element.

8. The abrasive article of claim 6, wherein the coating comprises titanium.

9. The abrasive article of claim 1, wherein the abrasive particles comprise a particle size distribution including at least one of:

a D50 of at least 65 microns and not greater than 150 microns;

a D10 of at least 57 microns and not greater than 127 microns; and

a D90 of at least 97 microns and not greater than 165 microns.

10. The abrasive article of claim 1, wherein the abrasive particles comprise a Vickers hardness of at least 2000 kg/mm2.

11. The abrasive article of claim 1, wherein the abrasive particles have an average toughness of at least 11850 cycles and not greater than 16000 cycles.

12. The abrasive article of claim 1, wherein the abrasive particles have an ellipticity of at least 1.01 and not greater than 1.17.

13. The abrasive article of claim 1, wherein the body comprises a content of:

the abrasive particles of at least 2 wt % and not greater than 10 wt % for a total weight of the body;

the bond material of at least 20 wt % and not greater than 95 wt % for the total weight of the body; and

a porosity of at least 0.5 vol % and not greater than 50 vol % for a total volume of the body.

14. The abrasive article of claim 1, wherein the bond material comprises:

cobalt in a content of at least 0.1 wt % and not greater than 99 wt % for a total weight of the body;

tin in a content of at least 1 wt % and not greater than 15 wt % for the total weight of the body,

tungsten in a content of at least 0.05 wt % and not greater than 20 wt % for the total weight of the body;

copper in a content of not greater than 20 wt % for the total weight of the body; or

any combination thereof.

15. The abrasive article of claim 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 aluminum, copper, manganese, lead, silicon, and titanium.

16. The abrasive article of claim 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.

17. The abrasive article of claim 16, wherein the first region and the second region are in the form of a layer, wherein the second region is directly contacting the first region.

18. The abrasive article of claim 16, 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.

19. 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; abrasive particles contained within bond material and further comprising at least one of: a) an ellipticity of not greater than 1.18; or b) an average toughness of at least 11257 cycles.

20. The method of claim 19, wherein the mixture includes a precursor bond material having an average particle size of not greater than 25 microns.