Brazed diamond tools and methods for making the same

Abstract

Multi-layered superabrasive tools and methods for the making thereof are disclosed and described. In one aspect, superabrasive particles are chemically bonded to a matrix support material according to a predetermined pattern by a braze alloy. The brazing alloy may be provided as a powder, thin sheet, or sheet of amorphous alloy. A template having a plurality of apertures arranged in a predetermined pattern may be used to place the superabrasive particles on a given substrate or matrix support material.

1 . A method of making a superabrasive tool, comprising: 
 a) providing a plurality of matrix support material layers having exposed surfaces and a plurality of sheets of amorphous brazing alloy; and    b) brazing a plurality of superabrasive particles directly to the exposed surface of the matrix support material using the plurality of sheets of amorphous brazing alloy.    
     
     
         2 . The method of  claim 1 , further comprising: 
 a) affixing the superabrasive particles on the plurality of amorphous braze sheets in a predetermined pattern;    b) applying the plurality of sheets having superabrasive particles thereon to the exposed surfaces of the matrix support material to form a plurality of individual superabrasive segments;    c) assembling the individual superabrasive segments into a tool precursor having a three-dimensional arrangement of superabrasive particles in accordance with a predetermined pattern; and    d) consolidating the tool precursor by heating to a temperature sufficient to melt the brazing alloy and sinter the matrix support material.    
     
     
         3 . The method of  claim 1 , wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.  
     
     
         4 . The method of  claim 3 , wherein the brazing alloy includes between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.  
     
     
         5 . The method of  claim 4 , wherein the material is chromium.  
     
     
         6 . The method of  claim 1 , wherein the sheets of amorphous brazing alloy have a liquidus temperature of less than 1,100° C.  
     
     
         7 . The method of  claim 1 , further comprising: 
 a) affixing the superabrasive particles on the exposed surface of the matrix support material; and    b) applying the sheet of amorphous braze on the superabrasive particles.    
     
     
         8 . The method of  claim 7 , wherein the superabrasive particles are affixed to the matrix support material using an adhesive.  
     
     
         9 . The method of  claim 7 , wherein the step of affixing further comprises placing the superabrasive particles in a predetermined pattern.  
     
     
         10 . The method of  claim 1 , wherein the superabrasive particles are placed in a predetermined pattern by the steps of: 
 a) providing a template having a plurality of apertures corresponding to the predetermined pattern;    b) placing the template on a transfer sheet;    c) filling the apertures with the superabrasive particles;    d) removing the template, such that the superabrasive particles remain in place on the transfer sheet in accordance with the predetermined pattern of the template; and    e) transferring the superabrasive particles to the exposed surface of the substrate using the transfer sheet, such that the superabrasive particles become affixed to the exposed surface of the substrate in accordance with the predetermined pattern.    
     
     
         11 . The method of  claim 10 , wherein the sheet of amorphous brazing alloy is the transfer sheet.  
     
     
         12 . A superabrasive tool comprising: 
 a) a plurality of consolidated metal support material layers each having a plurality of superabrasive particles; and    b) a plurality of sheets of amorphous brazing alloy chemically bonding the plurality of superabrasive particles to each consolidated metal support material layers.    
     
     
         13 . The superabrasive tool of  claim 12 , wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.  
     
     
         14 . The superabrasive tool of  claim 13 , wherein the brazing alloy includes between about 2% and 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.  
     
     
         15 . The superabrasive tool of  claim 13 , wherein the material is chromium.  
     
     
         16 . The method of  claim 12 , wherein the sheets of amorphous brazing alloy have a liquidus temperature of less than 1,100° C.  
     
     
         17 . The superabrasive tool of  claim 12 , wherein the plurality of superabrasive particles are placed in a predetermined pattern.  
     
     
         18 . The superabrasive tool of  claim 17 , wherein the predetermined pattern consists of superabrasive particles positioned substantially along an exterior edge of the superabrasive tool.  
     
     
         19 . The superabrasive tool of  claim 17 , wherein the predetermined pattern comprises an exterior portion concentration of superabrasive particles that is higher than an interior portion concentration of superabrasive particles.  
     
     
         20 . The superabrasive tool of  claim 17 , wherein the predetermined pattern is a uniform grid.