Abstract: The invention provides a method of making an abrasive compact using conventional compact synthesis conditions. The method is characterized by the use of an ultra-hard abrasive particle mass comprising at least 25 percent by mass of ultra-hard abrasive particles having an average particle size in the range 10 to 100 microns, and consisting of particles having at least three different average particle sizes, and at least 4 percent by mass of ultra-hard abrasive particles having an average particle size of less than 10 microns. The abrasive compact is preferably a diamond compact.

Abstract: A spade in a bit body is disclosed to have a planar body shaped with two intersecting cutting faces. The cutting faces extend to side faces defining spade width for cutting a hole to gauge. Inserts positioned in the body are at the comer of the spade. The inserts are formed of very hard material, and provide longer life.

Abstract: A sol-gel process of producing durable alpha alumina-based ceramic particularly useful as abrasive grain from alpha alumina monohydrate is improved by the addition of a nucleating agent. Improved abrasive products containing the durable ceramic abrasive grains are also provided.

Abstract: An abrasive article having a sheet-like structure having at least one major surface having deployed thereon a plurality of individual abrasive composites, each abrasive composite comprising a plasticizer and a plurality of abrasive particles dispersed in a binder, wherein said binder is formed by polymerizing a binder precursor and said plasticizer being combined with said binder precursor prior to said polymerizing in an amount of 30 to 70 parts plasticizer per 100 parts by weight of the combined binder precursor and plasticizer. There is also a method of using such as abrasive article to reduce the surface finish of a workpiece and a process of making the abrasive article.

Abstract: An abrasive article produced by injection molding or the like, utilizing a thermoformable material with abrasive grit and secondary fillers intermixed homogeneously therein.

Abstract: The present invention provides a method of forming an abrasive article comprising the steps of providing an embossed carrier web having a plurality of recesses formed in the front surface thereof; filling the recesses with an abrasive composite slurry that includes a plurality of abrasive grains dispersed in a hardenable binder precursor, hardening the binder precursor to form individual abrasive composite members, laminating a backing sheet to the front surface of the embossed carrier web. The resulting article includes a plurality of precisely spaced abrasive composite members, positioned in a predetermined pattern and orientation on a backing sheet.

Abstract: A novel process for producing highly crystalline, fine .alpha.-alumina is disclosed. Aluminum hydroxide is calcined in the presence of fine silica powder. The obtained alumina is in the alpha form and has a specific surface area of least 10 m.sup.2 /g.

Abstract: A pad for cleaning porcelain greenware comprising an abrasive sheet for contacting and cleaning porcelain greenware; a foam backing member; and a glue secured to the abrasive sheet and to the foam backing member for securing together the abrasive sheet and the foam backing member. A process or a method for wetcleaning porcelain greenware comprising the steps of: providing a porcelain greenware; providing a container with water; providing the pad; contacting the porcelain greenware and the pad with the water; and sliding the abrasive sheet against the porcelain greenware.

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: An improved process for improving the adhesion between a cemented carbide substrate and a diamond layer deposited thereon by removing the binder phase of the cemented material from the surface of the substrate prior to diamond coating. For this purpose, the process of the invention uses an apparatus as is conventionally used in various technologies for the CVD process of diamond layers. The process parameters are here altered from those of the conventional diamond coating in such a way that binder metal is evaporated from a very narrow boundary zone of the substrate surface, utilizing the reaction heat from the recombination of previously dissociated hydrogen gas directly at the substrate surface.

Abstract: Gelled overbased materials are prepared by mixing an overbased composition of a metal salt of an organic acid material containing at least 8 carbon atoms, a metal salt of an organic acid material containing fewer than 6 carbon atoms, and a metal carbonate in an oleophilic medium, with an alcohol or an alcohol-water mixture, and heating the mixture.

Abstract: A synthetic diamond or cubic boron nitride particle is characterized by containing two or more stable isotopes of an element present in a ratio which is different to the ratio in which the isotopes exist in nature. The diamond or cubic boron nitride particle thus has a fingerprint. A preferred example of the element is nitrogen.

Abstract: A hafnium nitride coating is applied over the cubic boron nitride layer of conventional CBN tools by the process of arc physical-vapor-deposition at temperatures below the tempering temperature of the core metal. The hafnium nitride coating protects the cubic boron nitride or diamond abrasive and the core, resulting in a grinding tool with greater strength and longer life.

Abstract: An abrasive member comprising an electrically conductive or non-conductive open, porous layer comprising a nonwoven fabric supporting a metal structure which carries an abrasive material. The porous layer, at a side thereof not containing abrasive material, may be provided with a backing layer having heat conductive properties. Further, the porous layer may consist of two or more layers stacked together, at least one of these layers being a nonwoven fabric. Such an abrasive member is excellently suitable for heavy duty dry-grinding operations, such as the grinding of granite. The abrasive metal structure can be applied onto and through the porous layer by an electroplating or electro-deposition process.

Abstract: The present invention provides a method for forming uniform CVD diamond coatings on a substrate wherein diamond is deposited on a plurality of substrates which are rotated in unison during the coating process to provide for more uniform radial growth. An advantageous substrate is a wire which can be coated with a layer of CVD diamond for making components in water-jet cutting apparatus, wire-drawing dies, or other tubular articles when the wire is separated from the resulting diamond tube. Identical tubes with higher uniformity in wall thickness are among the products which can be obtained. In addition, tubes having a uniform particle size distribution along their wall thickness which supports columnar diamond growth are also provided.

Abstract: The present invention is a metal bond comprising a filler with a Vickers hardness from about 300 kg/mm.sup.2 to about 800 kg/mm.sup.2 wherein the Vickers hardness of the filler is maintained above 300 kg/mm.sup.2 upon firing of the bond at a temperature above 700.degree. C. for at least about 10 minutes. The present invention further is an abrasive tool comprising a metal core; an abrasive composition comprising diamond and the above metal bond, bonded to the metal core.

Abstract: Disclosed is a process for preparing activated compositions and the compositions derived therefrom which are suitable for polishing surfaces, particularly integrated circuits, wherein a base abrasive is activated by addition of a second cation whose oxide exhibits a higher polishing rate than the base abrasive alone. The activation is effected by chemical adsorption of the activating cation onto the base abrasive during cyclic impact in an aqueous medium whose pH is at a level which is favorable for adsorption of the activating cation onto the base abrasive surface.

Abstract: A blast media for stripping contaminants from a solid surface comprises abrasive particles and a surfactant in the form of a granular surfactant-clathrate compound formed of a surfactant and a water soluble compound having clathration capability such as urea. The surfactant reduces the amount of water soluble residues which remain on the targeted surface and enhances the removal of dirt, grease and oil from the targeted surface.

Abstract: An abrasive article comprising a plurality of abrasive particles bonded together, bonded into a substrate, or bonded onto a backing by a cured binder, the cured binder being formed by solidifying a binder precursor comprising an aqueous acrylate polymer emulsion. In preferred embodiments, the binder precursor includes a phenolic resin.

Abstract: Disclosed is a precise grinding grindstone in which the-heights of the grinding particles can be aligned even if large particles are employed. An underlying plated layer is formed on a substrate, and grinding particles are dispersed as a single layer thereon. The grinding particles are pressed toward the plated layer by a mold member and are partly pressed into the plated layer, whereby the heights of the grinding particles are aligned. Then, the particles are supported by a binding plated layer. The protrusion of the particles can be arbitrarily selected by regulating the thickness of the binding plated layer.

Abstract: A tool insert comprising an abrasive compact layer having a working surface and an opposite surface bonded to a cemented carbide substrate along an interface. At least one cemented carbide projection extends through the compact layer from the compact/substrate interface to the working surface in which it presents a matching surface. The total area of the carbide matching surface is less than that of the compact working surface. The cemented carbide projection may take the form of one or more islands, or the form of a skeleton enclosing within it a plurality of discrete abrasive compact zones or sections.

Abstract: A ceramic material for use as a cutting tool in the high speed machining of high temperature alloys and cast irons is provided with a composition of beta prime sialon (Si.sub.6-z Al.sub.z O.sub.z N.sub.8-2 ; where 1<Z<3) and intergranular phase. The material has high wear resistance and reliability when used in the high speed machining of high temperature alloys at speeds of 300 to 1500 surface feet per minute.

Abstract: A grinding material or product which may be utilized in different forms and comprises laminated layers which interlock with each other when laminated to provide greater tensile strength. Layers of the basic material are formed by sandwiching abrasive particles between two layers of pre-bonded carded fiber. One sheet of a layer is initially passed through an adhesive and later spread in a controlled fashion with abrasive particles. A second sheet of the carded fiber is passed together with the first sheet through a pair of nip rolls which compress the two sheets together with the abrasive particles therebetween and provide a first layer of adhered sheets with the abrasive particles therebetween.Subsequently, the resulting layer may be cut into sections and a plurality laminated together for a desired thickness.

Abstract: A polycrystalline diamond cutting tool comprises a tool material of polycrystalline diamond formed by low-pressure vapor deposition, which is bonded to a shank of cemented carbide through a brazing layer. The thickness of the polycrystalline diamond layer is set at 0.1 to 1.0 mm, while that of the brazing layer is set at 10 to 50 .mu.m. The brazing layer is made of a material having a melting point of 950.degree. to 1300.degree. C., which is in the form of an alloy layer containing at least one material selected from metals belonging to the groups IVa, Va, VIa and VIIa of the periodic table and carbides thereof and at least one material selected from Au, Ag, Cu, Pt, Pd and Ni. The polycrystalline diamond cutting tool is improved in heat resistance and tool strength. In order to improve deposition resistance of the cutting tool, the surface roughness of a tool rake face is set to be not more than 0.2 .mu.m in Rmax. A portion of the polycrystalline diamond layer up to a depth of 10 .mu.

Abstract: An abrasive article comprising a binder and abrasive grits, wherein the abrasive grits comprise abrasive particles having specified shapes. Coated abrasive articles of this invention comprise a backing having at least one layer of abrasive material adhered thereto by means of a binder. A portion of this layer contains abrasive particles having specified shapes. It is preferred that the geometric shape of these abrasive particles be triangular. For triangular-shaped particles, about 35% to about 65% of the particles are oriented with a vertex pointing away from the backing and a base in contact with the binder, with about 35% to about 65% of the particles being oriented with a base pointing away from the backing and a vertex in contact with the binder.

Abstract: Abrasive grains such as boron carbide, silicon carbide, alumina, diamond, cubic boron nitride, and mullite are combined with a cement primarily comprised of zinc oxide and a reactive liquid setting agent and solidified into abrasive grinding tools. Such grinding tools are particularly suitable for grinding and polishing stone, such as marble and granite.

Abstract: Synthetic diamond film produced by chemical vapor deposition can be crushed to obtain diamond grit which has useful abrasive properties. The flexibility of CVD deposition processes in determining diamond film properties means that CVD diamond grit properties can be tailored to particular abrasive applications. In a disclosed embodiment, the grit particles are coated with a magnetic material. The coated grit particles can then be aligned with a magnetic field, and the coated grit particles are bonded to a matrix while aligned. In a further disclosed form of the invention, a chemical vapor deposition system, such as an arc jet plasma deposition system, is provided in a chamber.

Abstract: Synthetic abrasive stones and method for making same. A mixture of glass and 10-20% by weight foaming agent is provided. The mixture is heated to a temperature of from 788.degree. to 899.degree. C., and is then cooled to room temperature.

Abstract: An improved earth-boring bit the rolling cone variety and an insert for use therein is provided. A superabrasive element is coated with at least one layer of metallic material. The superabrasive element then is placed in a receptacle cavity in a pre-formed hard metal jacket. The superabrasive element then is brazed or infiltrated to the hard metal jacket. Metallurgical and mechanical bonds between the superabrasive element, the at least one layer of metallic material on superabrasive element, the braze or infiltrant binder material, and the fracture-tough material of the hard metal jacket retain the superabrasive element in the cavity of the hard metal jacket. Improved earth-boring bits according to this embodiment of the present invention provide abrasion-resistant earth-boring bits of the rolling cutter variety. Such improved bits, and the inserts therefore, are formed without resort to high-temperature, high-pressure processes.

Abstract: An abrasive medium suitable for the cutting tip of a turbine blade of a gas turbine engine comprises cubic boron nitride grit coated with a layer of aluminum nitride. Coating of the grit particles is carried out by vapour deposition in a fluidised bed reaction.

Abstract: A substantially polycrystalline diamond compact cutting element for drilling subterranean formations. The cutting element includes a cemented carbide substrate having radially extending raised lands on one side thereof, to and over which is formed and bonded a polycrystalline diamond table.

Abstract: The present invention relates to whisker reinforced ceramic bodies with new and improved properties. By replacing the tool pressing with injection molding, surprisingly a more homogeneous structure and more advantageous whisker orientation has been obtained. By choosing the conditions of the molding, it is possible to control the whisker orientation to get optimal material properties. Bodies according to the invention are particularly suitable for chip forming machining of heat resistant materials.

Abstract: A non-woven abrasive material including a lofty, open, three dimensional web of non-woven fibers randomly intertwined and carrying abrasive particles and a binder material bonding the fibers together and bonding the abrasive particles to the fibers, with hydrogenated vegetable oil in solid form coating the fibers, particles and binder material at the surface of the web and within voids in the interior of the web, and preferably also with a coating of resinous plastic binder encapsulating the hydrogenated vegetable oil at the surface of the web and within its interior.

Abstract: A method of recycling a reusable composite blasting media comprising a plurality of discrete particles of an abrasive component combined with a carrier component. The method comprises the steps of collecting the recyclable composite blasting media after at least one blasting cycle, mixing at least one of additional abrasive component and additional carrier component with the collected composite blasting media, and forming the composite media into a plurality of granules each containing a plurality of discrete particles of the abrasive component and the carrier component.

Abstract: A layer of diamond formed by chemical vapor deposition (CVD) is brazed to a drill bit body to form a cutting element thereon. The ability to withstand high temperatures permits the cutting elements to be brazed using alloys requiring much higher temperatures than those used in connection with brazing convention PDC cutting elements. In an infiltrated bit, a CVD cutting element formed by chemical vapor deposition is placed in a bit mold which is thereafter filled with infiltration powder and placed in a furnace with temperature in excess of 1100.degree. Centigrade. The CVD cutting element may also be mounted on a slug or stud via brazing and the slug or stud in turn mounted on or infiltrated into the bit body or brazed thereto.

Abstract: A product and a process for producing a matrix and a tool for use in abrasive or cutting applications including a base tool structure which may be armed with a plurality of triangular or conically shaped structures 24B consisting of abrasive particles 32 bonded together in a braze metal 38. The structures 24B may be prepared in a manner which provides a selectable rake angle. Rake angles including negative 46, neutral 46' and positive 46" may be produced. The process is accomplished by diffusing magnetizable abrasive particles on a release mechanism which has been placed on a reusable fixture 10 consisting of a plurality of balls 16 secured to a magnetized surface 14. The particles 32 stack to form structures 24 which are then encapsulated in a braze paste 26. The axis of the structures 24 is aligned with the applied magnetic field. The cones are symmetrical if the magnetic field emanates perpendicularly from the magnetized surface.

Abstract: Abrasive and/or refractory products comprising at least one compound from the group of oxynitrides of one or more metals or metalloids (such as Al, Mg, alkaline earth metals, Si, Ti or Zr) and obtained by melting and solidification.

Abstract: Synthetic abrasive stones and method for making same. A mixture of glass and 10.5-28% by weight foaming agent is provided. The mixture is heated to a temperature of from 765.degree. to 960.degree. C., and is then cooled to room temperature.

Abstract: A trace amount of a polytetrafluoroethylene resin is incorporated with an abrasive pigment prior to or during the preparation of an aqueous pigment slurry or is applied to dry pigment to reduce the abrasivity of the pigment. The treated pigment can be employed in the manufacture of filled and coated paper.

Abstract: A sintered polycrystalline compact of cubic boron nitride is made by first forming a mixture of about 30 to 60 percent by weight cubic boron nitride, up to about 50 percent by weight hexagonal boron nitride, and from about 2 to 7 percent by weight adjuvant materials, or sintering aids, comprising an aluminum containing material selected from the group consisting of aluminum, aluminum nitride, or aluminum diboride, and up to 50 percent by weight of nitride, carbide, or carbonitride binder material containing a group IVb, Vb, or VIb transition metal. The mixture of cBN crystals, hBN and other materials is compacted into a preform and subjected to heat treatment in a non-oxidizing atmosphere. The preform is placed onto a cemented tungsten-carbide/cobalt substrate and subjected to elevated pressure and temperature conditions at which cubic boron nitride is thermodynamically stable.

Abstract: A blast media for stripping contaminants from a substrate comprises abrasive particles which are formed by agglomerating fine particles of sodium bicarbonate with an aqueous binder solution of sodium carbonate to form composite particles of sodium bicarbonate and sodium sesquicarbonate which is formed by the reaction of the bicarbonate with the carbonate in solution.

Abstract: A method of forming abrasive grinding wheels includes the steps of preheating abrasive grains, an open circular mold and liquid epoxy binder, to a temperature below the curing temperature of the binder and at which the binder has relatively low viscosity. The binder is placed in the mold and the mold is rotated, or the mold is held stationary and grains are added from a moving delivery source. The abrasive is added along a radian with respect to an axis of the mold. The rate of the addition of the abrasive grains and the rotational speed of the mold or delivery source are controlled such that abrasive grains added during a prior rotation submerge in the binder by the time the mold or delivery source again reaches the area where more grains are added. After the binder is suitably filled with abrasive, the wheel is cured by heating and the solid mass removed from the mold and trimmed to size, removing any skin of excess binder.

Abstract: A honing tool characterized in one form by an elongated rectangular cup element or holder having a bottom interior surface, a bundle of closely packed relatively short discrete generally parallel abrasive containing filaments secured in the holder, and a layer of instant gel adhesive securing all of the filaments at one end face of the bundle to the bottom interior surface of the holder. To make such a honing tool, a measured bundle of uniformly closely packed nonwoven, generally parallel discrete filaments is formed. A holder is supported and a measured amount of gel adhesive is placed in the bottom interior of the holder so that a layer of such adhesive completely covers the bottom of the interior of the holder. The bundle is then promptly driven into the holder so that all of the filaments at one end of the bundle are in contact with the adhesive prior to the curing of the adhesive. The adhesive is then cured.

Abstract: An abrasive article comprising abrasive elements dispersed in a binder matrix, the abrasive elements comprising individual particles of abrasive material, substantially all of which are partially embedded in a metal binder. The abrasive particles, when introduced into an electrolyte bath only during the final stages of an electrodeposition process, are embedded only on a major surface of the metal binder. Methods of making the abrasive elements and the abrasive articles are also presented as aspects of the invention.

Abstract: Chemical-mechanical polishing methods are disclosed for removing insulating inorganic metal oxide materials from semiconductor wafers. Such utilize aqueous acids or base slurries having a pK ionization constant of less than or equal to 5.0. Alternately, aqueous slurries having an oxidizing agent with an E.degree. reduction potential of greater than or equal to 1.0 volt are utilized. Further alternatively, non-aqueous slurries having a liquid halogenated or pseudohalogenated reactant are utilized. Further, slurries having an organic ligand precursor are utilized.

Abstract: A dicing blade is formed by plating a composition of diamond particles and silicon carbide whiskers suspended in a nickel solution upon an aluminum hub. To obtain bonding rather than capturing of the diamond particles, nickel coated diamond particles may be used to form an inter-metallic bond between the coated diamond particles, the silicon carbide whiskers and the nickel matrix.

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: The present invention relates to an abrasive article comprising:(a) a flexible substrate having a front side and a back side;(b) at least one layer of abrasive grains bonded to said front side of said substrate by means of a make coat;(c) optionally one or more additional coats selected from the group consisting of a size coat, a supersize coat, a saturant coat, a presize coat, and a backsize coat;wherein at least one of said make, size supersize, saturant, presize, and backsize coats comprises a maleimide binder. The invention also relates to a method of making the abrasive articles.

Abstract: An abrasive tool such as a grinding wheel or a saw is characterized by the working portion comprising a mass of ultra-hard abrasive particles dispersed in a non-porous thermoplastic polymer matrix. Examples of suitable thermoplastic polymers are polyetheretherketone, polyaryletherketone, poly (amide-imide), polyphenylene sulphide, liquid crystal polymer and mixtures thereof.

Abstract: Super-hard grinding particles are electrodeposited on a metallic grinder matrix having recessed portions defined in an outer peripheral surface thereof to thereby produce a desired grinder used for a grinding machine. The grinder matrix is disposed within a mesh-like grinding-particle holder provided in a plating tank. Further, the grinding particles are packed into the grinding-particles holder. The grinding particles held in contact with the recessed portions of the grinder matrix are bonded to the grinder matrix using a plating layer formed by electroplating. The grinder matrix is reversed upsidedown and holding the grinding particles in contact with the recessed portions of the reversed grinder matrix. The grinding particles are bonded again to the grinder matrix using a plating layer formed by electroplating.