Fused abrasive particles, abrasive articles, and methods of making and using the same

Abstract

Fused abrasive particles comprising at least one eutectic. The fused abrasive particles can be incorporated into abrasive products such as coated abrasives, bonded abrasives, non-woven abrasives, and abrasive brushes.

What is claimed is:  
     
         1 . Fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein said abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         2 . The fused, crystalline abrasive particles according to  claim 1  comprising at least 50 percent by volume, based on the total metal oxide volume of the respective particle, of said eutectic.  
     
     
         3 . The fused, crystalline abrasive particles according to  claim 2  comprising, on a theoretical oxide basis, at least 40 percent by weight Al 2 O 3 , based on the total metal oxide content the respective particle.  
     
     
         4 . The fused, crystalline abrasive particles according to  claim 3 , wherein said second average microhardness is at least 90% of said first average microhardness.  
     
     
         5 . The fused, crystalline abrasive particles according to  claim 4 , wherein said first average microhardness is at least 14 GPa.  
     
     
         6 . The fused, crystalline abrasive particles according to  claim 4 , wherein said first average microhardness is at least 16 GPa.  
     
     
         7 . The fused, crystalline abrasive particles according to  claim 4 , wherein said eutectic is Al 2 O 3 —Y 3 Al 5 O 12  eutectic.  
     
     
         8 . The fused, crystalline abrasive particles according to  claim 4 , wherein said eutectic is selected from the group consisting of Al 2 O 3 —Dy 3 Al 5 O 12  eutectic, Al 2 O 3 —Er 3 Al 5 O 12  eutectic, Al 2 O 3 —GdAlO 3 , eutectic and Al 2 O 12  eutectic.  
     
     
         9 . The fused, crystalline abrasive particles according to  claim 4 , wherein said eutectic is selected from the group consisting of CeAlO 3 —CeAl 11 O 18  eutectic, EuAlO 3 —EuAl 11 O 18  eutectic, LaAlO 3 —LaAl 11 O 18  eutectic, NdAlO 3 —NdAl 11 O 18  eutectic, PrAlO 3 —PrAl 11 O 18  eutectic, and SmAlO 3 —SmAl 11 O 18  eutectic.  
     
     
         10 . The fused, crystalline abrasive particles according to  claim 4 , wherein said second average microhardness is at least 95% of said first average microhardness.  
     
     
         11 . Fused, crystalline abrasive particles comprising at least one eutectic, the eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide, wherein the abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein the second average microhardness is at least 85% of the first average microhardness.  
     
     
         12 . The fused, crystalline abrasive particles according to  claim 11  comprising at least 50 percent by volume, based on the total metal oxide volume of the respective particle, of said eutectic.  
     
     
         13 . The fused, crystalline abrasive particles according to  claim 12  comprising, on a theoretical oxide basis, at least 40 percent by weight Al 2 O 3 , based on the total metal oxide content the respective particle.  
     
     
         14 . The fused, crystalline abrasive particles according to  claim 13 , wherein said second average microhardness is at least 90% of said first average microhardness.  
     
     
         15 . The fused, crystalline abrasive particles according to  claim 14 , wherein said first average microhardness is at least 14 GPa.  
     
     
         16 . The fused, crystalline abrasive particles according to  claim 14 , wherein said first average microhardness is at least 16 GPa.  
     
     
         17 . The fused, crystalline abrasive particles according to  claim 14 , wherein said eutectic is Al 2 O 3 —Y 3 Al 5 O 12 —ZrO 2  eutectic.  
     
     
         18 . The fused, crystalline abrasive particles according to  claim 14 , wherein said second average microhardness is at least 95% of said first average microhardness.  
     
     
         19 . Fused, crystalline abrasive particles comprising at least one eutectic, the eutectic comprising at least (i) at least one of crystalline, complex Al 2 O 3 .Y 2 O 3  or crystalline, complex Al 2 O 3 .REO and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein said abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         20 . The fused, crystalline abrasive particles according to  claim 19  comprising at least 50 percent by volume, based on the total metal oxide volume of the respective particle, of said eutectic.  
     
     
         21 . The fused, crystalline abrasive particles according to  claim 20  comprising, on a theoretical oxide basis, at least 40 percent by weight Al 2 O 3 , based on the total metal oxide content the respective particle.  
     
     
         22 . The fused, crystalline abrasive particles according to  claim 21 , wherein said second average microhardness is at least 90% of said first average microhardness.  
     
     
         23 . The fused, crystalline abrasive particles according to  claim 22 , wherein said first average microhardness is at least 14 GPa.  
     
     
         24 . Fused, crystalline abrasive particles comprising at least one eutectic, the eutectic comprising at least (i) crystalline, complex Al 2 O 3 .Y 2 O 3  and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein said abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         25 . The fused, crystalline abrasive particles according to  claim 24  comprising at least 50 percent by volume, based on the total metal oxide volume of the respective particle, of said eutectic.  
     
     
         26 . The fused, crystalline abrasive particles according to  claim 25  comprising, on a theoretical oxide basis, at least 40 percent by weight Al 2 O 3 , based on the total metal oxide content the respective particle.  
     
     
         27 . The fused, crystalline abrasive particles according to  claim 26 , wherein said second average microhardness is at least 90% of said first average microhardness.  
     
     
         28 . The fused, crystalline abrasive particles according to  claim 27 , wherein said first average microhardness is at least 14 GPa.  
     
     
         29 . A plurality of particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         30 . A plurality of particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         31 . A plurality of particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of particles are fused, crystalline abrasive particles comprising at least (i) crystalline, complex Al 2 O 3 .REO and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         32 . A plurality of particles having a particle size distribution ranging from fine to coarse, wherein at least a portion of said plurality of particles are fused, crystalline abrasive particles comprising at least (i) crystalline, complex Al 2 O 3 .Y 2 O 3  and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         33 . A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         34 . A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least one eutectic, said eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         35 . A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least (i) crystalline, complex Al 2 O 3 .REO and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         36 . A plurality of abrasive particles having a specified nominal grade, said plurality of abrasive particle having a particle size distribution ranging from fine to coarse, wherein at least a portion of said abrasive particles is a plurality of fused, crystalline abrasive particles, said fused abrasive particles comprising at least (i) crystalline, complex Al 2 O 3 .Y 2 O 3  and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         37 . A method for making fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide, wherein the abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness, said method comprising: 
 melting at least one Al 2 O 3  source and at least one reactive Al 2 O 3  metal oxide source to provide a melt; and  
 converting the melt to said fused, crystalline abrasive particles.  
 
     
     
         38 . The method according to  claim 37 , wherein converting includes: 
 cooling the melt to provide a solidified material; and    crushing the solidified material to provide said fused, crystalline abrasive particles.    
     
     
         39 . The method according to  claim 38 , wherein cooling the melt includes cooling the melt with metallic plates.  
     
     
         40 . The method according to  claim 38 , wherein cooling the melt includes cooling the melt with metallic balls.  
     
     
         41 . A method for making fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide, wherein the abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness, said method comprising: 
 melting at least one Al 2 O 3  source and at least one reactive Al 2 O 3  metal oxide source to provide a melt; and  
 converting the melt to said fused, crystalline abrasive particles.  
 
     
     
         42 . An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         43 . The abrasive article according to  claim 42 , wherein said article is a coated abrasive article, and further comprises a backing.  
     
     
         44 . The abrasive article according to  claim 42 , wherein said article is a bonded abrasive article.  
     
     
         45 . The abrasive article according to  claim 42 , wherein said article is a nonwoven abrasive article, and further comprises a nonwoven web.  
     
     
         46 . An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         47 . An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising at least (i) crystalline, complex Al 2 O 3 .REO and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         48 . An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of said abrasive particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising at least (i) crystalline, complex Al 2 O 3 .Y 2 O 3  and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         49 . A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         50 . The vitrified bonded abrasive article according to  claim 49 , wherein said vitrified bonding material comprises silica, alumina, and boria.  
     
     
         51 . The vitrified bonded abrasive article according to  claim 50 , wherein said vitrified bonding material comprises at least 10 percent by weight of said alumina.  
     
     
         52 . The vitrified bonded abrasive article according to  claim 51 , wherein said vitrified bonding material comprises at least 10 percent by weight of said boria.  
     
     
         53 . A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least one eutectic, said eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         54 . A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least (i) crystalline, complex Al 2 O 3 .REO and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         55 . A vitrified bonded abrasive article comprising a plurality of abrasive particles bonded together via vitrified bonding material, wherein at least a portion of said plurality of abrasive particles are fused, crystalline abrasive particles comprising at least (i) crystalline, complex Al 2 O 3 .Y 2 O 3  and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness.  
     
     
         56 . A method of abrading a surface comprising: 
 contacting a plurality of abrasive particles comprising at least one eutectic, said eutectic comprising, on a theoretical oxide basis, Al 2 O 3  and at least one other metal oxide with a surface of a workpiece, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness; and    moving at least one of said plurality of abrasive particles or said surface relative to the other to abrade at least a portion of said surface with at least one of said fused abrasive particles.    
     
     
         57 . A method of abrading a surface comprising: 
 contacting a plurality of abrasive particles comprising at least one eutectic, said eutectic comprising ZrO 2 , on a theoretical oxide basis, Al 2 O 3 , and at least one other metal oxide with a surface of a workpiece, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness; and    moving at least one of said plurality of abrasive particles or said surface relative to the other to abrade at least a portion of said surface with at least one of said fused abrasive particles.    
     
     
         58 . A method of abrading a surface comprising: 
 contacting a plurality of abrasive particles comprising at least one eutectic, said eutectic comprising at least (i) crystalline, complex Al 2 O 3 .REO and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al with a surface of a workpiece, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness; and    moving at least one of said plurality of abrasive particles or said surface relative to the other to abrade at least a portion of said surface with at least one of said fused abrasive particles.    
     
     
         59 . A method of abrading a surface comprising: 
 contacting a plurality of abrasive particles comprising at least one eutectic, said eutectic comprising at least (i) crystalline, complex Al 2 O 3 .Y 2 O 3  and (ii) at least one of aluminoxy-D or M-aluminoxy-D, wherein D is at least one of carbide or nitride, and M is at least one metal cation other than Al with a surface of a workpiece, wherein said abrasive particles have a first average microhardness of at least 11 GPa, wherein the abrasive particles have a second average microhardness after being heated in air at 1000° C. in air for 4 hours, and wherein said second average microhardness is at least 85% of said first average microhardness; and    moving at least one of said plurality of abrasive particles or said surface relative to the other to abrade at least a portion of said surface with at least one of said fused abrasive particles.