Methods of maximizing retention of superabrasive particles in a metal matrix

Inactive Publication Date: 2006-09-28
SUNG CHIEN MIN
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0012] Accordingly, the present invention provides superabrasive tools having improved superabrasive particle retention, and methods of making such tools. As such, in one aspect a method is provided for making a superabrasive tool having improved retention of superabrasive particles in a metal matrix. Such a method may comprise providing a substrate, providing superabrasive particles, chemically bonding the superabrasive particles with the metal matrix to a degree which holds the superabrasive particles in the metal matrix without substantially degrading the superabrasive particles, and metallurgically bonding the superabrasive particles to the substrate with the metal matrix. Various methods of avoiding substantially degrading the superabrasive part

Problems solved by technology

A problem with maintaining the top of the pad is caused by an accumulation of polishing debris coming from the work piece, abrasive slurry, and dressing disk.
This accumulation causes a “glazing” or hardening of the top of the pad, and mats the fibers down, thus making the pad less able to hold the abrasive particles of the slurry, and thus significantly decreases the pad's overall polishing performance.
Further, with many pads the pores used to hold the slurry become clogged, and the overall asperity of the pad's polishing surface becomes depressed and matted.
However, because the matrix surrounding the superabrasive particles is softer than the superabrasive particles, it wears away more quickly during use, and leaves the diamond particles overexposed, and unsupported.
As a result, the diamond particles become prematurely dislodged and shorten the service life of the tool.
Such processes, however, may be difficult for a variety of reasons, including the highly inert nature of most superabrasive particles, and the high melting point of most reactive materials.
Moreover, while chemically bonding the superabrasive particle to the matrix material via carbide bonds creates a much stronger relationship between the superabrasive particle and the matrix material, the carbide materials formed are not as strong as the superabrasive materials, thus potentially decreasing the integrity of the

Method used

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  • Methods of maximizing retention of superabrasive particles in a metal matrix
  • Methods of maximizing retention of superabrasive particles in a metal matrix
  • Methods of maximizing retention of superabrasive particles in a metal matrix

Examples

Experimental program
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Example

Example 1

[0110] Diamond particles of 40 / 50 mesh were covered with a thin film of an acrylic binder.

[0111] The binder covered diamond was then mixed with a powdered metallic alloy containing B, Ni, Cr, Si, having an average particle size of about 325 mesh, and sold under the trade name NICHROBRAZ LM® (Wall Colomnoy). The result was a braze powder wrapped diamond. These coated particles were then mixed with fine powder of Al2O3. The mixture was heated in a vacuum furnace held at 10−5 torr to a maximum temperature of about 1005° C. for approximately 17 minutes to assure that the metallic alloy coating became molten and liquefied and flowed around the diamond particles wetting them. The mixture was then cooled and retrieved from the furnace. After separating the diamond particles from Al2O3, a number of coated particles were mixed with a cobalt powder and sintered in a hot press to form rectangular segments. Some of these segments were broken by bending with pliers. The fractured surf...

Example

Example 2

[0112] The same procedure as outlined in Example 1 was followed, but the Al2O3 separator powder was replaced with diamond particles having an average mesh size of from about 325 to about 400 mesh. During the heating process, the smaller diamond particles were wetted by the braze alloy coating, and became chemically bonded to the outside of the coated diamond particle. Thus, coated diamond particles having a chemically bonded metallic alloy shell with smaller diamond particles further bonded to the outside of the shell were produced. These “spiky” coated particles were incorporated into a cobalt matrix and fracture tested as above with similar results achieved.

Example

Example 3

[0113] The process of Example 2 was followed, but the smaller diamond particles were replaced with particles of SiC. The process yielded a coated diamond particle having ceramic particles bonded to the outside of the metallic coating similar to the diamond particles of Example 2. Moreover, the fracture testing yielded results similar to that of Examples 1 and 2.

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Abstract

Methods of making superabrasive tools having improved retention of superabrasive particles in a metal matrix are provided. Such methods may include providing a substrate, providing superabrasive particles, chemically bonding the superabrasive particles with the metal matrix to a degree which holds the superabrasive particles in the metal matrix without substantially degrading the superabrasive particles, and metallurgically bonding the superabrasive particles to the substrate with the metal matrix.

Description

PRIORITY DATA [0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11 / 223,790, filed Sep. 8, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 11 / 009,370, filed Dec. 9, 2004, which is a continuation-in-part of U.S. patent application Ser. No. 10 / 627,441, filed Jul. 25, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10 / 254,057, filed Sep. 24, 2002, which has issued as U.S. Pat. No. 6,830,598, each of which is incorporated herein by reference.FIELD OF THE INVENTION [0002] The present invention relates to devices that incorporate superabrasive materials, and methods for the production and use thereof. Accordingly, the present invention involves the fields of chemistry, physics, and materials science. BACKGROUND OF THE INVENTION [0003] Various industries use chemical mechanical planarization (CMP) for polishing certain work pieces. Specifically, the computer manufacturing industry has begun to rely heavi...

Claims

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Application Information

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IPC IPC(8): B24D3/02B22F1/17B24B1/00B24D3/00B24D18/00B24D99/00C09K3/14C22CE21B10/00
CPCB22F1/025B22F2005/001B22F2998/10B24D3/08B24D18/00C09K3/1445C22C26/00B22F1/0059C22C1/05B22F3/10B22F1/17
Inventor SUNG, CHIEN-MIN
Owner SUNG CHIEN MIN
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