Abrasive article and method of use

Abstract

An abrasive article comprising a body comprising abrasive particles contained in a metal bond material comprising nickel, tin and copper wherein a total content of tin is not greater than 55 wt% wherein the metal bond comprises a first phase (P1) and a second phase (P2) and wherein the ratio of P1:P2 is not greater than 2.5.

Description

[0001] ABRASIVE ARTICLE AND METHOD OF USE

[0002] TECHNICAL FIELD

[0003] The following is directed to an abrasive article for use with grinding wheels, and particularly abrasive segments for use with segmented grinding wheels.

[0004] BACKGROUND ART

[0005] A variety of abrasive tools have been developed over the past century for various industries for the general function of removing material from a workpiece, including for example, sawing, drilling, polishing, cleaning, carving, and grinding. In the production of electronic devices, the surface of a wafer may be ground to prepare for the deposition of electronic devices thereon. Additionally, the back surface of the wafer may be ground after the formation of electronic devices and prior to dicing. Generally, the article utilized to conduct certain grinding processes are grindstones, which typically include abrasive segments.

[0006] The industry continues to demand improved grindstone materials, capable of achieving improved grinding performance.

[0007] SUMMARY

[0008] According to one aspect, an abrasive article comprises a body comprising abrasive particles contained in a metal bond material comprising nickel, tin, and copper; wherein the metal bond comprises a coppertin ratio of at least 0.30: 1 and not greater than 0.45: 1 and a total content of tin of not greater than 55 wt% wherein the body further comprises a SiC Removal Factor of at least 60 microns.

[0009] In another aspect, an abrasive article comprises a body comprising abrasive particles contained in a metal bond material comprising nickel, tin and copper wherein a total content of tin is not greater than 55 wt% wherein the metal bond comprises a first phase (Pl) and a second phase(P2) and wherein the ratio of Pl :P2 is not greater than 2.5.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

[0012] FIG. 1 includes a flow chart illustrating a method of forming an abrasive article in accordance with an embodiment. FIG. 2 includes an illustration of a cross section of a body of an abrasive article according to an embodiment.

[0013] FIG. 3 includes a cross section of a body of an abrasive article according to an embodiment.

[0014] FIG. 4A includes a perspective view of an abrasive article including a base having abrasive segments in accordance with an embodiment.

[0015] FIG. 4B includes a top view of an abrasive article including a base having abrasive segments in accordance with an embodiment.

[0016] FIG. 5 includes an example of the segmentation process for measuring porosity of a sample according to an embodiment.

[0017] FIG. 6 includes a top view of an abrasive article including a base having abrasive segments in accordance with an embodiment.

[0018] The use of the same reference symbols in different drawings indicates similar or identical items.

[0019] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0020] The following description in combination with the figures is provided to assist in understanding the teachings provided herein. The following disclosure will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.

[0021] As used herein, the terms “comprises,” “comprising,” ’’includes,” “including,” ’’has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0022] Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.

[0023] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.

[0024] The following relates to bonded abrasive articles or tools, such as grinding wheels, grinding segments, grinding discs and hones, having certain compositional structures, methods of manufacturing such tools so as to create particular tool structures, and to methods of grinding, polishing or surface finishing using such tools. In particular, the description is directed to abrasive articles, particularly abrasive segments, for use with grinding wheels for finishing of surfaces. The abrasive articles herein incorporate abrasive segments having particular designs, which may facilitate improved grinding performance of the abrasive article and improved post-finishing properties of the workpiece. Notably, the abrasive articles described herein may be particularly suited in finishing of sensitive materials such as wafers used in the electronics industry, which can be made of materials such as silicon carbide, silicon, and sapphire. In certain instances, the process of moving the abrasive article relative to the one or more wafers can include rotating the abrasive article relative to the one or more wafers, which may be held in a stationary position. In other instances, the process of moving the abrasive article relative to the one or more wafers can include rotating the plurality of wafers relative to the abrasive article, which may be held in a stationary position. It will be appreciated in such processes the relative movement between the abrasive article can include movement of the abrasive article and / or one or more wafers relative to each other. In a particular instance, the embodiments herein have shown to be particularly suitable in Silicon carbide grinding as compared to conventional products.

[0025] FIG. 1 includes a process flow for forming an abrasive article in accordance with an embodiment. In particular, FIG. 1 includes a process for forming a body of an abrasive article having a particular bond in accordance with embodiments herein. The process can be initiated at step 101 by forming a mixture of abrasive particles in a bond material. The abrasive particles can include inorganic materials, such as oxides, carbides, borides, nitrides, and a combination thereof. Still, in other instances, the abrasive particles can include a superabrasive material. Suitable superabrasive materials can include diamond, cubic boron nitride, and a combination thereof. Certain mixtures may be formed with abrasive particles selected primarily from diamond, such that the final-formed abrasive article includes abrasive particles consisting essentially of diamond.

[0026] In still another embodiment, the body may include a particular content of abrasive particles that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a content of abrasive particles of at least 1 wt% based on a total weight of the body or at least 2 wt% or at least 3 wt% or at least 4 wt% or at least 5 wt%. In a particular embodiment, the body may include a content of abrasive particles of not greater than 10 wt% based on a total weight of the body or not greater than 9 wt% or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% or not greater than 5 wt%. The content of abrasive particles in the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 wt% to not greater than 10 wt% such as within a range from at least 2 wt% to not greater than 9 wt%.

[0027] In still another embodiment, the abrasive particles can have an average particle size (D50) that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the abrasive particles can have an average particle size (D50) of at least 1 micron, such as at least 2 microns or at least 3 microns or at least 4 microns. In a particular embodiment, the abrasive can have an average particle size (D50) of not greater than 500 microns such as not greater than 400 microns or not greater than 300 microns or not greater than 200 microns or not greater than 100 microns or not greater than 75 microns or not greater than 50 microns or not greater than 25 microns or not greater than 15 microns or not greater than 10 microns or not greater than 5 microns or not greater than 3 microns or not greater than 2 microns. The average particle size (D50) of the abrasive particles may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 micron to not greater than 500 microns such as within a range from at least 1 micron to not greater than 100 microns.

[0028] In an embodiment, the abrasive particles may include a 10thpercentile (D10) value of the particle size that may facilitate improved manufacturing and / or performance of the abrasive article. As used herein, the D10 value signifies the size value in the particle size distribution, up to and including which, 10% of the total counts of abrasive particles defining the distribution are ‘contained.’ For example, in a non-limiting example, if the DIO is 5 microns, 10% of the abrasive particles have a size of 5 microns or smaller. In a further embodiment, the 10thpercentile (DIO) value of the particle size of the abrasive particles can be at least 0.5 micron or at least 1 micron or at least 2 microns or at least 3 microns or at least

[0029] 4 microns or at least 5 microns. In another aspect, the 10thpercentile (DIO) value of the particle size can be not greater than 10 microns or not greater than 9 microns or not greater than 8 microns or not greater than 7 microns or not greater than 6 microns or not greater than

[0030] 5 microns or not greater than 4 microns or not greater than 3 microns or not greater than 2 microns or not greater than 1 micron. The 10thpercentile (D10) value of the particle size can be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 0.5 microns to not greater than 10 microns or within a range of at least 1 micron to not greater than 5 microns.

[0031] In an embodiment, the abrasive particles may include a 90thpercentile (D90) value of the particle size that may facilitate improved manufacturing and / or performance of the abrasive article. As used herein, the D90 value signifies the size value in the particle size distribution, up to and including which, 90% of the total counts of abrasive particles defining the distribution are ‘contained.’ For example, in a non-limiting example, if the D90 is 5 microns, 90% of the abrasive particles have a size of 5 microns or smaller. In a further embodiment, the 90thpercentile (D90) value of the particle size of the abrasive particles can be at least 1 micron or at least 2 microns or at least 3 microns or at least 4 microns or at least 5 microns or at least 6 microns or at least 7 microns or at least 8 microns or at least 9 microns or at least 10 microns. In another aspect, the 90thpercentile (D90) value of the particle size can be not greater than 10 microns or not greater than 9 microns or not greater than 8 microns or not greater than 7 microns or not greater than 6 microns or not greater than 5 microns or not greater than 4 microns or not greater than 3 microns or not greater than 2 microns or not greater than 1 micron. The 90thpercentile (D90) value of the particle size can be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 micron to not greater than 10 microns or within a range of at least 1 micron to not greater than 5 microns. It may be considered unexpected that the abrasive particle having a particular particle size distribution in combination with other features, such as the bond material, may impact the performance of the abrasive article, particularly in the context of polishing SiC materials. It will be appreciated that the D10, D50, and D90 values of the abrasive particles can be measured using the Malvern Zetasizer “Nano series” running the Zetasizer Software ver. 6.2. To run a sample of abrasive particles for particle size distribution, 40 mL of DI water can be poured into a beaker and 50ul of the abrasive particle sample (solids loading of 25 wt% in water) can also transferred into the beaker. The beaker can then be placed on a jack stand in a soundproof box used for sonicating. Using the Mxsonix Touch-Screen S-4000 sonicator, the ultrasonic horn can then be placed through a hole at the top of the soundproof box and centered so that the bottom of the horn is approximately 0.25 inches from the bottom of the beaker. The sonicator can then be started for 30 seconds at amplitude 40. The sample can then be removed from the soundproof box and enough sample can be extracted into the sample cuvette until the cuvette is about 14 full. The cuvette can then be placed into the sample holder of the Zetasizer and the Malvern software for Diamond material with a refractive index of 41 - 1.80i can be run on the sample. Intensity based D Values for DIO, D50, and D90 are then generated by the Zetasizer software.

[0032] In a particular embodiment, the bond material used in forming the mixture can include an inorganic material. In a particular embodiment, the inorganic material can include at least one of a metal oxide or a non-metal oxide. In a particular embodiment, the bond material may include a metal or metal alloy. In still another embodiment, the bond material can include at least one transition metal element. In still another embodiment, the bond material can include at least one metal selected from the group consisting of copper, tin, silver, tungsten, iron, titanium, nickel, chrome, bronze or any combination thereof. In a particular embodiment, the bond material can include a combination of nickel, tin and copper. In an embodiment, the bond material can consist essentially of nickel, tin and copper.

[0033] In still another embodiment, the bond material can include a tin content that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the bond material can include a tin content of at least 1 wt% based on a total weight of the bond material or at least 2 wt% or at least 3 wt% or at least 4 wt% or at least 5 wt% or at least 6 wt% or at least 7 wt% or at least 8 wt% or at least 9 wt% or at least 10 wt% or at least 11 wt% or at least 12 wt% or at least 13 wt% or at least 14 wt% or at least 15 wt% or at least 16 wt% or at least 17 wt% or at least 18 wt% or at least 19 wt% or at least 20 wt% or at least 21 wt% or at least 22 wt% or at least 23 wt% or at least 24 wt% or at least 25 wt% or at least 26 wt% or at least 27 wt% or at least 28 wt% or at least 29 wt% or at least 30 wt% or at least 31 wt% or at least 32 wt% or at least 33 wt% or at least 34 wt% or at least 35 wt% or at least 36 wt% or at least 37 wt% or at least 38 wt% or at least 39 wt% or at least 40 wt% or at least 41 wt% or at least 42 wt% or at least 43 wt% or at least 44 wt% or at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least 49 wt% or at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least 54 wt% based on a total weight of the bond material. In a particular embodiment, the bond material can include a tin content of not greater than 55 wt% based on a total weight of the bond material or not greater than 54 wt% or not greater than 53 wt% or not greater than 52 wt% or not greater than 51 wt% or not greater than 50 wt% or not greater than 49 wt% or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt% based on a total weight of the bond material. The tin content of the bond material may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 wt% to not greater than 55 wt% such as within a range from at least 20 wt% to not greater than 50 wt%.

[0034] In still another embodiment, the bond material can include a copper content that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the bond material can include a copper content of at least 10 wt% based on a total weight of the bond material or at least 11 wt% or at least 12 wt% or at least 13 wt% or at least 14 wt% or at least 15 wt% or at least 16 wt% or at least 17 wt% or at least 18 wt% or at least 19 wt% based on a total weight of the bond material. In a particular embodiment, the bond material can include a copper content of not greater than 20 wt% based on a total weight of the bond material or not greater than 19 wt% or not greater than 18 wt% or not greater than 17 wt% or not greater than 16 wt% or not greater than 15 wt% or not greater than 14 wt% or not greater than 13 wt% or not greater than 12 wt% or not greater than 11 wt% based on a total weight of the bond material. The copper content of the bond material may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 wt% to not greater than 20 wt% such as within a range from at least 11 wt% to not greater than 19 wt%.

[0035] In still another embodiment, the bond material can include a nickel content that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the bond material can include a nickel content of at least 20 wt% based on a total weight of the bond material or at least 21 wt% or at least 22 wt% or at least 23 wt%, or at least 24 wt%, or at least 25 wt%, or at least 26 wt%, or at least 27 wt%, or at least 28 wt%, or at least 29 wt%, or at least 30 wt%, or at least 31 wt%, or at least 32 wt%, or at least 33 wt%, or at least 34 wt%, or at least 35 wt%, or at least 36 wt%, or at least 37 wt%, or at least 38 wt%, or at least 39 wt%, or at least 40 wt%, or at least 41 wt%, or at least 42 wt%, or at least 43 wt%, or at least 44 wt%, or at least 45 wt%, or at least 46 wt%, or at least 47 wt%, or at least 48 wt%, or at least 49 wt%, or at least 50 wt%, or at least 51 wt%, or at least 52 wt%, or at least 53 wt%, or at least 54 wt%, or at least 55 wt%, or at least 56 wt%, or at least 57 wt%, or at least 58 wt%, or at least 59 wt% based on a total weight of the bond material. In a particular embodiment, the bond material can include a nickel content of not greater than 60 wt% based on a total weight of the bond material or not greater than 59 wt% or not greater than 58 wt% or not greater than 57 wt% or not greater than 56 wt% or not greater than 55 wt% or not greater than 54 wt% or not greater than 53 wt% or not greater than 52 wt% or not greater than 51 wt% or not greater than 50 wt% or not greater than 49 wt% or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt% or not greater than 44 wt% or not greater than 43 wt% or not greater than 42 wt% or not greater than 41 wt% or not greater than 40 wt% or not greater than 39 wt% or not greater than 38 wt% or not greater than 37 wt% or not greater than 36 wt% or not greater than 35 wt% or not greater than 34 wt% or not greater than 33 wt% or not greater than 32 wt% or not greater than 31 wt% or not greater than 30 wt% or not greater than 29 wt% or not greater than 28 wt% or not greater than 27 wt% or not greater than 26 wt% or not greater than 25 wt% or not greater than 24 wt% or not greater than 23 wt% or not greater than 22 wt% or not greater than 21 wt% based on a total weight of the bond material. The nickel content of the bond material may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 20 wt% to not greater than 60 wt% such as within a range from at least 25 wt% to not greater than 55 wt%. The weight percentage of tin, nickel and copper in the bond material may be measured using Inductively Coupled Plasma - Optical Emission Spectrometry (ICP-OES). First, a 0.5 gram sample of the metal bond is digested in a Teflon beaker with 10 mL Nitric Acid and 10 mL Hydrofluoric Acid. The Teflon beaker is placed on a hot plate at 120°C for 2 hours. The beaker is then removed and cooled down and the remaining solids are collected by filtration while the solution is collected in a 250 mL volumetric flask and then diluted to the 250 mL gradation with Deionized water. The solution is then measured with ICP-OES analysis to determine the wt% of each element nickel, copper and tin.

[0036] In still another embodiment, the bond material can include a bronze content that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the bond material can include a bronze content of at least 30 wt% based on a total weight of the bond material or at least 31 wt% or at least 32 wt%, or at least 33 wt%, or at least 34 wt%, or at least 35 wt%, or at least 36 wt%, or at least 37 wt%, or at least 38 wt%, or at least 39 wt%, or at least 40 wt% or at least 41 wt%, or at least 42 wt%, or at least 43 wt%, or at least 44 wt%, or at least 45 wt%, or at least 46 wt%, or at least 47 wt%, or at least 48 wt%, or at least 49 wt%, or at least 50 wt% based on a total weight of the bond material. In a particular embodiment, the bond material can include a bronze content of not greater than 50 wt% based on a total weight of the bond material or not greater than 49 wt% or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt% or not greater than 44 wt% or not greater than 43 wt% or not greater than 42 wt% or not greater than 41 wt% or not greater than 40 wt% or not greater than 39 wt% or not greater than 38 wt% or not greater than 37 wt% or not greater than 36 wt% or not greater than 35 wt% or not greater than 34 wt% or not greater than 33 wt% or not greater than 32 wt% or not greater than 31 wt% based on a total weight of the bond material. The bronze content of the bond material may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 30 wt% to not greater than 50 wt% such as within a range from at least 32 wt% to not greater than 49 wt%.

[0037] In still another embodiment, the bond material can include a nickel Tin ratio that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the bond material can include a nickel Tin ratio of at least 1 : 1 or at least 1 : 1.1 or at least 1 : 1.2 or at least 1 : 1.3. In a particular embodiment, the bond material can include a nickel Tin ratio of not greater than 1 : 1.4 or not greater than 1 : 1.3 or not greater than 1 : 1.2 or not greater than 1 : 1.1. The nickel Tin ratio of the bond material may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 : 1 to not greater than 1 : 1.4 such as within a range from at least 1 : 1.1 to not greater than 1 : 1.3

[0038] In still another embodiment, the bond material can include a copperTin ratio that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the bond material can include a copperTin ratio of at least 0.2:1 or at least 0.21 : 1 or at least 0.22:1 or at least 0.23: 1 or at least 0.24: 1 or at least 0.25: 1 or at least 0.26:1 or at least 0.27: 1 or at least 0.28: 1 or at least 0.29: 1 or at least 0.30: 1 or at least 0.31 : 1 or at least 0.32: 1 or at least 0.33: 1 or at least 0.34: 1 or at least 0.35: 1 or at least at least 0.36:1 or at least 0.37: 1 or at least 0.38: 1 or at least 0.39: 1 or at least 0.40: 1 or at least 0.41 : 1 or at least 0.42: 1 or at least 0.43 : 1 or at least 0.44: 1. In a particular embodiment, the bond material can include a coppertin ratio of not greater than 0.45 : 1 or not greater than 0.44: 1 or not greater than 0.43 : 1 or not greater than 0.42: 1 or not greater than 0.41 : 1 or not greater than 0.40: 1 or not greater than 0.39: 1 or not greater than 0.38: 1 or not greater than 0.37: 1 or not greater than 0.36: 1 or not greater than 0.35 : 1 or not greater than 0.34 : 1 or not greater than 0.33 : 1 or not greater than 0.32:1 or not greater than 0.31 : 1 or not greater than 0.30: 1 or not greater than 0.29: 1 or not greater than 0.28: 1 or not greater than 0.27: 1 or not greater than 0.26: 1 or not greater than 0.25 : 1 or not greater than 0.24: 1 or not greater than 0.23 : 1 or not greater than 0.22: 1 or not greater than 0.21 : 1 or not greater than 0.20: 1. The coppertin ratio of the bond material may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 0.2: 1 to not greater than 0.45: 1 such as within a range from at least 0.3 : 1 to not greater than 0.45:1.

[0039] In still another embodiment, the body may include a particular content of bond material that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a content of bond material of at least 10 wt% bond material based on the total weight of the body or at least 20 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% bond material based on a total weight of the body. In a particular embodiment, the body may include a content of bond material of not greater than 95 wt% bond material based on the total weight of the body or not greater than 90 wt% or not greater than 85 wt% or not greater than 80 wt% or not greater than 75 wt% or not greater than 70 wt% or not greater than 60 wt% bond material based on a total weight of the body. The content of bond material in the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 wt% to not greater than 95 wt% such as within a range from at least 50 wt% to not greater than 90 wt%.

[0040] In still another embodiment, the body may include a particular content of filler that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a content of filler of at least 10 wt% filler based on the total weight of the body or at least 12 wt%, or at least 14 wt%, or at least 16 wt%, or at least 18 wt%, or at least 20 wt%, or at least 22 wt%, or at least 23 wt%, or at least 24 wt%, or at least 26 wt%, or at least 28 wt%, or at least 30 wt%, or at least 32 wt% filler based on a total weight of the body. In a particular embodiment, the body may include a content of filler of not greater than 40 wt% filler based on the total weight of the body, or not greater than 38 wt%, or not greater than 36 wt%, or not greater than 34 wt%, or not greater than 32 wt%, or not greater than 30 wt%, or not greater than 28 wt%, or not greater than 26 wt%, or not greater than 24 wt%, or not greater than 22 wt%, or not greater than 20 wt% filler based on a total weight of the body. The content of filler in the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 wt% to not greater than 40 wt% such as within a range from at least 16 wt% to not greater than 36 wt%.

[0041] In a particular embodiment, the filler can include inorganic materials, organic materials, and a combination thereof. In particular instances, the filler includes an organic material, such as a synthetic material, including by not limited to a polymer, such as thermoplastics, thermosets, and a combination thereof. In still another instance, the filler includes glass pore formers. Some particularly suitable polymer materials can include elastomers, such as rubber, styrenes, silicones, fluorelastomers, silica spheres (SiCh), polymer spheres, and a combination thereof. Other suitable filler materials include salt, ceramic spheres, and a combination thereof.

[0042] In still another embodiment, the filler can have an average filler particle size (D50) that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the filler particles can have an average filler particle size (D50) of at least 10 microns, such as at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns or at least 60 microns or at least 70 microns or at least 80 microns or at least 90 microns or at least 100 microns or at least 110 microns or at least 120 microns or at least 130 microns or at least 140 microns or at least 150 microns or at least 160 microns or at least 170 microns or at least 180 microns or at least 190 microns or at least 200 microns or at least 210 microns or at least 220 microns or at least 230 microns. In a particular embodiment, the filler can have an average filler particle size (D50) of not greater than 250 microns such as not greater than 240 microns or not greater than 230 microns or not greater than 220 microns or not greater than 210 microns or not greater than 200 microns or not greater than 190 microns or not greater than 180 microns or not greater than 170 microns or not greater than 160 microns or not greater than 150 microns or not greater than 140 microns or not greater than 130 microns or not greater than 120 microns or not greater than 110 microns or not greater than 100 micron or not greater than 90 microns. The average filler particle size (D50) of the filler particles may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 microns to not greater than 250 microns such as within a range from at least 50 microns to not greater than 230 microns.

[0043] In still another embodiment, the filler may include a particular shape that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the filler may include a body having an elongated, flat or “flaky” shape wherein the body includes a length, a width and a thickness and wherein the body includes an elongated cross- sectional shape in the plane defined by the length and width and a flat cross-sectional shape in the plane defined by the width and thickness, and wherein the aspect ratio of width-to- thickness (w:t) is at least 1.1 : 1 or at least 1.5: 1 or at least 2: 1 such as at least 3: 1 or at least 4: 1 or at least 5: 1. In still other embodiments, the aspect ratio of width-to-thickness (w:t) of the body of the filler may be not greater than 100: 1 or not greater than 90: 1 or not greater than 80: 1 or not greater than 70: 1 or not greater than 60: 1 or not greater than 50:1 or not greater than 40: 1 or not greater than 30: 1 or not greater than 20: 1 or not greater than 10: 1. The aspect ratio of width-to-thickness (w:t) of the body of the filler may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1.1 : 1 to not greater than 100: 1 such as within a range from at least 2: 1 to not greater than 10: 1.

[0044] In still another embodiment, the filler may include a particular length-to-thickness (l:t) ratio that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the filler may include a body having an aspect ratio of length-to-thickness (l:t) of at least 1.1 : 1 or at least 1.5: 1 or at least 2:1 such as at least 3: 1 or at least 4: 1 or at least 5: 1. In still other embodiments, the aspect ratio of length-to-thickness (l:t) of the body of the filler may be not greater than 100: 1 or not greater than 90: 1 or not greater than 80: 1 or not greater than 70: 1 or not greater than 60: 1 or not greater than 50: 1 or not greater than 40: 1 or not greater than 30: 1 or not greater than 20: 1 or not greater than 10: 1. The aspect ratio of length- to-thickness (l:t) of the body of the filler may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1.1 : 1 to not greater than 100: 1 such as within a range from at least 2: 1 to not greater than 10: 1.

[0045] In still another embodiment, the body may include a weight percent ratio [Cb:Ca] of the weight percent of the bond material [Ct>] for the total weight of the body to the weight percent of the abrasive particles [Ca] for a total weight of the body that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a weight percent ratio [Cb:Ca] of the weight percent of the bond material [Ct>] to the weight percent of the abrasive particles [Ca] of at least 9: 1 or at least 10:1 or at least 11 : 1 or at least 12: 1 or at least 13: 1 or at least 14: 1 or at least 15: 1 or at least 16: 1 or at least 17: 1 or at least 18: 1 or at least 19: 1. In a particular embodiment, the body may include a weight percent ratio [Cb:Ca] of the weight percent of the bond material [Cb] to the weight percent of the abrasive particles [Ca] of not greater than 20: 1 or not greater than 19: 1 or not greater than 18: 1. The weight percent ratio [Cb:Ca] in the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 9: 1 to not greater than 20: 1 such as within a range from at least 10:1 to not greater than 19: 1. The weight of the bond material and the weight of the abrasive particles was measured according to the following procedure. An abrasive sample of about 0.5 g was weighed and digested in a Teflon beaker with 10 mL HNO3 + 10 mL HF. The Teflon beaker was placed on a hot plate at 120°C for 2 hours to expedite the digestion. After 2 hours, when the beaker was removed and cooled down, it was observed that the bond was dissolved. The remaining solids were collected by filtration while the solution was collected in a 250 mL volumetric flask and then diluted to the 250 mL gradation with deionized water. The filter containing the abrasive particles was ashed (removing organic material by drying at high temperature) in a platinum crucible at 450°C for 10 hrs. After ashing, the particles were weighed against the weight of starting abrasive material to determine the concentration of the abrasive particle.

[0046] After forming the mixture including abrasive particles and bond material, the process can continue at step 103 by forming an abrasive body. Various forming methods can be used including molding, casting, pressing (hot pressing or cold pressing), and a combination thereof. In a particular embodiment, the abrasive body can be formed via hot pressing at a suitable temperature in a heating process.

[0047] For bond materials utilizing a metal material, the heating process may utilize temperatures of at least about 500°C, such as at least about 600°C, at least about 700°C, at least about 750°C or even at least about 770°C. Particular forming processes may utilize a heating temperature within a range between about 300°C and about 1300°C depending upon the combination of elements within the metal bond materials. In other instances, the treating temperature can be within a range between about 300°C and about 900°C between about 300°C and about 800°C between about 400°C and about 770°C, or even between about 700°C and about 770°C. After forming the body of the abrasive article in step 103, the process can continue at step 105 by shaping the body. In particular, the process of shaping can give the body certain design features described in embodiments herein. That is, the treated blank may be shaped such that it has certain shapes and surfaces, including but not limited to, first and second portions, arm portions, turns, and cavities in accordance with the designs of embodiments herein. Suitable shaping processes can include cutting, milling, and the like. One particular process can include a water-jet cutting process, wherein water with abrasives is directed at the blank at high speeds and pressures to facilitate cutting of the blank into a specified shape. In other instances, the shaping process may include an ion-beam milling process or electrobeam milling process or electro-discharge machining.

[0048] After conducting the shaping process the body can be used as an abrasive segment suitable for fixation to a substrate material to form a fully-formed abrasive article, such as a grinding wheel. Various methods can be used to facilitate bonding between the abrasive segment and the substrate. For example, the abrasive segment may be affixed to the substrate using an adhesive, using a fastener, or even bonded (e.g. brazed) or welded to the substrate. As will be appreciated, a plurality of abrasive segments may be affixed to a substrate, such as in an ordered array or pattern to facilitate formation of the abrasive article. The abrasive segments may be bonded to the substrate in a manner to form a segmented bonded abrasive tool. In particular, the substrate can have particular regions, such as recesses designed to contain a portion of the abrasive segments and aid fixation or the abrasive segments therein.

[0049] As illustrated in FIG. 2, the abrasive article body 200 can comprise abrasive particles 201 and a plurality of pores 202 evenly distributed within the metal bond material 203.

[0050] In still another embodiment, the metal bond material can include a first phase (Pl) and a second phase (P2) may facilitate improved manufacturing and / or performance of the abrasive article. As illustrated in FIG. 3, the metal bond material of the abrasive article 300 can have a first phase (Pl) 301 having a lighter appearance and a second phase (P2) 302 having a darker appearance. The first phase (Pl) having a lighter appearance is due to a lower presence of copper when compared to the second phase (P2) having a darker appearance due to a higher presence of copper.

[0051] In an embodiment, the metal bond material may include a first phase (Pl) and a second phase (P2) and a particular ratio of Pl :P2 that may facilitate improved manufacturing and / or performance of the abrasive article. The ratio of Pl :P2 is a measure of the area ratio between the two phases. For example, the metal bond material include a Pl :P2 ratio of at least 1 or at least 1.1 or at least 1.15 or at least 1.2 or at least 1.25 or at least 1.3 or at least 1 .35 or at least 1.4 or at least 1.45 or at least 1 .5 or at least 1 .55 or at least 1.6 or at least 1.65 or at least 1.7 or at least 1.75 or at least 1.8 or at least 1.85 or at least 1.9 or at least 1.95 or at least 2.0 or at least 2.05 or at least 2.1 or at least 2.15 or at least 2.2 or at least 2.25 or at least 2.3 or at least 2.35 or at least 2.4 or at least 2.45 or at least 2.5 or at least 2.55. In a particular embodiment, the metal bond material include a Pl :P2 ratio of not greater than 2.5 or not greater than 2.45 or not greater than 2.4 or not greater than 2.35 or not greater than 2.3 or not greater than 2.25 or not greater than 2.2 or not greater than 2.15 or not greater than 2.1 or not greater than 2.05 or not greater than 2.0 or not greater than 1.95 or not greater than 1.9 or not greater than 1.85 or not greater than 1.8 or not greater than 1.75 or not greater than 1.7 or not greater than 1.65 or not greater than 1.6 or not greater than 1.55 or not greater than 1.5 or not greater than 1.45 or not greater than 1.4 or not greater than 1.35 or not greater than 1.3 or not greater than 1.25 or not greater than 1.2 or not greater than 1.15 or not greater than 1.1. The content of bond material in the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 wt% to not greater than 95 wt% such as within a range from at least 50 wt% to not greater than 90 wt%. The ratio of Pl :P2 was measured using a combination of Backscatter Detector and Image J analysis to determine the area fraction of Pl and P2. The area ratio of Pl and P2 was measured by obtaining a cross-section of the bond sample and mechanically polishing the sample to a mirror finish with a polishing slurry having 1 pm diamond.

[0052] A Phenom XL Benchtop SEM was used for the analysis using a backscatter detector using a contrast setting of 70-90% and brightness setting of 30-60% to take the images, under beam energy of 15 keV. Two images from each sample with a field view of 450pm X 450pm were obtained for the phase area analysis. The images were analyzed using an image analysis tool called ‘Image J’. The image was converted into an 8 bit format and the scale bar was set. Thresholding feature from the Image J tool was used to highlight only the Pl darker phase region. The completely black region (porosity) was omitted during thresholding and the brighter P2 phase. Then “Analyze Particles” feature in Image J was used to determine the area of the Pl phase in urn2. The outlines of the particle analysis were outputted to determine if the complete Pl region was correctly outlined. If not, the thresholding step was repeated until a distinct Pl region could be determined. The area column of the output data was recorded and kept aside. Using the same image, the brighter P2 phase was highlighted using the threshold feature while omitting the Pl phase and the black region (porosity). Then “Analyze Particles” feature in Image J was used to determine the area of the P2 phase in urn2. The area column of the output data was recorded. The total summed area of Pl phase was divided by the total summed area of the P2 phase to determine the area fraction ratio between Pl and P2.

[0053] In an embodiment, the metal bond material may include a first phase (Pl) including a blend of nickel, copper and tin that may facilitate improved manufacturing and / or performance of the abrasive article. The composition of the first phase (Pl) may be done using For example, the first phase (Pl) may include at least 1 wt% of copper for a total weight of the first phase (Pl) or at least 2 wt% of copper or at least 3 wt% or at least 4 wt% or at least 5 wt% or at least 6 wt% or at least 7 wt% or at least 8 wt% or at least 9 wt%. In a particular embodiment, the first phase (Pl) may include not greater than 10 wt% of copper for a total weight of the first phase (Pl) or not greater than 9 wt% of copper or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt%. The content of copper in the first phase (Pl) may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 wt% to not greater than 10 wt% such as within a range from at least 2 wt% to not greater than 10 wt%.

[0054] In an embodiment, the metal bond material may include a first phase (Pl) including a blend of nickel, copper and tin that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the first phase (Pl) may include at least 30 wt% of nickel for a total weight of the first phase (Pl) or at least 31 wt% or at least 32 wt% or at least 33 wt% or at least 34 wt% or at least 35 wt% or at least 36 wt% or at least 37 wt% or at least 38 wt% or at least 39 wt%. In a particular embodiment, the first phase (Pl) may include not greater than 40 wt% of nickel for a total weight of the first phase (Pl) or not greater than 39 wt% of nickel or not greater than 38 wt% or not greater than 37 wt% or not greater than 36 wt% or not greater than 35 wt% or not greater than 34 wt%. The content of nickel in the first phase (Pl) may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 30 wt% to not greater than 40 wt% such as within a range from at least 30 wt% to not greater than 38 wt%.

[0055] In an embodiment, the metal bond material may include a first phase (Pl) including a blend of nickel, copper and tin that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the first phase (Pl) may include at least 55 wt% of tin for a total weight of the first phase (Pl) or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt%. In a particular embodiment, the first phase (Pl) may include not greater than 40 wt% of tin for a total weight of the first phase (Pl) or not greater than 60 wt% of tin or not greater than 59 wt% or not greater than 58 wt% or not greater than 57 wt%. The content of tin in the first phase (Pl) may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 55 wt% to not greater than 60 wt% such as within a range from at least 56 wt% to not greater than 60 wt%.

[0056] In an embodiment, the metal bond material may include a second phase (P2) including a blend of nickel, copper and tin that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the second phase (P2) may include at least 18 wt% of copper for a total weight of the second phase (P2) or at least 19 wt% of copper or at least 20 wt% or at least 21 wt% or at least 22 wt%, or at least 23 wt%, or at least 24 wt%. In a particular embodiment, the second phase (P2) may include not greater than 25 wt% of copper for a total weight of the second phase (P2) or not greater than 24 wt% of copper or not greater than 23 wt% or not greater than 22 wt% or not greater than 21 wt% or not greater than 20 wt%. The content of copper in the second phase (P2) may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 18 wt% to not greater than 25 wt% such as within a range from at least 19 wt% to not greater than 25 wt%.

[0057] In an embodiment, the metal bond material may include a second phase (P2) including a blend of nickel, copper and tin that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the second phase (P2) may include at least 30 wt% of nickel for a total weight of the second phase (P2) or at least 31 wt% or at least 32 wt% or at least 33 wt% or at least 34 wt% or at least 35 wt%. In a particular embodiment, the second phase (P2) may include not greater than 36 wt% of nickel for a total weight of the second phase (P2) or not greater than 35 wt% of nickel or not greater than 34 wt% or not greater than 33 wt% or not greater than 32 wt% or not greater than 31 wt%. The content of nickel in the second phase (P2) may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 30 wt% to not greater than 35 wt% such as within a range from at least 31 wt% to not greater than 35 wt%. In an embodiment, the metal bond material may include a second phase (P2) including a blend of nickel, copper and tin that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the second phase (P2) may include at least 41 wt% of tin for a total weight of the second phase (P2) or at least 42 wt% or at least 43 wt% or at least 44 wt% or at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least 49 wt%. In a particular embodiment, the second phase (P2) may include not greater than 50 wt% of in for a total weight of the second phase (P2) or not greater than 49 wt% of tin or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt%. The content of tin in the second phase (P2) may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 41 wt% to not greater than 50 wt% such as within a range from at least 42 wt% to not greater than 50 wt%. The wt% of nickel, copper, and tin within each of the phases Pl and P2 may be measured using a combination of Backscatter Detector and Energy Dispersive Spectroscopy (EDS). A Phenom XL Benchtop SEM was used for the analysis using a backscatter detector using a contrast setting of 70-90% and brightness setting of 30-60% to take the images, under beam energy of 15 keV. A sample of the bond crosssection was prepared using mechanical polishing to a mirror finish with a polishing slurry having 1 pm diamond. An image with a field of view of 90pm x 90pm was selected that provided at least five distinct light phases (Pl) and five distinct dark phases (P2). Five random points were selected within the dark phases and five random points were selected within the light phases for EDS spot analysis, being sure the points measured were separated from each other by a porosity or another phase. The wt% of copper, tin and nickel were selected in the software and the composition of each element was determined within each phase. Each point analysis was timed from 10 to 15 seconds per point to ensure enough signal for a good measurement

[0058] In still another embodiment, the body may include a density that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a density of at least 1.0 g / cm3or at least 2.0 g / cm3or at least 2.5 g / cm3or at least 3.0 g / cm3, or at least 3.5 g / cm3or at least 4.0 g / cm3or at least 4.5 g / cm3or at least 4.8 g / cm3. In a particular embodiment, the body may include a density of not greater than 6 g / cm3or not greater than 5 g / cm3or not greater than 4.9 g / cm3or not greater than 4.8 g / cm3. The density of the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1.0 g / cm3to not greater than 5.0 g / cm3such as within a range from at least 4.0 g / cm3to not greater than 4.9 g / cm3.

[0059] In still another embodiment, the body may include a SiC Removal Factor that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a SiC Removal Factor of at least 60 microns or at least 61 microns or at least 62 microns or at least 63 microns or at least 64 microns or at least 65 microns or at least 66 microns or at least 67 microns or at least 68 microns or at least 69 microns or at least 70 microns or at least 71 microns or at least 72 microns or at least 73 microns or at least 74 microns or at least 75 microns or at least 76 microns or at least 77 microns or at least 78 microns or at least 79 microns or at least 80 microns or at least 81 microns or at least 82 microns or at least 83 microns or at least 84 microns or at least 85 microns or at least 86 microns or at least 87 microns or at least 88 microns or at least 89 microns or at least 90 microns or at least 91 microns or at least 92 microns or at least 93 microns or at least 94 microns or at least 95 microns or at least 96 microns or at least 97 microns or at least 98 microns or at least 99 microns or at least 100 microns or at least 101 microns or at least 102 microns or at least 103 microns or at least 104 microns or at least 105 microns or at least 106 microns or at least 107 microns or at least 108 microns or at least 109 microns or at least 110 microns or at least 111 microns or at least 112 microns or at least 113 microns or at least 114 microns or at least 115 microns or at least 116 microns or at least 117 microns or at least 118 microns or at least 119 microns or at least 120 microns or at least 121 microns or at least 122 microns or at least 123 microns or at least 124 microns or at least 125 microns or at least 126 microns or at least 127 microns or at least 128 microns or at least 129 microns or at least 130 microns or at least 131 microns or at least 132 microns or at least 133 microns or at least 134 microns or at least 135 microns or at least 136 microns or at least 137 microns or at least 138 microns or at least 139 microns or at least 140 microns or at least 141 microns or at least 142 microns or at least 143 microns or at least 144 microns or at least 145 microns or at least 146 microns or at least 147 microns or at least 148 microns or at least 149 microns or at least 150 microns.

[0060] As will be appreciated, the abrasive segments of embodiments herein can be bonded abrasive articles, having a volume of material containing abrasive particles dispersed throughout the volume of the body, which are bonded to each other via a matrix of bonding material. Accordingly, the abrasive segments are distinct from single layered cutting devices. Moreover, the abrasive segments can be formed such that the body has a particular volume of porosity contained throughout the volume of the body. The porosity may be closed pores that are generally rounded and dispersed throughout the body, open porosity which is defined by a network of interconnected channels extending throughout the body, or a combination of closed porosity and open porosity.

[0061] In still another embodiment, the body may include a particular content of porosity that may facilitate improved manufacturing and / or performance of the abrasive article. For example, the body may include a content of porosity of at least 10 vol% for a total volume of the body, or at least 15 vol% or at least 20 vol% or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% or at least 45 vol% or at least 50 vol% or at least 55 vol% or at least 60 vol% of at least 65 vol% or at least 66 vol %. In a particular embodiment, the body may include a content of porosity of not greater than 70 vol% or not greater than 67 vol % or not greater than 65 vol% 60 vol% for a total volume of the body or not greater than 55 vol% or not greater than 50 vol% or not greater than 45 vol%. The content of porosity in the body may be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 wt% to not greater than 60 wt% such as within a range from at least 20 wt% to not greater than 60 wt%. As used herein, the term “porosity” (unless indicated otherwise) relates to the total porosity obtained from samples measured using the following procedure. A cross-section of the bond sample was obtained and mechanically polished to a mirror finish. The sample was embedded in epoxy and polished. The polished cross-sections were imaged using an Olympus DSX500 opto-digital microscope equipped with a 50x lens. Since the samples were reflective, the brightfield observation mode was used to quickly distinguish pores from sample material. A stitched panorama (having size 7000+ pixels by 2000+ pixels) was collected for each sample using the Extended Focal Image option to improve focal uniformity. The images were then processed using image analysis software. Additional calculations and plotting were done using the NumPy, pandas, matplotlib, and seaborn libraries. Binary images were obtained after thresholding were inverted, so that pores appeared as white and non-pores appeared as black. The total porosity was therefore calculated by dividing the number of white pixels by the total number of pixels in the image. Pore size distributions were then obtained by dividing the pores into sections based on the largest circles that could fill a pore region before reaching the centroids of neighboring circles or pore edges due to the highly interconnected pore network. Algorithms were used to segment the pore networks in this way. After the pores within the images were segmented, they were passed into a function to measure size and shape parameters of each pore region. The pore region’s area - the number of pixels contained in the region - was used to calculate an equivalent circular diameter, which was then used to calculate an equivalent spherical volume. The volume-weighted pore size distribution was then measured. The following steps were taken to process images. FIG. 5 illustrates this segmentation process for a lOOOxlOOO-pixel region (1031x1031 um) of a sample according to an embodiment. The segmented pore images for both small and large pores were then passed into a function to measure the size and shape of all pores. The result was a dataframe of all pore measurements for all samples. The pores’ equivalent spherical diameter and volume in microns was then calculated, using the scale factor of 1.031 microns per pixel. NOTE that all pores smaller than 6 pixels in area were removed, setting the lower limit of equivalent spherical diameter to 2.8 microns. Volume-weighted quantiles at the dlO, d50, and d90 were then calculated.

[0062] In an embodiment, the body may include an average pore size (D50) that may facilitate improved manufacturing and / or performance of the abrasive article. As used herein, the D50 value signifies the size value in the pore size distribution, up to and including which, 50% of the total counts of pores defining the distribution are ‘contained’. For example, in a non-limiting example, if the D50 is 10 microns, 50% of the pores have a size of 10 microns or smaller. It will be appreciated, the D50 value may also be referred to as the median value of a sample. In one embodiment, the average pore size (D50) of the body can be at least 1 micron or at least 10 microns or at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns or at least 60 microns or at least 70 microns or at least 80 microns or at least 90 microns or at least 100 microns or at least 110 microns or at least 115 microns. In yet another embodiment, the average pore size (D50) may be not greater than 200 microns or not greater than 150 microns or not greater than 140 microns or not greater than 130 microns or not greater than 120 microns. The average pore size (D50) can be a value between any of the minimum and maximum values noted above, including for example, but not limited to at least 1 micron and not greater than 200 microns, such as within a range of at least 100 microns to not greater than 15 microns.

[0063] In an embodiment, the body may include a 10thpercentile (D10) value of the pore size that may facilitate improved manufacturing and / or performance of the abrasive article. As used herein, the DIO value signifies the size value in the pore size distribution, up to and including which 10% of the total counts of pores defining the distribution are ‘contained.’ For example, in a non-limiting example, if the DIO is 5 microns, 10% of the pores have a size of 5 microns or smaller. In a further embodiment, the 10thpercentile (DIO) value of the pore size of the body can be at least 1 micron or at least 10 microns or at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns or at least 60 microns or at least 65 microns. In another aspect, the 10thpercentile (D10) value of the pore size can be not greater than 100 microns or not greater than 90 microns or not greater than 80 microns or not greater than 70 microns or not greater than 67 microns. The 10thpercentile (D10) value of the pore size can be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 1 micron to not greater than 100 microns or within a range of at least 50 microns to not greater than 7microns.

[0064] In an embodiment, the body may include a 90thpercentile (D90) value of the pore size that may facilitate improved manufacturing and / or performance of the abrasive article. As used herein, the D90 value signifies the size value in the pore size distribution, up to and including which, 90% of the total counts of pores defining the distribution are ‘contained.’ For example, in a non-limiting example, if the D90 is 1 micron, 90% of the pores have a size of 1 micron or smaller. In yet a further embodiment, the 90thpercentile value (D90) of the pore size can be at least 25 microns or at least 50 microns or at least 75 microns or at least 100 microns or at least 125 microns or at least 150 microns or at least 160 microns or at least 165 microns. In another aspect, the 90thpercentile value (D90) may be not greater than 250 microns or not greater than 200 microns or not greater than 190 microns or not greater than 180 microns or not greater than 175 microns or not greater than 170 microns. The 90thpercentile value (D90) can be a value between any of the minimum and maximum values noted above, including, for example, but not limited to within a range of at least 25 microns to not greater than 250 microns or within a range of at least 100 microns to not greater than 180microns.

[0065] In another embodiment, the body can have a pore size distribution, wherein the difference between the average pore size (D50) and the 10thpercentile value (D10) of the pore size, i.e., D50-D10, may facilitate improved manufacturing and / or performance of the abrasive article. In a particular embodiment, the body can have a pore size distribution, wherein the difference between the average pore size (D50) and the 10thpercentile value (D10) of the pore size, i.e., D50-D10 may be not greater than 100 microns or not greater than 90 microns or not greater than 80 microns or not greater than 70 microns or not greater than 60 microns or not greater than 55 microns. In another aspect, the difference between the average pore size (D50) and the 10thpercentile value (D10) of the pore size, i.e., D50-D10, may be at least 10 microns or at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns. The difference between the average pore size (D50) and the 10thpercentile value (D10) of the pore size, i.e., D50-D10 can be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 microns to not greater than 100 microns or within a range of at least 40 micron and not greater than 55 microns.

[0066] In yet another embodiment, the body can have a pore size distribution, wherein the difference between the 90thpercentile value (D90) and the 10thpercentile value (D10) of the pore size, i.e., D90-D10, may facilitate improved manufacturing and / or performance of the abrasive article. In a particular embodiment, the body can have a pore size distribution, wherein the difference between the 90thpercentile value (D90) and the 10thpercentile value (D10) of the pore size, i.e., D90-D10, may be not greater than 100 microns or not greater than 90 microns or not greater than 80 microns or not greater than 70 microns or not greater than 60 microns or not greater than 55 microns. In another aspect, the difference between the 90thpercentile value (D90) and the 10thpercentile value (D10) of the pore size, i.e., D90-D10, may be at least 10 microns or at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns. The difference between the 90thpercentile value (D90) and the average pore size (D10), i.e., D90-D10 can be a value between any of the minimum and maximum values noted above, including for example, but not limited to within a range of at least 10 microns to not greater than 100 microns, such as within a range of at least 40 microns to not greater than 55 microns.

[0067] It will be appreciated that the body may have any suitable size and shape as known in the art and can be incorporated into various types of abrasive articles to form a bonded abrasive article. For example, the body can be attached to a substrate, such as a hub of a wheel to facilitate formation of a bonded abrasive grinding wheel. FIG. 4 A includes a perspective view illustration of an abrasive article comprising a plurality of bodies according to one embodiment. FIG. 4B includes a top view illustration of an abrasive article comprising a plurality of bodies according to one embodiment. In a particular embodiment, the abrasive article 400 may have abrasive segments 401 attached to a substrate 402. The abrasive article 400 can include a first surface 405 and a second surface 406 (not shown) opposite the first surface 405 and an inner side surface 407 defining a central aperture 408 and extending between the first surface 405 and second surface 406. It will be appreciated that the body segment shown in FIG. 4 is only one non-limiting embodiment, and the shape of the body segment and arrangement of the plurality of bodies on a substrate can have a large variety including the embodiments described herein. Furthermore, the abrasive article 400 can have a diameter size larger or smaller than 8 inches, for example, 11 inches or 10 inches. As illustrated, the abrasive segments 401 can be affixed to the surface of the substrate 402 and circumferentially spaced apart from each other at equal intervals around the substrate 402.

[0068] In accordance with embodiments herein, the substrate 402 can be made of an inorganic material including for example a metal, metal alloy, and a combination thereof. Moreover, as will be appreciated the substrate 402 can have various shapes including cylindrical, cup-shaped, conical, and a combination thereof.

[0069] During grinding operations, the abrasive segments 401 can be placed in contact with a workpiece, such as a wafer, wherein the work surfaces of the abrasive segments 401 are substantially flush with a flat surface of the wafer. The substrate 402 can be rotated relative to the workpiece to affect material removal, and particularly a thinning of the wafer. The substrate 402 can be rotated alone, or alternatively, the workpiece can be rotated alone, and even in certain instances, the substrate 402 and the workpiece can both be rotated, such as in opposite directions or the same directions. A fluid may be applied to the workpiece and / or abrasive segments to reduce damage to the workpiece during the process.

[0070] EMBODIMENTS

[0071] Embodiment 1. An abrasive article comprising: a body comprising abrasive particles contained in a metal bond material comprising nickel, tin, and copper; wherein the metal bond comprises a coppertin ratio of at least 0.30: 1 and not greater than 0.45: 1 and a total content of tin of not greater than 55 wt% for a total weight of the bond material; wherein the body further comprises a SiC Removal Factor of at least 60 microns.

[0072] Embodiment 2. An abrasive article comprising: a body comprising abrasive particles contained in a metal bond material comprising nickel, tin and copper wherein a total content of tin is not greater than 55 wt% for a total weight of the bond material; wherein the metal bond comprises a first phase (Pl) and a second phase (P2) and wherein the ratio of Pl :P2 is not greater than 2.5. Embodiment 3. The abrasive article of any one of Embodiments 1 or 2, wherein the total content of tin is at least 1 wt% based on a total weight of the bond material or at least 2 wt% or at least 3 wt% or at least 4 wt% or at least 5 wt% or at least 6 wt% or at least 7 wt% or at least 8 wt% or at least 9 wt% or at least 10 wt% or at least 11 wt% or at least 12 wt% or at least 13 wt% or at least 14 wt% or at least 15 wt% or at least 16 wt% or at least 17 wt% or at least 18 wt% or at least 19 wt% or at least 20 wt% or at least 21 wt% or at least 22 wt% or at least 23 wt% or at least 24 wt% or at least 25 wt% or at least 26 wt% or at least 27 wt% or at least 28 wt% or at least 29 wt% or at least 30 wt% or at least 31 wt% or at least 32 wt% or at least 33 wt% or at least 34 wt% or at least 35 wt% or at least 36 wt% or at least 37 wt% or at least 38 wt% or at least 39 wt% or at least 40 wt% or at least 41 wt% or at least 42 wt% or at least 43 wt% or at least 44 wt% or at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least 49 wt% or at least 50 wt% or at least 51 wt% or at least 52 wt% or at least 53 wt% or at least 54 wt% based on a total weight of the bond material.

[0073] Embodiment 4. The abrasive article of any one of Embodiments 1 or 2, wherein the total content of tin is not greater than 55 wt% based on a total weight of the bond material or not greater than 54 wt% or not greater than 53 wt% or not greater than52 wt% or not greater than 51 wt% or not greater than 50 wt% or not greater than 49 wt% or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt% based on a total weight of the bond material.

[0074] Embodiment 5. The abrasive article of any one of Embodiments 1 or 2, wherein the total content of copper is at least 10 wt% based on a total weight of the bond material or at least 11 wt% or at least 12 wt% or at least 13 wt% or at least 14 wt% or at least 15 wt% based on a total weight of the bond material.

[0075] Embodiment 6. The abrasive article of any one of Embodiments 1 or 2, wherein the total content of copper is not greater than 20 wt% based on a total weight of the bond material or not greater than 19 wt% or not greater than 18 wt% or not greater than 17 wt% or not greater than 16 wt% or not greater than 15 wt% or not greater than 14 wt% or not greater than 13 wt% or not greater than 12 wt% or not greater than 11 wt%.

[0076] Embodiment 7. The abrasive article of any one of Embodiments 1 or 2, wherein the metal bond comprises a nickel :tin ratio of at least 1 : 1 or at least 1 : 1.1 or at least 1 : 1.2 or at least 1 : 1.3. Embodiment 8. The abrasive article of any one of Embodiments 1 or 2, wherein the metal bond comprises a nickektin ratio of not greater than 1 : 1.4 or not greater than 1 : 1.3 or not greater than 1 : 1.2 or not greater than 1 : 1.1.

[0077] Embodiment 9. The abrasive article of Embodiment 1, wherein the body further comprises a SiC Removal Factor of at least 60 microns or at least 61 microns or at least 62 microns or at least 63 microns or at least 64 microns or at least 65 microns or at least 66 microns or at least 67 microns or at least 68 microns or at least 69 microns or at least 70 microns or at least 71 microns or at least 72 microns or at least 73 microns or at least 74 microns or at least 75 microns or at least 76 microns or at least 77 microns or at least 78 microns or at least 79 microns or at least 80 microns or at least 81 microns or at least 82 microns or at least 83 microns or at least 84 microns or at least 85 microns or at least 86 microns or at least 87 microns or at least 88 microns or at least 89 microns or at least 90 microns or at least 91 microns or at least 92 microns or at least 93 microns or at least 94 microns or at least 95 microns or at least 96 microns or at least 97 microns or at least 98 microns or at least 99 microns or at least 100 microns or at least 101 microns or at least 102 microns or at least 103 microns or at least 104 microns or at least 105 microns or at least 106 microns or at least 107 microns or at least 108 microns or at least 109 microns or at least 110 microns or at least 111 microns or at least 112 microns or at least 113 microns or at least 114 microns or at least 115 microns or at least 116 microns or at least 117 microns or at least 118 microns or at least 119 microns or at least 120 microns or at least 121 microns or at least 122 microns or at least 123 microns or at least 124 microns or at least 125 microns or at least 126 microns or at least 127 microns or at least 128 microns or at least 129 microns or at least 130 microns or at least 131 microns or at least 132 microns or at least 133 microns or at least 134 microns or at least 135 microns or at least 136 microns or at least 137 microns or at least 138 microns or at least 139 microns or at least 140 microns or at least 141 microns or at least 142 microns or at least 143 microns or at least 144 microns or at least 145 microns or at least 146 microns or at least 147 microns or at least 148 microns or at least 149 microns or at least 150 microns.

[0078] Embodiment 10. The abrasive article of any one of Embodiments 1 or 2, wherein the metal bond comprises a first phase (Pl) and a second phase (P2) and wherein the ratio of P1 :P2 is at least 1 or at least 1.1 or at least 1.15 or at least 1.2 or at least 1.25 or at least 1.3 or at least 1.35 or at least 1.4 or at least 1.45 or at least 1.5 or at least 1.55 or at least 1.6 or at least 1.65 or at least 1.7 or at least 1.75 or at least 1.8 or at least 1.85 or at least 1.9 or at least 1.95 or at least 2.0 or at least 2.05 or at least 2.1 or at least 2.15 or at least 2.2 or at least 2.25 or at least 2.3 or at least 2.35 or at least 2.4 or at least 2.45.

[0079] Embodiment 11. The abrasive article of any one of Embodiments 1 or 2, wherein the metal bond comprises a first phase (Pl) and a second phase (P2) and wherein the ratio of Pl :P2 is not greater than 2.45 or not greater than 2.4 or not greater than 2.35 or not greater than 2.3 or not greater than 2.25 or not greater than 2.2 or not greater than 2.15 or not greater than 2.1 or not greater than 2.05 or not greater than 2.0 or not greater than 1.95 or not greater than 1.9 or not greater than 1.85 or not greater than 1.8 or not greater than 1.75 or not greater than 1.7 or not greater than 1.65 or not greater than 1.6 or not greater than 1.55 or not greater than 1.5 or not greater than 1.45 or not greater than 1.4 or not greater than 1.35 or not greater than 1.3 or not greater than 1.25 or not greater than 1.2 or not greater than 1.15 or not greater than 1.1.

[0080] Embodiment 12. The abrasive article of Embodiment 10, wherein the first phase (Pl) comprises a blend of nickel, copper and tin, and wherein the wt% of copper is at least 1 wt% and not greater than 10 wt% for a total weight of the first phase (Pl).

[0081] Embodiment 13. The abrasive article of Embodiment 12, wherein the first phase (Pl) comprises at least 2 wt% of copper or at least 3 wt% or at least 4 wt% or at least 5 wt% or at least 6 wt% or at least 7 wt% or at least 8 wt% or at least 9 wt% for a total weight of the first phase (Pl).

[0082] Embodiment 14. The abrasive article of Embodiment 13, wherein the first phase (Pl) comprises not greater than 9 wt% of copper or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% for a total weight of the first phase (Pl).

[0083] Embodiment 15. The abrasive article of Embodiment 12, wherein the first phase (Pl) comprises at least 30 wt% of nickel or at least 31 wt% or at least 32 wt% or at least 33 wt% or at least 34 wt% or at least 35 wt% or at least 36 wt% or at least 37 wt% or at least 38 wt% or at least 39 wt% for a total weight of the first phase (Pl).

[0084] Embodiment 16. The abrasive article of Embodiment 15, wherein the first phase (Pl) comprises not greater than 40 wt% of nickel or not greater than 39 wt% or not greater than 38 wt% or not greater than 37 wt% or not greater than 36 wt% or not greater than 35 wt% or not greater than 34 wt% for a total weight of the first phase (Pl).

[0085] Embodiment 17. The abrasive article of Embodiment 12, wherein the first phase (Pl) comprises at least 55 wt% of tin or at least 56 wt% or at least 57 wt% or at least 58 wt% or at least 59 wt% for a total weight of the first phase (Pl). Embodiment 18. The abrasive article of Embodiment 17, wherein the first phase (Pl) comprises not greater than 60 wt% of tin or not greater than 59 wt% or not greater than 58 wt% or not greater than 57 wt% for a total weight of the first phase (Pl).

[0086] Embodiment 19. The abrasive article of Embodiment 10, wherein the second phase (P2) comprises a blend of nickel, copper and tin, and wherein the wt% of copper is at least 18 wt% and not greater than 25 wt% for a total weight of the second phase (P2).

[0087] Embodiment 20. The abrasive article of Embodiment 19, wherein the second phase (P2) comprises at least 19 wt% of copper or at least 20 wt% or at least 21 wt% or at least 22 wt%, or at least 23 wt%, or at least 24 wt% for a total weight of the second phase (P2).

[0088] Embodiment 21. The abrasive article of Embodiment 20, wherein the second phase (P2) comprises not greater than 25 wt% of copper or not greater than 24 wt% or not greater than 23 wt% or not greater than 22 wt% or not greater than 21 wt% or not greater than 20 wt% for a total weight of the second phase (P2).

[0089] Embodiment 22. The abrasive article of Embodiment 19, wherein the second phase (P2) comprises at least 30 wt% of nickel or at least 31 wt% or at least 32 wt% or at least 33 wt% or at least 34 wt% or at least 35 wt% for a total weight of the second phase (P2).

[0090] Embodiment 23. The abrasive article of Embodiment 22, wherein the second phase (P2) comprises not greater than 36 wt% of nickel or not greater than 35 wt% or not greater than 34 wt% or not greater than 33 wt% or not greater than 32 wt% or not greater than 31 wt% for a total weight of the second phase (P2).

[0091] Embodiment 24. The abrasive article of Embodiment 19, wherein the second phase (P2) comprises at least 41 wt% of tin or at least 42 wt% or at least 43 wt% or at least 44 wt% or at least 45 wt% or at least 46 wt% or at least 47 wt% or at least 48 wt% or at least 49 wt% for a total weight of the second phase (P2).

[0092] Embodiment 25. The abrasive article of Embodiment 24, wherein the second phase (P2) comprises not greater than 50 wt% of tin or not greater than 49 wt% or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt% for a total weight of the second phase (P2).

[0093] Embodiment 26. The abrasive article of any one of Embodiments 1 or 2, wherein the metal bond material comprises a total content of nickel of at least 20 wt% based on a total weight of the bond material or at least 21 wt% or at least 22 wt% or at least 23 wt%, or at least 24 wt%, or at least 25 wt%, or at least 26 wt%, or at least 27 wt%, or at least 28 wt%, or at least 29 wt%, or at least 30 wt%, or at least 31 wt%, or at least 32 wt%, or at least 33 wt%, or at least 34 wt%, or at least 35 wt%, or at least 36 wt%, or at least 37 wt%, or at least 38 wt%, or at least 39 wt%, or at least 40 wt%, or at least 41 wt%, or at least 42 wt%, or at least 43 wt%, or at least 44 wt%, or at least 45 wt%, or at least 46 wt%, or at least 47 wt%, or at least 48 wt%, or at least 49 wt%, or at least 50 wt%, or at least 51 wt%, or at least 52 wt%, or at least 53 wt%, or at least 54 wt%, or at least 55 wt%, or at least 56 wt%, or at least 57 wt%, or at least 58 wt%, or at least 59 wt% based on a total weight of the bond material.

[0094] Embodiment 27. The abrasive article of Embodiment 26, wherein the metal bond material comprises a total content of nickel of not greater than 60 wt% based on a total weight of the bond material or not greater than 59 wt% or not greater than 58 wt% or not greater than 57 wt% or not greater than 56 wt% or not greater than 55 wt% or not greater than 54 wt% or not greater than 53 wt% or not greater than 52 wt% or not greater than 51 wt% or not greater than 50 wt% or not greater than 49 wt% or not greater than 48 wt% or not greater than 47 wt% or not greater than 46 wt% or not greater than 45 wt% or not greater than 44 wt% or not greater than 43 wt% or not greater than 42 wt% or not greater than 41 wt% or not greater than 40 wt% or not greater than 39 wt% or not greater than 38 wt% or not greater than 37 wt% or not greater than 36 wt% or not greater than 35 wt% or not greater than 34 wt% or not greater than 33 wt% or not greater than 32 wt% or not greater than 31 wt% or not greater than 30 wt% or not greater than 29 wt% or not greater than 28 wt% or not greater than 27 wt% or not greater than 26 wt% or not greater than 25 wt% or not greater than 24 wt% or not greater than 23 wt% or not greater than 22 wt% or not greater than 21 wt% based on a total weight of the bond material.

[0095] Embodiment 28. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises at least 10 wt% bond material based on the total weight of the body or at least 20 wt% or at least 30 wt% or at least 40 wt% or at least 50 wt% or at least 60 wt% or at least 70 wt% or at least 80 wt% bond material based on a total weight of the body.

[0096] Embodiment 29. The abrasive article of any one of Embodiments 1, 2 and 28, wherein the body comprises not greater than 95 wt% bond material based on the total weight of the body or not greater than 90 wt% or not greater than 85 wt% or not greater than 80 wt% or not greater than 75 wt% or not greater than 70 wt% or not greater than 60 wt%.

[0097] Embodiment 30. The abrasive article of any one of Embodiments 1 or 2, wherein the body comprises abrasive particles.

[0098] Embodiment 31. The abrasive article of Embodiment 30, wherein the abrasive particles comprise a superabrasive. Embodiment 32. The abrasive article of Embodiment 30, wherein the abrasive particles comprise diamond and / or cubic boron nitride.

[0099] Embodiment 33. The abrasive article of Embodiment 30, wherein the abrasive particles consist essentially of diamond.

[0100] Embodiment 34. The abrasive article of Embodiment 30, wherein the body comprises a content of abrasive particles of at least 1 wt% based on a total weight of the body or at least 2 wt% or at least 3 wt% or at least 4 wt% or at least 5 wt%.

[0101] Embodiment 35. The abrasive article of Embodiment 34, wherein the body comprises a content of abrasive particles of not greater than 10 wt% based on a total weight of the body or not greater than 9 wt% or not greater than 8 wt% or not greater than 7 wt% or not greater than 6 wt% or not greater than 5 wt%.

[0102] Embodiment 36. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises a weight percent ratio [Cb:Ca] of a weight percent of the metal bond material [Cb] to a weight percent of the abrasive particles [Ca] of at least 9:1 or at least 10: 1 or at least 11 : 1 or at least 12: 1 or at least 13: 1 or at least 14: 1 or at least 15: 1 or at least 16: 1 or at least 17: 1 or at least 18: 1 or at least 19: 1.

[0103] Embodiment 37. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises a weight percent ratio [Cb:Ca] of a weight percent of the metal bond material [Cb] to a weight percent of the abrasive particles [Ca] of not greater than 20: 1 or not greater than 19:1 or not greater than 18: 1.

[0104] Embodiment 38. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises a porosity of at least 10 vol% for a total volume of the body, or at least 15 vol% or at least 20 vol% or at least 25 vol% or at least 30 vol% or at least 35 vol% or at least 40 vol% or at least 45 vol% or at least 50 vol% or at least 55 vol% or at least 60 vol% of at least 65 vol% or at least 66 vol%.

[0105] Embodiment 39. The abrasive article of any one of Embodiments 1, 2, and 38, wherein the body comprises a porosity of not greater than 70 vol% for a total volume of the body or not greater than 67 vol % or not greater than 65 vol% 60 vol% for a total volume of the body or not greater than 55 vol% or not greater than 50 vol% or not greater than 45 vol%.

[0106] Embodiment 40. A system including a grinding machine, a wafer comprising a material suitable for forming electronic devices thereon, and the abrasive article of any one of Embodiments 1 and 2. Embodiment 41. The system of Embodiment 40, wherein the abrasive article is configured to be moved relative to a surface of the wafer to remove material from the surface of the wafer.

[0107] Embodiment 42. An abrasive system comprising: a substrate having a generally annular shape including a first surface, a second surface, an outer side surface extending between the first surface and the second surface, and an inner side surface defining a central aperture and extending between the first surface and second surface; and a plurality of segments coupled to the first surface, wherein at least a portion of the segments include the abrasive articles of any one of Embodiments 1 and / or Embodiment 2.

[0108] Embodiment 43. The abrasive system of Embodiment 42, wherein each of the segment of the plurality of segments include the abrasive article of Embodiment 1.

[0109] Embodiment 44. The abrasive system of Embodiment 42, wherein each of the segment of the plurality of segments include the abrasive article of Embodiment 2.

[0110] Embodiment 45. The abrasive system of Embodiment 42, wherein at least a portion of the segments include any one or more combination of claimed features herein.

[0111] Embodiment 46. The abrasive article of Embodiment 2, wherein the metal bond comprises a coppertin ratio of at least 0.36: 1 and not greater than 0.6: 1.

[0112] Embodiment 47. The abrasive article of any one of Embodiments 1 or 46, wherein the coppertin ratio is at least at least 0.2: 1 or at least 0.21 : 1 or at least 0.22: 1 or at least 0.23: 1 or at least 0.24: 1 or at least 0.25: 1 or at least 0.26: 1 or at least 0.27: 1 or at least 0.28: 1 or at least 0.29:1 or at least 0.30: 1 or at least 0.31 : 1 or at least 0.32: 1 or at least 0.33:1 or at least 0.34: 1 or at least 0.35: 1 or at least 0.36: 1 or at least 0.37: 1 or at least 0.38: 1 or at least 0.39: 1 or at least 0.40: 1 or at least 0.41 : 1 or at least 0.42: 1 or at least 0.43: 1 or at least 0.44: 1.

[0113] Embodiment 48. The abrasive article of any one of Embodiments 1 or 46, wherein the coppertin ratio is not greater than 0.45 : 1 or not greater than 0.44: 1 or not greater than 0.43 : 1 or not greater than 0.42: 1 or not greater than 0.41 : 1 or not greater than 0.40: 1 or not greater than 0.39: 1 or not greater than 0.38: 1 or not greater than 0.37: 1 or not greater than 0.36: 1 or not greater than 0.35 : 1 or not greater than 0.34 : 1 or not greater than 0.33 : 1 or not greater than 0.32:1 or not greater than 0.31 : 1 or not greater than 0.30: 1 or not greater than 0.29: 1 or not greater than 0.28: 1 or not greater than 0.27: 1 or not greater than 0.26: 1 or not greater than 0.25 : 1 or not greater than 0.24: 1 or not greater than 0.23 : 1 or not greater than 0.22: 1 or not greater than 0.21 : 1 or not greater than 0.20: 1. Embodiment 49. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises an average pore size (D50) of at least 1 micron or at least 10 microns or at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns or at least 60 microns or at least 70 microns or at least 80 microns or at least 90 microns or at least 100 microns or at least 110 microns or at least 115 microns.

[0114] Embodiment 50. The abrasive article of Embodiment 49, wherein the body comprises an average pore size (D50) of not greater than 200 microns or not greater than 150 microns or not greater than 140 microns or not greater than 130 microns or not greater than 120 microns.

[0115] Embodiment 51. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises a 10th percentile (D10) value of the pore size of at least 1 micron or at least 10 microns or at least 20 microns or at least 30 microns or at least 40 microns or at least 50 microns or at least 60 micron or at least 65 microns.

[0116] Embodiment 52. The abrasive article of Embodiment 51, wherein the body comprises a 10th percentile (D10) value of the pore size of not greater than 100 microns or not greater than 90 microns or not greater than 80 microns or not greater than 70 microns or not greater than 67 microns.

[0117] Embodiment 53. The abrasive article of any one of Embodiments 1 and 2, wherein the body comprises a 90th percentile (D90) value of the pore size of at least 25 microns or at least 50 microns or at least 75 microns or at least 100 microns or at least 125 microns or at least 150 microns or at least 160 microns or at least 165 microns.

[0118] Embodiment 54. The abrasive article of Embodiment 53, wherein the body comprises a 90th percentile (D90) value of the pore size of not greater than 250 microns or not greater than 200 microns or not greater than 190 microns or not greater than 180 microns or not greater than 175 microns or not greater than 170 microns.

[0119] Embodiment 55. The abrasive article of any one of Embodiments 1 and 2, wherein the abrasive particles comprise an average particle size (D50) of at least 1 micron, or at least 2 microns or at least 3 microns or at least 4 microns.

[0120] Embodiment 56. The abrasive article of any one of Embodiments 1 and 2, wherein the abrasive particles comprise an average particle size (D50) of not greater than 500 microns or not greater than 400 microns or not greater than 300 microns or not greater than 200 microns or not greater than 100 microns or not greater than 75 microns or not greater than 50 microns or not greater than 25 microns or not greater than 15 microns or not greater than 10 microns or not greater than 5 microns or not greater than 3 microns or not greater than 2 microns. EXAMPLES

[0121] Example 1

[0122] A raw material powder was used to create four samples, SI, S2, S3 and S4. The raw material powder was a homogeneous fine powder mixture made from 5.0 wt% diamond particles having an average particles size (D50) of about 4.2 microns, metal bond material including copper, tin and bronze (50Cu-Sn50) powders having an average particle size of 9 microns, 3 microns and 7 microns respectively and 23.2 wt% of a dissolvable pore former, salt (available as Cargill Alberger Shur-Flo Fine Flake Salt). The amount of bronze and tin varied between each sample SI, S2 and S3 and is summarized in Table 1. Table 1

[0123] The powders were mixed by adding the powder in a container and agitating the powder and each sample was placed into a mold at the mold charge summarized in Table 2 below. The mold inner diameter measured 11.95 cm. After filling the mold with the desired weight of powder it was then transferred to a hot press system with an induction coil heating system. The mold was then placed under a press at line pressure of 28 tons (3600 PSI) and increased in temperature to 750°C at a 37.5 °C / min ramp rate. The mold was held at 750°C for 10 mins for SI, S2 and S3 and 20 at 775°C for 20 mins for S4. The Induction coil is then shut off and the mold is cooled to room temperature.

[0124] Table 2 The puck is then removed from the mold and the puck measured 11.95 cm diameter and 1.3 cm in thickness for a puck volume of 145.8 cc. The density of the puck was maintained between 4.8 to 4.9 g / cc. The puck was then submerged in a water bath at 50°C with a slow flow of water for 48 - 72 hours until all the salt was removed from the puck. The final density of the puck after leaching was maintained at 3.5 to 3.8 g / cc.

[0125] Each of the samples SI, S2, S3, and S4, were observed to have metal bonds having a first phase (Pl) and a second phase (P2). Using Backscatter Detector, Energy Dispersive Spectroscopy (EDS), and Image J analysis as described herein the area fraction of each of the phases and the composition of Pl and P2 were measured, including wt% of nickel, copper, and tin, for each of the samples. The analysis is summarized in Table 3. Table 3

[0126] Sintered bodies were cut from each of samples SI, S2, S3, and S4 into smaller body segments, herein also called a plurality of bodies, wherein each body segment had the shape of about 21.5 mm length, 10 mm height, and 3.5 mm in thickness.

[0127] Example 2

[0128] The body segments of SI, S2, S3, and S4 were attached to the outer surface of separate preformed wheel substrate using an epoxy adhesive to form wheels. Wheel W1 contained the abrasive segments of SI. Wheel W2 contained the abrasive segments of S2. Wheel W3 contained the segments of S3. Wheel W4 contained the segments of S4. An illustration of an example wheel containing 24 attached body segments (a plurality of 24 bodies) covering a round substrate area of a diameter of 6 inches is shown in FIG. 6.

[0129] Sample wheels Wl, W2, W3, and W4 were tested for comparison of performance. Each wheel was mounted of a Disco DAG810 machine for wafer grinding a Silicon Carbide Wafer. The wafer has a diameter of 6 inches. Each wheel was tested for a run at three different feed rates according to Table 4 below. The run was repeated three times for each sample. The wheels were dressed before each run. Table 4

[0130] The results of the test can be seen in Table 5 below.

[0131] Table 5

[0132] As can be seen, wheels W 1 and W2 having a Pl :P2 ratio according to the embodiments herein had higher material removal before forcing out compared to W3 and W4.

[0133] The embodiments herein are directed to abrasive articles for use with grinding wheels that represent a departure from the state-of-the-art bonded abrasive articles. Notably, the embodiments herein utilize a combination of material components, design structures, and derived ratios present within an abrasive segment that facilitate improved grinding. Particular features of the embodiments that can be combined in various manners include abrasive grain sizes, bond materials, percentages of porosity with the abrasive body, shape of the twisted path joining angles, edge ratios, cutting distance, volume of cavities, placement of cavities, designs of leading edges, trailing edges, and neutral edges. The foregoing describes a combination of features, which can be combined in various manners to describe and define the bonded abrasive articles of the embodiments. The description is not intended to set forth a hierarchy of features, but different features that can be combined in one or more manners to define the invention.

[0134] In the foregoing, reference to specific embodiments and the connections of certain components is illustrative. It will be appreciated that reference to components as being coupled or connected is intended to disclose either direct connection between said components or indirect connection through one or more intervening components as will be appreciated to carry out the methods as discussed herein. As such, the above-disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiments, which fall within the true scope of the present invention. Thus, to the maximum extent allowed by law, the scope of the present invention is to be determined by the broadest permissible interpretation of the following claims and their equivalents and shall not be restricted or limited by the foregoing detailed description. The Abstract of the Disclosure is provided to comply with Patent Law and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.

Claims

WHAT IS CLAIMED IS:

1. An abrasive article comprising: a body comprising abrasive particles contained in a metal bond material comprising nickel, tin, and copper; wherein the metal bond comprises a coppertin ratio of at least 0.30: 1 and not greater than 0.45: 1 and a total content of tin of not greater than 55 wt% for a total weight of the bond material; wherein the body further comprises a SiC Removal Factor of at least 60 microns.

2. The abrasive article of claim 1, wherein the total content of tin is at least 1 wt% and not greater than 55 wt% based on a total weight of the bond material.

3. The abrasive article of claim 1, wherein the total content of copper is at least 10 wt% and not greater than 20 wt% based on a total weight of the bond material.

4. The abrasive article of claim 1, wherein the metal bond comprises a nickel Tin ratio of at least 1 : 1 and not greater than 1 : 1.4.

5. The abrasive article of claim 1, wherein the metal bond comprises a first phase (Pl) and a second phase (P2) and wherein the ratio of Pl :P2 is at least 1 and not greater than 2.5.

6. An abrasive article comprising: a body comprising abrasive particles contained in a metal bond material comprising nickel, tin and copper wherein a total content of tin is not greater than 55 wt% for a total weight of the bond material; wherein the metal bond comprises a first phase (Pl) and a second phase (P2) and wherein the ratio of Pl :P2 is not greater than 2.5.

7. The abrasive article of claim 6, wherein the total content of tin is at least 1 wt% and not greater than 55 wt% based on a total weight of the bond material.

8. The abrasive article of claim 6, wherein the total content of copper is at least 10 wt% and not greater than 20 wt% based on a total weight of the bond material.

9. The abrasive article of claim 6, wherein the metal bond comprises a nickel Tin ratio of at least 1 : 1 and not greater than 1 : 1.4.

10. The abrasive article of claim 6, wherein the metal bond comprises a first phase (Pl) and a second phase (P2) and wherein the ratio of Pl :P2 is at least 1.

11. The abrasive article of claim 6, wherein the first phase (Pl) comprises a blend of nickel, copper and tin, and wherein the wt% of copper is at least 1 wt% and not greater than 10 wt% for a total weight of the first phase (Pl).

12. The abrasive article of claim 11, wherein the first phase (Pl) comprises at least 55 wt% and not greater than 60 wt% of tin for a total weight of the first phase (Pl).

13. The abrasive article of claim 6, wherein the second phase (P2) comprises a blend of nickel, copper and tin, and wherein the wt% of copper is at least 18 wt% and not greater than 25 wt% for a total weight of the second phase (P2).

14. The abrasive article of claim 13, wherein the second phase (P2) comprises at least 41 wt% and not greater than 50 wt% of tin for a total weight of the second phase (P2).

15. An abrasive system comprising: a substrate having a generally annular shape including a first surface, a second surface, an outer side surface extending between the first surface and the second surface, and an inner side surface defining a central aperture and extending between the first surface and second surface; and a plurality of segments coupled to the first surface, wherein at least a portion of the segments include the abrasive articles of claim 6.

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