Molten braze-coated superabrasive particles and associated methods

Abstract

A superabrasive particle coated with a solidified coating of a molten braze alloy that is chemically bonded to the superabrasive particle, where the molten braze alloy includes a substantially less-reactive protective material, is disclosed and described. In one aspect, the molten braze alloy may coat at least about 80% of an outer surface of the superabrasive particle. Various methods for making and using such a coated superabrasive particle are additionally disclosed and described.

1 . A method for preserving the strength of a superabrasive particle having a braze alloy coating bonded thereto by application of the braze alloy coating in a molten state, comprising: 
 protecting said superabrasive particle with a protective material that is substantially less-reactive with the superabrasive particle than the braze alloy during application of the braze alloy coating to the superabrasive particle.    
     
     
         2 . The method of  claim 1 , wherein the superabrasive particle is diamond.  
     
     
         3 . The method of  claim 1 , wherein the superabrasive particle is cubic boron nitride.  
     
     
         4 . The method of  claim 1 , wherein protecting the superabrasive particle is accomplished by coating the substantially less-reactive protective material on the superabrasive particle prior to the application of the braze alloy coating.  
     
     
         5 . The method of  claim 1 , wherein protecting the superabrasive particle is accomplished by admixing the substantially less-reactive protective material in the braze alloy coating.  
     
     
         6 . The method of  claim 1 , wherein the substantially less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.  
     
     
         7 . The method of  claim 6 , wherein the substantially less-reactive protective material is copper.  
     
     
         8 . The method of  claim 6 , wherein the substantially less-reactive protective material is tin.  
     
     
         9 . The method of  claim 6 , wherein the substantially less-reactive protective material is zinc.  
     
     
         10 . A method for coating a superabrasive particle having improved strength, a braze alloy coating bonded thereto by application of the braze alloy coating in a molten state, comprising steps of: 
 providing a superabrasive particle;    protecting the superabrasive particle as recited in  claim 1 , while coating the superabrasive particle with a molten braze alloy; and    allowing the coating to solidify.    
     
     
         11 . The method of  claim 10 , wherein the superabrasive particle is diamond.  
     
     
         12 . The method of  claim 10 , wherein the superabrasive particle is cubic boron nitride.  
     
     
         13 . The method of  claim 10 , wherein the step of protecting the superabrasive particle is accomplished by coating the substantially less-reactive protective material on the superabrasive particle prior to the application of the braze alloy coating.  
     
     
         14 . The method of  claim 10 , wherein the step of protecting the superabrasive particle is accomplished by admixing the substantially less-reactive protective material in the braze alloy coating.  
     
     
         15 . The method of  claim 10 , wherein the substantially less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.  
     
     
         16 . The method of  claim 15 , wherein the substantially less-reactive protective material is copper.  
     
     
         17 . The method of  claim 15 , wherein the substantially less-reactive protective material is tin.  
     
     
         18 . The method of  claim 15 , wherein the substantially less-reactive protective material is zinc.  
     
     
         19 . The method of  claim 10 , further comprising the step of pre-coating the superabrasive particle with a reactive material.  
     
     
         20 . The method of  claim 19 , wherein the step of pre-coating the superabrasive particle includes admixing the reactive material with the substantially less-reactive protective material.  
     
     
         21 . The method of  claim 19 , wherein the reactive material is selected from the group consisting of chromium, silicon, titanium, tungsten, and mixtures thereof, including carbides, nitrides, and alloys.  
     
     
         22 . The method of  claim 21 , wherein the reactive material is titanium.  
     
     
         23 . The method of  claim 21 , wherein the reactive material is tungsten carbide.  
     
     
         24 . The method of  claim 21 , wherein the reactive material is silicon carbide.  
     
     
         25 . The method of  claim 21 , wherein the reactive material is chromium.  
     
     
         26 . A method of making a superabrasive tool precursor, comprising steps of: 
 providing a superabrasive particle; and    coating the superabrasive particle as recited in  claim 10 .    
     
     
         27 . The method of  claim 26 , further comprising the step of metallurgically bonding together a plurality of coated superabrasive particles with the braze alloy coating.  
     
     
         28 . The method of  claim 27 , wherein the step of metallurgically bonding together a plurality of coated superabrasive particles forms a one dimensional structure.  
     
     
         29 . The method of  claim 27 , wherein the step of metallurgically bonding together a plurality of coated superabrasive particles forms a two dimensional structure.  
     
     
         30 . The method of  claim 27 , wherein the step of metallurgically bonding together a plurality of coated superabrasive particles forms a three dimensional structure.  
     
     
         31 . The method of  claim 27 , further comprising the step of arranging the plurality of coated superabrasive particles in a predetermined pattern, wherein the coated superabrasive particles are bonded together to substantially conform to said predetermined pattern.  
     
     
         32 . A method of making a superabrasive tool, comprising: 
 providing a support matrix;    providing a tool precursor made by the method recited in  claim 26;  and    metallurgically bonding the tool precursor to the support matrix.    
     
     
         33 . The method of  claim 32 , wherein the support matrix comprises a consolidated metal powder.  
     
     
         34 . The method of  claim 33 , wherein the support matrix is porous.  
     
     
         35 . The method of  claim 32 , wherein the support matrix comprises a solid metal substrate.  
     
     
         36 . The method of  claim 32 , further comprising the step of metallurgically bonding a plurality of tool precursors to the support matrix.  
     
     
         37 . The method of  claim 36 , further comprising the step of arranging the plurality of tool precursors such that the coated superabrasive particles substantially conform to a predetermined pattern.  
     
     
         38 . The method of  claim 32 , wherein the step of metallurgically bonding a tool precursor to the support matrix forms a layer.  
     
     
         39 . The method of  claim 38 , further comprising the step of metallurgically bonding together a plurality of layers.  
     
     
         40 . A superabrasive tool precursor comprising: 
 at least one superabrasive particle bonded with a braze alloy coating, said braze alloy coating including a substantially less-reactive protective material, said braze alloy coating including the substantially less-reactive protective material providing improved strength to the coated superabrasive particle as compared with the braze alloy alone.    
     
     
         41 . The superabrasive tool precursor of  claim 40 , wherein the superabrasive particle is diamond.  
     
     
         42 . The superabrasive tool precursor of  claim 40 , wherein the superabrasive particle is cubic boron nitride.  
     
     
         43 . The superabrasive tool precursor of  claim 40 , wherein the substantially less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.  
     
     
         44 . The method of  claim 43 , wherein the substantially less-reactive protective material is copper.  
     
     
         45 . The method of  claim 43 , wherein the substantially less-reactive protective material is tin.  
     
     
         46 . The method of  claim 43 , wherein the substantially less-reactive protective material is zinc.  
     
     
         47 . The superabrasive tool precursor of  claim 40 , wherein the at least one coated superabrasive particle is a plurality of coated superabrasive particles metallurgically bonded together by the braze alloy coating.  
     
     
         48 . The tool precursor of  claim 47 , wherein the bonded plurality of coated superabrasive particles forms a one dimensional structure.  
     
     
         49 . The tool precursor of  claim 47 , wherein the bonded plurality of coated superabrasive particles forms a two dimensional structure.  
     
     
         50 . The tool precursor of  claim 47 , wherein the bonded plurality of coated superabrasive particles forms a three dimensional structure.  
     
     
         51 . The tool precursor of  claim 47 , wherein the bonded plurality of coated superabrasive particles are each arranged and held in accordance with a predetermined pattern.  
     
     
         52 . A superabrasive tool, comprising: 
 a support matrix; and    a tool precursor as recited in  claim 40  metallurgically bonded to the support matrix.    
     
     
         53 . The superabrasive tool of  claim 52 , wherein the support matrix comprises a consolidated metal powder.  
     
     
         54 . The superabrasive tool of  claim 53 , wherein the support matrix is porous.  
     
     
         55 . The superabrasive tool of  claim 52 , wherein the support matrix comprises a solid metal substrate.  
     
     
         56 . The superabrasive tool of  claim 52 , further comprising a plurality of tool precursors metallurgically bonded to the support matrix.  
     
     
         57 . The superabrasive tool of  claim 56 , wherein the plurality of tool precursors are arranged such that the coated superabrasive particles substantially conform to a predetermined pattern.  
     
     
         58 . The superabrasive tool of  claim 52 , wherein the support matrix and tool precursor form a layer.  
     
     
         59 . The superabrasive tool of  claim 58 , further comprising a plurality of layers metallurgically bonded together.  
     
     
         60 . The superabrasive tool of  claim 59 , wherein the substrate of each layer comprises a solid metal, and each tool precursor is porous.  
     
     
         61 . The superabrasive tool of  claim 60 , wherein the coated superabrasive particles of each tool precursor are arranged in accordance with a predetermined pattern.  
     
     
         62 . The superabrasive tool of  claim 61 , wherein the pores in each tool precursor occur in accordance with a predetermined pattern.  
     
     
         63 . The superabrasive tool of  claim 60 , wherein the tool is a saw segment.  
     
     
         64 . The superabrasive tool of  claim 63 , wherein the saw segment is a reciprocating saw.  
     
     
         65 . The superabrasive tool of  claim 63 , wherein the saw segment is a circular saw.  
     
     
         66 . A superabrasive tool comprising: 
 a plurality of superabrasive particles bonded together with a braze alloy coating, said braze alloy coating including a substantially less-reactive protective material, said braze alloy coating including the substantially less-reactive protective material providing improved strength to the coated superabrasive particle as compared with the braze alloy alone; and    a plurality of spacer particles chemically bonded to the molten braze alloy.    
     
     
         67 . The superabrasive tool of  claim 66 , wherein the superabrasive particle is diamond.  
     
     
         68 . The superabrasive tool of  claim 66 , wherein the superabrasive particle is cubic boron nitride.  
     
     
         69 . The superabrasive tool of  claim 66 , wherein the less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.  
     
     
         70 . The superabrasive tool of  claim 69 , wherein the less-reactive protective material is copper.  
     
     
         71 . The superabrasive tool of  claim 69 , wherein the less-reactive protective material is tin.  
     
     
         72 . The superabrasive tool of  claim 69 , wherein the less-reactive protective material is zinc.  
     
     
         73 . The superabrasive tool of  claim 66 , wherein the braze alloy is porous.  
     
     
         74 . The superabrasive tool of  claim 66 , wherein the coated superabrasive particles are arranged in accordance with a predetermined pattern.  
     
     
         75 . The superabrasive tool of  claim 66 , wherein the spacer particles are arranged in accordance with a predetermined pattern.  
     
     
         76 . The superabrasive tool of  claim 73 , wherein braze alloy pores occur in accordance with a predetermined pattern.  
     
     
         77 . The superabrasive tool of  claim 66 , wherein the spacer particles include particles of SiC.