Abstract: A polishing pad having a substantially uniform, continuously interconnected porous surface. The pad can be produced by pressure sintering powder compacts of thermoplastic polymer at a temperature above the glass transition temperature but not exceeding the melting point of the polymer. The sintering process is conducted in a mold at a pressure in excess of 100 psi (0.07 MPa). In a preferred version, a mixture of two polymer powders is used, where one polymer has a lower melting point than the other.

Abstract: A system and method for attaching an abrasive article to a backing pad is provided. The system includes a backing pad including loop-textile material applied to an attachment surface thereof and an abrasive article, which is removably attached thereto. The abrasive article has at least first and second surfaces including a plurality of abrasive particles adhered thereto. The first surface of the abrasive article includes abrasive particles having a size and density selected to provide a desired surface finish of a workpiece surface being abraded with the abrasive article. The second surface includes a plurality of abrasive particles having a size and density selected to releasably engage textile loops extending from the loop textile material applied to the backing pad attachment surface. Various embodiments, including double-sided sandpaper sheets and sanding screens, which adhere to the textile loops extending from the loop textile material applied to the backing pad attachment surface are disclosed.

Abstract: Coated abrasives with engineered abrasive surfaces are produced using superabrasive particles mixed with metal particles in a cold-forming process.

Abstract: An abrasive vitreous bonded solid mass having a vitrified abrasive structure comprising abrasive grains which are held together by an inorganic bonding agent, the abrasive structure is impregnated with a composition which comprises a thermosetting synthetic resin and a surfactant. The abrasive solid mass is manufactured by preparing the composition including the resin and the surfactant, impregnating the vitrified abrasive structure with the composition, and curing the composition.

Abstract: A method for making an abrasive article having at least two abrasive coatings having different abrasive natures. The abrasive natures can differ, for example, by abrasive particle size, abrasive particle type, abrasive particle shape, filler, surfactant, or coupling agent. In another embodiment, the abrasive article can be a structured abrasive article comprising abrasive composites. In another aspect of the invention, the article can have a coating having a single abrasive nature, where the composites comprising the coating are free of abrasive particles.

Abstract: The present invention provides a master tool and method for making a master tool. The master tool includes a plurality of precise three-dimensional shapes upraised from the surface of the master tool. Each of the precise shapes is defined by a distinct and discernible boundary including specific dimensions, wherein not all said three-dimensional shapes are identical. The master tool of the present invention can be used to form a production tool containing a plurality of precise three-dimensional-shaped cavities. The production tool can be used in the manufacture of abrasive articles to shape an abrasive slurry into an array of precise three dimensional-shaped abrasive composites.

Abstract: A coated abrasive backing consisting of an endless, seamless, loop is provided. The backing loop includes about 40-99% by weight of an organic polymeric binder, based upon the weight of the backing; and an effective amount of a fibrous reinforcing material engulfed within the organic polymeric binder material. The endless, seamless backing loop includes a length with parallel side edges, and at least one layer of fibrous reinforcing material engulfed within the organic polymeric binder material such that there are regions of organic binder material free of fibrous reinforcing material on opposite surfaces of the layer of fibrous reinforcing material. The fibrous reinforcing material can be in the form of individual fibrous strands, a fibrous mat structure, or a combination of the these. A method for preparing the endless, seamless backing loop for a coated abrasive belt is also provided.

Abstract: Bonded abrasive products comprising alumina-based abrasive grains and a geopolymer bond system are significantly improved by providing the grain with a vitreous coating before incorporation in the geopolymer bond.

Abstract: Grinding tool for the machining of particularly brittle materials, whose abrasive rim bond is constructed of two components, whereby one component consists of resinoid such as, for example, high temperature thermoplast or pressure sintered polymer and a second component of low melting sintered metal. The processing temperature of both components by the joint pressure sintering is the same. The nature of the invention consists in the construction of a particular connected network for each of the two different bonding agents and their interrelated spatial intertwining in the abrasive rim to an interpenetrating network. A process for the production of abrasive rims for grinding tools according to the invention is indicated.

Abstract: A straight, thin, monolithic abrasive wheel formed of hard and rigid abrasive grains and a sintered metal bond including a stiffness enhancing metal component exhibits superior stiffness. The metals can be selected from among many sinterable metal compositions. Blends of nickel and tin are preferred. The stiffness enhancing metal is a metal capable of providing substantially increased rigidity to the bond without significantly increasing bond hardness. Molybdenum, rhenium, tungsten and blends of these are favored. The sintered bond is generally formed from powders. A diamond abrasive, nickel/tin/molybdenum sintered bond abrasive wheel is preferred. Such a wheel is useful for abrading operations in the electronics industry, such as cutting silicon wafers and alumina-titanium carbide pucks.

Abstract: Method for making alpha alumina-based abrasive grain, wherein during an impregnation step of the method, alpha alumina-based ceramic precursor particles conchoidally fracture. The abrasive grain can be incorporated into abrasive products such as coated abrasives, bonded abrasives, and non-woven abrasives.

Abstract: Abrasive tools, such as coated abrasives, made using radaition curable resin binders can be given a greater depth of cure of the binder if they include an acylphosphine oxide initiator.

Abstract: In a method for the manufacture of a coating on a grinding tool, a rough diamond layer (8, 10) is produced as an abrasive layer on the surface (2) of the body (1) of the grinding tool by vapor-phase deposition. This diamond layer is deposited on the grinding tool by the Hot Filament Chemical Vapor Deposition (HF-CVD) process.

Abstract: An aluminum-boron-carbon abrasive article is comprised of at least three phases selected from the group consisting of: B.sub.4 C; AlB.sub.2 ; AlB.sub.12 ; AlB.sub.12 C.sub.2 ; Al.sub.4 C.sub.3 ; AlB.sub.24,C.sub.4 ; Al.sub.4 B.sub.1-3 C.sub.4 ; AlB.sub.24 C.sub.4 and Al.sub.4 BC. At least a portion of the surface of the abrasive article is comprised of abrasive grains of at least one phase selected from the group consisting of AlB.sub.24 C.sub.4, Al.sub.4 BC and AlB.sub.2, where the abrasive grains have an average grain size that is at least about two times greater than the average grain size of the grains containing boron and carbon within the abrasive article. The aluminum-boron-carbon abrasive article of claim 1 is prepared by heating, under a vacuum or inert atmosphere, a body comprised of at least one boron containing phase and at least one carbon containing phase in the presence of a separate source of aluminum, such as aluminum metal or alloy thereof.

Abstract: An innovative method of manufacturing polishing pads using photocuring polymers and photolithography. The photolithography enables the creation of useful surface patterns not possible with conventional machining techniques and enables the use of pad materials otherwise too soft to pattern by conventional machining techniques.

Abstract: A polishing tool for polishing optical and technical glass, semiconductors, ceramics and other materials has a high concentration of cerium dioxide or aluminum oxide particles in the quantity of 85-96% by weight, and a high molecular binder based on synthetic rubber and including a combination of high-molecular components and other components for vulcanization, plasticization and stabilization.

Abstract: A coated abrasive material comprising a substrate and maker coat and adhered by means of the maker coat a plurality of abrasive grits in the form of U-shaped particles or coils.

Abstract: An abrasive sheet for precisely abrading a workpiece surface includes an adhesive and an abrading layer made by drying a slurry which is a mixture of abrasive particles and a binder. The abrading layer is preferably of thickness less than about 1.5 times the average size of the abrading particles and has one surface attached to a plastic base sheet through a layer of the adhesive. At least some of the abrading particles in the abrading layer have their end parts at the other surface of the abrading layer which, together with these end parts of the abrading particles, forms a smooth flat abrading surface without irregularly distributed protrusions and indentations.

Abstract: A method for fabricating a tool used in cutting, grinding and machining operations, is provided. The method is used to deposit a mixture comprising an abrasive material and a bonding material on a tool surface. The materials are propelled toward the receiving surface of the tool substrate using a thermal spray process. The thermal spray process melts the bonding material portion of the mixture, but not the abrasive material. Upon impacting the tool surface, the mixture or composition solidifies to form a hard abrasive tool coating.

Abstract: The present invention relates to an abrasive article. The abrasive article of the present invention contains an abrasive layer, a polyurethane structure bonded to the abrasive layer and a substrate bonded to the polyurethane structure. The present invention also involves a method for making said abrasive article.

Abstract: A method of making abrasive particles having a specified shape and abrasive articles containing abrasive particles having a specified shape.

Abstract: A superabrasive cutting element, the substrate of which is structured with a reduced dimension circumferential portion about which is formed an annular portion of superabrasive material, such as sintered diamond in the form of a polycrystalline diamond compact, to provide a ring- or skirt-like portion of superabrasive material at the perimeter of the cutting element to reduce residual tensile stresses existing at the perimeter of the cutting element after formation.

Abstract: The structure of a forceful grinding medium comprised of two half-housings engaged with each other, the half-housings both are integrally formed with a plurality of raised circle shaped blades. The raised circle shaped blades improve the three dimensional vibration mode grinding and polishing.

Abstract: The present invention is a polishing pad for use in chemical-mechanical planarization of semiconductor wafers, and a method for making the polishing pad. The polishing pad has a body, molecular bonding links, and abrasive particles dispersed substantially uniformly throughout the body. The body is made from a polymeric matrix material and the molecular bonding links are covalently bonded to the matrix material. Substantially all of the abrasive particles are covalently bonded to at least one molecular bonding link. The molecular bonding links securely affix the abrasive particles to the matrix material to enhance the uniformity of the distribution of the abrasive particles throughout the pad and to substantially prevent the abrasive particles from breaking away from the pad.

Abstract: A method and system whereby an abrasive ring having an axis and a given number of abrasive sheet elements projecting with respect to the axis is formed by forming an orderly first pack of abrasive sheet elements having a first number of elements smaller than the given number of the ring; forming at least a second pack of elements having a second number of elements at most equal to the difference between the given number and the first number; curving the first pack to form a base ring; circumferentially compacting the elements in the base ring to form at least one gap; and inserting at least a second pack of elements inside the gap.

Abstract: For producing an abrasive tape (11) including a film substrate (2) and a polishing abrasive layer (10) laminated on one surface of the film substrate (2) and having on the outer surface thereof a plurality of recessed parts (9), the film substrate (2) is wrapped partially around the outer peripheral surface of a roll formplate (1) having on the surface thereof a plurality of concavities (5), and, as the roll formplate (1) is rotated, the film substrate (2) is fed thereto. On one hand, an ionizing radiation curing type resin (3) is supplied into the interface between the roll formplate (1) and the film substrate (2) therearound to be formed by the concavities (5), and the recessed parts (9) are formed on the resin surface. During this forming, radiation rays (R) are projected from an ionizing radiation ray source (8) toward the resin (3) thereby to cure the resin (3) and, at the same time, to render the resin (3) and the film substrate (2) into an integral structure.

Abstract: In a method for removing metal from the surface of a workpiece by continuously rubbing the surface with a tool in a friction-inducing manner and in the presence of a friction-enhancing agent (an anti-lubricant) and in which a thin layer of the friction-enhancer must be available at the tool surface, there is provided a tool which carries the friction-enhancing agent in the form of a composition of an abrasive and a rubbery solid siloxane reaction product admixed with a liquid, mobile, anti-lubricant siloxane stably dispersed therewithin, and the use of the tool to excoriate and condition the surface by removing therefrom the oxide film thereon and leaving its place a siloxane film, and a conditioned metal surface having siloxane molecules each individually bonded directly to the metal over a relatively large area of the surface to provide a relatively uniform siloxane layer.

Abstract: Method for making alpha alumina-based abrasive grain from a dispersion comprising boehmite, wherein the method involves the impregnation of an alpha alumina-based ceramic precursor material. The abrasive grain can be incorporated into abrasive products such as coated abrasives, bonded abrasives, and non-woven abrasives.

Abstract: Super hard composite material for tools, comprising a substrate of CBN sintered body containing more than 20% by volume of cubic boron nitride (CBN), improved in strength of base material, wear-resistance, hardness at high temperatures and acid-resistance usable in cutting work of steels which are difficult to be machined. The substrate (2) has a laminated film (1) consisting of super thin films (a) and (b) each deposited alternatively on the substrate (2), the super thin film (a) being made of nitride and/or carbide of at least one element selected from a group comprising IVa group elements, Va group elements, VIa group elements, Al and B and possessing a crystal structure of cubic system and metallic bond property, the super thin film (b) being made of at least one compound possessing a crystal structure other than cubic system and covalent bond property under equilibrium condition at ambient temperature and pressure, each unit layer of the super thin films (a) and (b) having a thickness of 0.

Abstract: The inventive polishing pad is used for planarizing semiconductor wafers or other substrates with a mechanical or CMP process; the polishing pad preferably has a body made from a matrix material, bonding molecules bonded to the matrix material, and abrasive particles bonded to the bonding molecules in a manner that affixes the abrasive particles to the matrix material and substantially maintains the affixation between the matrix material and the abrasive particles in the presence of an electrostatic CMP slurry or other planarizing solution. The bonding molecules are preferably covalently attached to the matrix material and substantially all of the abrasive particles are preferably covalently bonded to at least one bonding molecule.

Abstract: A composite body cutting instrument formed of a polycrystalline diamond layer sintered to a carbide substrate with a carbide/diamond transition layer. The transition layer is made by creating carbide projections perpendicular to the plane of the carbide substrate face in a random or nonlinear orientation. The transition layer manipulates residual stress caused by both thermal expansion and compressibility differences between the two materials and thus increases attachment strength between the diamond and carbide substrate by adjusting the pattern, density, height and width of the projections.

Abstract: The present invention is an under-pad placed between a polishing pad and a platen of a planarizing machine used in chemical-mechanical planarization of semiconductor wafers. The under-pad has a body and a plurality of thermal conductors positioned in the body to conduct heat through the body. The body has a top face upon which the polishing pad is positionable and a bottom face engageable with the platen. In operation, heat from the platen and polishing pad flows through the thermal conductors to reduce temperature gradients across the planarizing surface of the polishing pad.

Abstract: The present invention provides a vitreous-bonded abrasive tool wherein the abrasive grit portion comprises a thermally sensitive abrasive grain, such as sintered sol gel microcrystalline alpha alumina abrasive grain or superabrasive grain, and wherein the vitrified bond may be matured by firing at a temperature below about 875.degree. C. The invention further includes a novel vitrified bond composition.

Abstract: The present disclosure is directed to a method of converting the preferred hydrated alumina oxide, boehmite, into a green particle which is then sintered to form an abrasive alumina particle. The process involves dispersing boehmite in water at a slightly elevated temperature with an acidic pH, then seeding it with alumina seed particles and drying it, then crushing to desired shapes and sizes, calcining the dried precipitate and sintering the calcined material. This forms high quality alumina abrasive grains. The apparatus used for sintering incorporates an elongate hollow tube, an insulative sleeve thereabout to define an elevated temperature zone, and a microwave generator coupled through a wave guide into a microwave cavity incorporated in the tube. The particles are moved through the tube at a controlled rate to assure adequate exposure to the microwave radiation.

Abstract: The present invention provides a backing for a coated abrasive article, wherein the backing includes a tough, heat resistant, thermoplastic binder material, and an effective amount of a fibrous reinforcing material distributed throughout the thermoplastic binder material. The tough, heat resistant, thermoplastic binder material and the fibrous reinforcing material together form a hardened composition that will not substantially deform or disintegrate during use.

Abstract: Coated abrasives suitable for very fine abrading applications can be obtained by depositing formulations comprising abrasive grits, fillers, grinding aid, additives and a binder resin and in patterns on a surface using a rotogravure technique providing the viscosity is controlled such that the formulation deposited does not lose its shape prior to cure.

Abstract: A method of making a coated abrasive article and the product thereof, involving the steps of: providing an endless spliceless backing loop substrate; applying fibrous reinforcing material onto a major surface of the endless backing substrate by applying of a first binder precursor to the fibrous reinforcing material such that the first binder precursor bonds the fibrous reinforcing material to the endless backing substrate to form a reinforcing fiber layer; further solidifying the first binder precursor; and forming an abrasive coating on the surface of one of the fiber reinforcing layer, or alternatively, the exposed surface of the backing substrate.

Abstract: Structurally independent cutting members are formed with abrasive material comprising a plurality of particles protruding through a surface of the retaining material comprising a mesh material for durable cutting members; and, the structurally independent cutting members are selectively continuous or discontinuous and spatially mounted along the working edge of a core. Some of the cutting members or portions of the cutting members are arranged for stock removal, and some are arranged for gauge keeping. Since the individual portions of the cutting portions are separate, more stock removal portions can be included, with fewer gauge keeping portions as may be required. The structurally independent cutting members may have a variety of profile shapes, such as contoured configurations to provide stock removal using high pressure cutting forces applied normal to the cutting face of the workpiece and gauge keeping functions using low pressure cutting forces applied laterally to the cutting face to the workpiece.

Abstract: Method for making alpha alumina-based abrasive grain from a dispersion comprising boehmite. The abrasive grain can be incorporated into abrasive products such as coated abrasives, bonded abrasives, and non-woven abrasives.

Abstract: Abrasive grain with significantly improved toughness is obtained by pressureless sintering of .alpha.-silicon carbide powder with oxidic sinter additives, especially aluminum oxide/yttrium oxide, which is also suitable for those applications where an ordinary silicon carbide abrasive grain is too brittle.

Abstract: An efficient method for manufacturing bonded abrasive articles comprises the use of elongated abrasive grain having a length to cross-sectional width aspect ratio of at least 5:1 to yield abrasive articles which are highly permeable to the passage of fluids. A method for measuring permeability is provided. The abrasive articles are used to carry out soft grinding and deep cut grinding operations. The permeable abrasive articles provide an open structure of pores and channels permitting the passage of fluid through the abrasive article and the removal of swarf from the workpiece during grinding operations.

Abstract: A grinding agent containing polymers and/or copolymers partially neutralized by magnesium, for aqueous suspensions of mineral substances to be used in pigmentary applications is disclosed.A grinding agent composed of polymers and/or copolymers having a specific viscosity of between 0.3 and 0.8 and obtained by treatment, using one or several solvents, of a polymer and/or copolymer resulting from polymerization and/or copolymerization of acrylic and/or vinyl monomers comprising acid groups whose active acid sites are partially or completely neutralized to a degree of neutralization of 40 to 60%, including terminals, of the active acid sites using a neutralizing agent containing magnesium ions, and a degree of neutralization reaching 60% using a neutralizing agent containing sodium ions is disclosed.

Abstract: The present invention relates generally to abrasive stone pads for use in processing workpiece surfaces. The abrasive stones generally are produced by combining a phenolic resin mixture with a diluent and then injecting microballoon structures into the resin/diluent mixture to create a porous solution. The diluent is initially ball milled with an abrasive in a tumbler to eliminate the agglomerates and is then added to a resin monomer. A suitable catalyst is added to the mixture to create a chemical reaction, further increasing the porocity of the substance. The mixture is poured into molds and with through a filter or frit plate to remove excess resin and diluent. Finally, the mixture is cured, creating abrasive stones having a uniform surface and bulk structure with a uniform hardness, suitable for workpiece grinding.

Abstract: An abrasive material is proposed which is useful for the precision treatment of surfaces. This material may be in the form of an abrasive layer adhered by chemical and/or physical bonds to a carrier, the latter preferably made of a flexible material such as plastic. Alternatively, the abrasive material may be in the form of a free abrasive without a carrier. The abrasive material may be in the form of a vacuum condensate consisting of at last 80 atomic percent of an ultradispersed composite superhard diamond-like substance, preferably containing carbon, and including not more than 0.1 atomic percent hydrogen and oxygen, combined. The abrasive material is preferably obtained from the pulse-flows of an accelerated electroerosive plasma.

Abstract: An abrasive article having a sheet-like substrate having at least one major surface; an abrasive coating adhered to the at least one major surface of the substrate, wherein the abrasive coating comprises a plurality of abrasive particles and an organic binder medium; and, a hard carbon coating layer comprising a diamond-like carbon film. The hard carbon coating layer in the coated abrasive article can be provided as a top coat or, alternatively, as located between the abrasive coating and a covering layer based on an organic binder layer. The invention also pertains to a method of making such an abrasive article.

Abstract: In a plating process for constructing a nickel/embedded abrading particle saw blade on a saw blade substrate, the step of plating abrading particles onto and within the supporting copper substrate is disclosed. The beveled edge of a circular aluminum saw blade blank is first coated with a thin zinc layer. Thereafter, copper and abrading particles are plated followed by conventional abrading particle and nickel plating. Conventional material removal thereafter follows at the saw blade side adjacent the circular saw blade blank, saw blade edge, and copper layer. With removal of the copper layer, abrading particles originally partially embedded in the copper layer are exposed for cutting. The need for electro-polishing and garnating is eliminated in so far as exposure of abrading particles is concerned. The final saw blade product produced has uniform cutting edges on both sides with less likelihood of producing edge fractures, chips, or cracks in silicon wafers during separation.

Abstract: An abrasive construction for modifying a surface of a workpiece, such as a semiconductor wafer. The abrasive construction comprises: a three-dimensional, textured, fixed abrasive element; at least one resilient element generally coextensive with the fixed abrasive element; and at least one rigid element generally coextensive with and interposed between the resilient element and the fixed abrasive element, wherein the rigid element has a Young's Modulus greater than that of the resilient element.

Abstract: Abrasive grain including manganese oxide therein are provided. The inclusion of manganese oxide can be utilized to reduce the transition temperature of transitional alumina(s) to alpha alumina(s), during the formation of the abrasive grain. Further, manganese oxide presence can be utilized to generate sintered abrasive grain having a submicrometer, faceted microstructure. The abrasive grain are useful in abrasive articles such as coated abrasives, three-dimensional, low density abrasives, and bonded abrasives.

Abstract: An abrasive article produced by a molding process including injection molding blow molding, extrusion, and thermoforming where the article includes a thermoformable material having an abrasive grit intermixed homogeneously therein.

Abstract: A bonded abrasive grit structure which may be attached to a tool surface and a method for making a grit structure and tool therefrom. The grit structure includes a plurality of peaks which have a grit particle at the apex and are substantially the same height such that the apexes collectively define a plane. A setting matrix of preferably tungsten carbide particulate matter of high melting point surrounds the grit particle. A resin binder is dispersed throughout the structure. The binder is drivable from the structure at a first temperature. The structure is brazeable to a tool surface by infiltration of a brazing material therethrough at a second higher temperature.