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.

Abstract: A titanium nitride coating (or equivalent metal or alloy) is applied over the abrasive surface of conventional CBN and diamond tools by the process of physical vapor deposition at temperatures below the tempering temperature of the core metal and below the temperature at which the difference between the coefficients of expansion of the substrate and of the abrasive causes stresses that damage the bond between them. Specific operating conditions are required during the deposition process in order to ensure the proper level of adhesion of the titanium nitride layer to the underlying material. Under these conditions, the process does not affect the integrity of the steel core of the grinding tool and the titanium nitride or equivalent coating stabilizes and reinforces the existing bond between the cubic boron nitride or diamond and the core, resulting in a grinding tool with greater efficiency and longer life.

Abstract: Processes for making coated cubic boron nitride abrasive particles for use in grinding wheels are provided having thick multilayer metal coatings which improve retention of the particles within abrasive tools. The metal coatings comprise a primary metal layer chemically bonded to the surface of the abrasive particles and a secondary layer which forms the bulk of the coating. Coated CBN abrasive particles, abrasive tools made therefrom and processes for their production are also provided.

Abstract: Surface treating articles having varying degree of smear-resistance and their methods of manufacture are presented. One preferred article is characterized by an organic matrix substantially engulfed by a novel, tough, adherent elastomeric resinous binder system comprising the reaction product of either(1) a polyurethane prepolymer, or(2) a polyurethane polymer emulsion with an epoxy-functional material and an amine-functional material in an aqueous system.

Abstract: A coated abrasive article comprising a backing bearing on at least one major surface thereof abrasive composites comprising a plurality of abrasive grains dispersed in a binder. The binder serves as a medium for dispersing abrasive grains, and it may also bond the abrasive composites to the backing. The abrasive composites have a predetermined shape, e.g., pyramidal. The dimensions of a given shape can be made substantially uniform. Furthermore, the composites are disposed in a predetermined array. The predetermined array can exhibit some degree of repetitiveness. The repeating pattern of a predetermined array can be in linear form or in the form of a matrix.

Abstract: A sintered product useful for abrasion- and impact-resistant tools and the like is provided comprising an iron-group metal binder and refractory metal carbide particles, e.g. tungsten carbide, formed in situ during sintering by the exothermic reaction of a carbide-forming refractory metal powder with a carbon source mixed therewith. The sintering is carried out at an elevated temperature and at a pressure at which diamond is stable in the presence of a liquid phase comprised substantially of an iron-group binder metal, refractory metal, and dissolved carbon. The product may optionally contain diamond, up to about 95% in volume, enabling its properties to be tailored for a wide range of applications.

Abstract: A cutting insert for a rotary cutting tool comprises a body of tungsten carbide, with layers of polycrystalline diamond on opposite sides of the body. The diamond layers overlap across the centre-line of the insert. The cutting insert is shaped for retention at the end of the rotary cutting tool so that the first and second sides of the cutting insert are substantially parallel to the axis of the cutting tool, and the diamond layers are offset from one another across the width of the body so that they define the lips or major cutting edges of the cutting tool.

Abstract: The invention is directed to cubic boron nitride (CBN) particles coated with a thin inner layer formed by the reaction of a reactive glass or ceramic to form a chemical bond and, optionally, an outer layer of a vitreous material. The particles are useful as abrasive particles in a vitreous bonding matrix. In addition, a method of preparing the particles and abrasive tools containing the particles are encompassed.

Abstract: A method is provided for producing a tool component which comprises a CVD diamond layer bonded to a cemented carbide substrate. The method includes the steps of providing a mass of carbide particles bonded into a layer with an organic binder, removing the organic binder to produce a porous mass of the particles, depositing a layer of diamond by CVD on a surface of the porous mass, placing the porous mass in contact with a layer of binder metal particles bonded with an organic binder, and heating the product to allow the metal binder particles to melt and infiltrate the carbide particles and produce a cemented carbide substrate for the CVD diamond layer.

Abstract: An abrasive compact comprising 40 to 90 volume percent of cubic boron nitride (CBN) crystals bonded by 60 to 10 volume percent of a bonding matrix comprised mainly of an intimate mixture of silicon nitride and metallic diboride MB.sub.2 where M represents metal atoms chosen from the group of titanium, zirconium and hafnium atoms. The compact may be produced by a method which comprises intimately mixing particulate CBN crystals with a bonding agent in the proportion 95 to 60 volume percent of CBN and 5 to 40 volume percent of bonding agent, the bonding agent containing the metal atoms in the atomic proportions Si.sub.30 M.sub.70 to Si.sub.85 M.sub.15, subjecting the mixture of CBN crystals and bonding agent to temperatures in the range 900.degree. to 1800.degree. C. and pressures in the range 5 to 70 Kilobars, and maintaining the temperature and pressure conditions for a period of at least about 30 seconds, sufficient to cause most of bonding agent to form the bonding matrix.

Abstract: Abrasive filaments made of a composition which comprises 95-70 vol.% of a polyvinylidene fluoride resin, whose inherent viscosity (.eta..sub.inh) ranges from 0.9 to 1.4, and 5-30 vol.% of abrasive grains. They are produced by melt-spinning the composition and then stretching the resultant filaments at a draw ratio of 2.5 times-5.5 times within a temperature range of 100-200.degree. C.

Abstract: A novel platey alumina with essentially no aggregates, fines or fragments has been obtained. This product proves very advantageous in lapping substrate wafers for microelectronic applications. A process for making such products is also described.

Abstract: A cutting body is formed of compacted powder and has a lower side provided with a recess and a spaced protrusion. The body can be used as a cutting insert, or two identical such bodies can be sintered together to form an invertible cutting insert. Voids can be formed within the insert to contain sensors or conduct cooling fluid.

Abstract: Bonded abrasive compositions, articles incorporating same, and methods of making the compositions and articles are presented, the compositions comprising abrasive particles dispersed throughout and adhered within an elastomeric polyurea matrix. The polyurea matrix is formed from the polymerization reaction product of a polyfunctional amine and an isocyanate. The compositions exhibit excellent smear- and wear-resistance, and may be attached to a variety of backings. One preferred backing is integrally molded to the bonded abrasive composition.

Abstract: The present invention is directed to rotary drill bits and blanks which retain polycrystalline diamond or CBN compacts, but which do not suffer from disadvantages attendant by prior drill designs. The inventive rotary drill bit has a slot within the head thereof which slot has brazed therein with a brazing alloy preferably having a liquidus greater than 700.degree. C. an unsupported thermally-stable polycrystalline diamond or CBN compact. The drill bit is made in another aspect of the invention by forming a slot in the head of the rotary drill and then brazing an unsupported thermally-stable polycrystalline diamond or CBN compact therein with a brazing alloy preferably having a liquidus greater than 7000.degree. C. For present purposes, polycrystalline diamond and CBN compacts are termed "thermally stable" by being able to withstand a temperature of 1200.degree. C. in a vacuum without any significant structural degradation of the compact occurring.

Abstract: An abrasive composition and dental articles made from same, the composition including abrasive particles dispersed throughout and entrapped within a polyurea or polyurethane urea matrix which contains soft and hard segments wherein the matrix is made from the polymerization reaction of a polyfunctional amine and a polyfunctional isocyanate. The abrasive dental articles include prophylactic cups and polishing wheels, points and discs.

Abstract: A sintered polycrystalline compact of cubic boron nitride is made by forming a mixture of about 45 to 65 percent by weight cubic boron nitride (cBN), from about 30 to 45 percent by weight hexagonal boron nitride (hBN), and from about 2 to 7 percent by weight an aluminum containing material, preferably aluminum nitride, and cobalt aluminide having a melting temperature lower than the melting temperature of cobalt phase. The mixture of cBN crystals, hBN and adjuvant materials is compacted into preforms and subjected to heat treatment in a non-oxidizing atmosphere. The preforms are placed onto a cemented tungsten carbide substrate containing cobalt and subjected to elevated pressure and temperature conditions at which the boron nitride is thermodynamically stable. The elevated pressure and temperature conditions are maintained for a time sufficient to permit the infiltration of a cobalt phase into the cBN matrix and sinter the compact.

Abstract: A process for manufacturing an abrasive tape comprising the steps of preparing a coating solution by mixing, as main constituents, abrasive grains, a binder, and a solvent, applying this coating solution on a substrate and drying the coating, and curing the binder, wherein the binder used in preparation of the tape as its essential components either:I. (a) a polymer having repeating units of the formula ##STR1## and having a number average molecular weight of 1,000 to 5,000 (b) a polyester resin containing in its molecule a condensate of an aromatic dicarboxylic acid or an aliphatic dicarboxylic acid or an aromatic dicarboxylic acid and an aliphatic dicarboxylic acid, and an aliphatic diol and having a number average molecular weight of 10,000 to 30,000 terminal OH groups and a glass transition point (Tg) of -20.degree. C. to 40.degree. C., and(c) a polyfunctional isocyanateII.

Abstract: Coatable mixtures including erodable filler agglomerates, and abrasive articles into which they may be incorporated are presented, the agglomerates comprising a plurality of individual grains of water insoluble filler agglomerated by an agglomerating agent which includes water soluble filler and a binder. A preferred water soluble filler is Al.sub.2 (SO.sub.4).sub.3.14-18H.sub.2 O, a preferred water insoluble filler is Na.sub.3 AlF.sub.6 (cryolite), while a preferred binder is a phenolic resin. Methods of making coatable mixtures including erodable filler agglomerates are also presented.

Abstract: Using a treating solution which is easy to dispose after use, the surface of a plastic material is treated so that the treated surface has good adhesion to a coating film to be formed thereon. An aqueous dispersion containing an abrasive which is harder than a plastic material to be surface-treated, is pressurized to about 1.0-200 kg/cm.sup.2 and then is injected onto the surface of said plastic material through an injection nozzle. An airless spray gun having said injection nozzle is supported by a polyaxis type or articulated type robot. Thus, the surface of a plastic material is ground and converted into a rough surface and then coatings are applied thereon.

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: This invention relates to a composition comprising: water; particulate abrasive dispersed in said water, said abrasive having a Knoop scale hardness of at least about 1000 and an average particle size of from about 1 micron up to a U.S. Sieve Series Number of about 50; and an effective amount of at least one thickener to maintain a stable dispersion of said abrasive in said water. The inventive composition can contain one or more surfactants and/or one or more chelating agents. In one embodiment the invention provides for a water-based polish that can be used on any nonporous surface (e.g., glass, plastic, metal, painted surfaces, waxed surfaces, marble, ceramic, soft-precious and semi-precious stones, semi-conductor materials, metallurgical and geological specimens, Formica, etc.).

Abstract: An abrasive composition for use in polishing or planarizing the surface of a work piece is provided comprising about 30 to 50 percent of cerium oxide; about 8 to about 20 percent of fumed silica and about 15 to about 45 percent of precipitated silica. Methods using the composition to polish or planarize the surfaces of work pieces, as well as products produced by such methods, are also provided.

Abstract: The invention relates to polycrystalline, sintered abrasive granules based on .alpha.-Al.sub.2 O.sub.3 with a density of >98% of the theoretical density of corundum, a Vickers hardness of 21 GPa and greater and a crystallite size of 0.05 to 1.3 micron, as well as abrasives made from these abrasive granules and the use of these abrasive granules for the production of ceramic, refractory products.The polycrystalline, sintered abrasive granules based on .alpha.-Al.sub.2 O.sub.3 are produced by .alpha.-Al.sub.2 O.sub.3 crystal nuclei being added to a boehmite dispersion, the mixture of the boehmite dispersion and the crystal nuclei being acidified and gelled and the gel being dried, crushed, and sintered. In doing so, 0.5 to 35% by weight of .alpha.-Al.sub.2 O.sub.3 crystal nuclei, relative to the sintered abrasive granules, is added and the mixture of the boehmite dispersion and of the crystal nuclei is refluxed, while the pH of the mixture is kept in a range of 2.5 to 3.5 by adding acid.

Abstract: A granular abrasive material is produced from a dispersion consisting of raw materials containing alumina, compounds containing silica and other additives. The dispersion is ground to a sinterable slip with a grain size of less than 1 micrometer. The slip is dried and may be pressed before being subjected to a multi-stage heating process to produce sintered corundum crystals.

Abstract: A method for preparing a coated abrasive article wherein the a plurality of abrasive grains are applied to a make coat such that the abrasive grains are substantially a mono-layer. The make coat precursor is a pressure-sensitive adhesive-like or pressure-sensitive adhesive. The make coat precursor is partially cured to approximate a pressure-sensitive adhesive-like layer or when fully cured is a pressure-sensitive adhesive. The make coat precursor has sufficient "tack" to hold the abrasive grains during the application and curing of the size coat, resulting in a substantially monolayer of abrasive grains.

Abstract: A sheet of coated abrasive material including a backing having abrasive on one surface and loops projecting from its other surface by which the sheet of coated abrasive material can be held by hooks on the support surface of a pad. The backing comprises a polymeric bonding layer defining its rear surface. The sheet of coated abrasive material comprises a nonwoven sheet of longitudinally oriented fibers having anchor portions bonded in the polymeric bonding layer at spaced bonding locations, and arcuate portions projecting from the rear surface of the backing between the bonding locations to provide the loops.

Abstract: Bonded abrasive articles and methods of making and using same are presented, the bonded abrasive articles comprising abrasive particles dispersed throughout and adhered within an elastomeric polyurethane binder, at least a portion of the abrasive particles adhered to the polyurethane binder by a silane coupling agent. The silane coupling agent is preferably coated onto the abrasive particles before they are mixed with the uncured polyurethane resin. The articles of the invention exhibit excellent smear- and wear-resistance and provide improved abrasion efficiency.

Abstract: Multi-layer coated diamond abrasive particles which exhibit good retention in abrasive tools and are simpler to manufacture are provided, wherein the coating comprises a single homogenous, carbide forming metal primary layer, preferably of chromium, and at least one non-carbide forming secondary layer, preferably of nickel, iron, cobalt, or alloys thereof. The primary layer is preferably applied so as to chemically bond to the surface of the diamond abrasive particles without sintering following deposition by using chemical vapor deposition or packed salt bath deposition.

Abstract: A process using predetermined magnetic lines of flux to position, orient, and retain abrasive particles having a magnetic conductive coating thereon to a substrate surface for bonding to the surface by suitable electro-plating or other plating processes. The process allows use of high aspect ratio abrasive particles to produce desirable cutting, grinding, and sanding characteristics in a wide variety of tools such as saws, knives, abrasive drums, lapidary disks, and sandpaper, which are also part of the invention. Since the positioning of the abrasive particles can be controlled, various desirable patterns thereof can be produced on substrates of various shapes and sizes especially when the substrate is non-magnetic.

Abstract: A method of producing a composite diamond abrasive compact includes the steps of forming an unbonded assembly comprising a cemented carbide body, a layer of catalyst metal on a surface of the carbide body, a layer of carbide particles, alone or in admixture with other particles, on the catalyst metal layer, and a layer of diamond particles on the carbide layer and subjecting the unbonded assembly to conditions of elevated temperature and pressure at which diamond is crystallographically stable to form a composite diamond abrasive compact.

Abstract: Alumina-zirconia lapping abrasives containing tetragonal zirconia at a rate of 30% or less and optionally containing at least one oxide selected from the group consisting of yttrium oxide, calcium oxide, magnesium oxide, titanium oxide and other rare earth oxide in the form of solid solution, which are produced by fusing alumina-zirconia abrasive materials, quenching fused materials to obtain an ingot, crushing the ingot and subjecting the crushed ingot to a heat treatment at a higher temperature than the phase transition temperature of zirconia.

Abstract: A process is described for the production of bonded abrasive products in which the abrasive particles are filamentary alumina particles with a substantially uniform cross-section and an aspect ratio of at least about 1:1.

Abstract: A peripheral surface of an annular shaped grinder is distributed with grinding particles. The grinding particles have a particles distribution such that the spacing between the grinding particles in the axial direction is less than 2/3 of the mean diameter of the particle and that the spacing between grinding particles in the circumferential direction is about 5-80 times of the mean particle diameter. The grinder is manufactured by a method of forming a pattern of an adhesive layer on a synthetic resin sheet, fixing the grinding particles to the patterns and laminating the sheets with fixed particles.

Abstract: An abrasive suspension for wet honing for surface treatment of an electrically conductive substrate for an electrophotographic photoreceptor, the suspension comprising pure water having suspended therein at least 20% by weight, based on the total weight of the abrasive suspension, of an abrasive and having an electrical conductivity of not more than 10 .mu.s/cm. A conductive substrate having its surface roughened by using the abrasive suspension is free from impurities.

Abstract: A sintered material, especially usuable as an abrasive, based on .alpha.-aluminum oxide is produced from Al(OH).sub.3 or aluminum oxide calcined at a lower temperature. Aluminum hydroxide resulting in the Bayer process can be used as the Al(OH).sub.3. The sintered material is distinguished by a crystallite size of standard <0.5 .mu.m, high density and great hardness.

Abstract: A composite media comprising a plurality of discrete particles of an abrasive component mixed with and attached to a carrier component. The abrasive component and the carrier component are selected to provide desired wear of the composite media, during use, to expose additional underlying abrasive material and to enhance cleaning of the surface being treated. The composite media facilitates feeding of the blasting media and results in deeper penetration of the blasting media into the surface being treated. A method for forming the mixture of the composite media is also disclosed.

Abstract: Multi-layer coated diamond abrasive particles having improved wear performance in abrasive tools are provided, wherein the coating comprises a single homogenous, carbide forming metal primary layer, preferably of chromium, and at least one non-carbide forming secondary layer applied by electroless deposition, preferably comprised of nickel/phosphorus or cobalt/phosphorus.

Abstract: A one-piece abrasive sheet and method of manufacture. The abrasive pad has a planar sheet portion with a plurality abrasive protrusion extending therefrom. The protrusions are intimately molded with the planar sheet portion to form a one-piece sheet. Thermoplastic and abrasive grit mixture may be used to form the sheet. The resulting pad has improved durability.

Abstract: Coated abrasive grains and a manufacturing method for them are disclosed. The abrasive grains are coated using an immersion method with a coating comprising at least one substance selected from carbides, borides, and nitrides of a metal, comprising: preparing an immersion bath comprising a molten salt bath containing said metal; and immersing abrasive grains to be treated in said immersion bath for a suitable length of time.

Abstract: A mechanochemical polishing abrasive and a process for using the mechanochemical polishing abrasive to polish the surface of a hardened workpiece cheaply and efficiently. The mechanochemical polishing abrasive comprises a slurry of colloidal silica and a mechanical abrasive selected from one or more of the materials in the group comprising Fe.sub.2 O.sub.3, Fe.sub.3 O.sub.4, MgO, BaCO.sub.3, CaCO.sub.3, MnO.sub.2, CeO, SiO.sub.2, CeO.sub.2, Cr.sub.2 O.sub.3, and Al.sub.2 O.sub.3.

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. As the mold is rotated the abrasive is added along a radian with respect to an axis of rotation of the mold. The rate of the addition of the abrasive grains and the rotational speed of the mold are controlled such that abrasive grains added during a prior rotation submerge in the binder by the time the mold again reaches the radian 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. The method produces grinding wheels having low porosity, excellent balance and grinding characteristics.

Abstract: An abrasive sheet having a high flexibility, mechanical strength and heat resistance, comprises (A) a matrix comprising an aromatic polyimide resin and (B) abrasive grains having an average size of 65-150 .mu.m and evenly dispersed in an amount of 2 to 50% by weight in the matrix, and is produced by forming a thin liquid layer from a dispersion comprising an aromatic polyamic acid solution with a rotation viscosity of 3000 to 6000 poises at 30.degree. C. and the above-mentioned abrasion grains dispersed in the solution, and dry-solidifying the liquid layer of the dispersion while imidizing the aromatic polyamic acid to a corresponding aromatic polyimide, the abrasive sheet having a thickness of 1.1 to 3.0 times the average size of the abrasive grains.

Abstract: A grinding or separating tool has a base body with a synthetic plastic max and a plurality of reinforcing fibers, a working coating a plurality of hard grains, and an intermediate layer applied on the base body and located between the base body and the working coating so that the fibers of the base body extend outwardly beyond the plastic matrix of the base body and are embedded in the intermediate layer.

Abstract: The present invention provides an abrasive article that has abrasive composite members secured firmly in recesses in a backing sheet in a precise pattern whereby there is desired lateral spacing between each abrasive composite member. The present invention also provides a method for preparing the abrasive article comprising the steps of providing an embossed backing sheet having a plurality of recesses in the front surface of the backing sheet. The recesses are filled with an abrasive slurry that includes a plurality of abrasive grains dispersed in a binder precursor. An expanding agent is also provided in the recesses, either separate from the slurry or dispersed in the slurry. The expanding agent, when activated, expands the abrasive slurry outward and above the front surface of the embossed backing sheet. After the binder precursor of the abrasive slurry is hardened, individual abrasive composite members extend above the front surface of the embossed backing sheet.

Abstract: A sol-gel alumina abrasive grain with valuable grinding characteristics is obtained by inducing microcracking in the grain surfaces.

Abstract: An .alpha.-alumina-based ceramics material comprising crystals of a particle diameter of no greater than 0.2 .mu.m on an average or a particle diameter of substantially no greater than 0.2 .mu.m, and having a density of no lower than 95% of the theoretical density and a hardness of no lower than 2,000 kg/mm.sup.2, and a method for the production thereof.

Abstract: An abrasive article is provided, the article including a substrate having an abrasive surface thereon including particles of an abrasive material secured by a binding medium wherein at least a portion of the abrasive surface has thereon a coating including a crosslinked siloxane. Methods of making and using such an articles are also presented.

Abstract: Disclosed are abrasive wiping articles, e.g., nonwoven, preferably paper towels, which comprise an absorbant nonwoven substrate having printed thereon a cured scrubbing bead mixture which comprises a) certain carboxylated, ionically-charged polymeric abrasive particles, b) a carboxyl group-containing polymeric adhesive material, and c) an amino-epichlorohydrin, e.g., Kymene.RTM., cross-linking agent. The polymeric abrasive particles range in size from about 20 to 400 microns and have a Knoop hardness of from about 4 to 25. The polymeric adhesive material, upon curing, has a Knoop hardness of from about 0.5 to 17.Preferred wiping articles of the foregoing type have a pattern of the scrubbing bead mixture printed onto from about 20% to 70% of the surface area of a paper substrate with the abrasive particles affixed to the substrate in such a manner that their exposed portion extends for a distance of from about 40 to 300 microns above the surface of the paper substrate.

Abstract: An improved abrasive grain comprising the sintered product of a porous non-sintered particle having a coating of inorganic material thereon is provided. A preferred method of making such abrasive grains comprises coating the porous base particles with inorganic particles. The preferred step of coating comprises a step of mixing the base particles with a suspension containing the inorganic particles in a carrier fluid. The porous base particles having the coating of inorganic particles thereon are sintered, to generate the ceramic abrasive grain product. The abrasive grains may be incorporated, to advantage, in a variety of abrasive products including for example bonded abrasives, nonwoven abrasive products and coated abrasive products.