Low-melting point superabrasive tools and associated methods

Abstract

Superabrasive tools and their methods of manufacture are disclosed. In one aspect, a method for making a low-melting point superabrasive tool having a plurality of superabrasive particles is provided. Such a method may include coating each of the plurality of superabrasive particles with a reactive element that chemically bonds to each of the plurality of superabrasive particles and bonding together the plurality of superabrasive particles with a molten braze that wets the reactive element at a temperature of less than about 700° C. In some aspects, the method may further include arranging the plurality of superabrasive particles on a leveling surface and bonding the plurality of superabrasive particles together with the molten braze such that, upon formation of the superabrasive tool, the plurality of superabrasive particles have been leveled by the leveling surface to an RA value of less than about 40 μm.

1 . A method for making a low-melting point superabrasive tool having a plurality of superabrasive particles, comprising:
 coating each of the plurality of superabrasive particles with an intermediate layer that bonds to each of the plurality of superabrasive particles;   arranging the plurality of superabrasive particles on a leveling surface; and   bonding together the plurality of superabrasive particles with a molten braze that has a melting temperature of less than about 700° C.   
   
   
       2 . The method of  claim 1 , wherein upon formation of the superabrasive tool, the plurality of superabrasive particles have been leveled by the leveling surface to an RA value of less than about 40 μm. 
   
   
       3 . The method of  claim 2 , wherein the leveling surface is removed from the superabrasive tool. 
   
   
       4 . The method of  claim 2 , wherein arranging the plurality of superabrasive particles further comprises:
 disposing a spacer layer on the leveling surface; and   disposing the plurality of superabrasive particles at least partially within the spacer layer such that a portion of each of the plurality of superabrasive particles contact the leveling surface.   
   
   
       5 . The method of  claim 1 , wherein the plurality of superabrasive particles are mechanically bonded together with the molten braze. 
   
   
       6 . The method of  claim 1 , wherein the plurality of superabrasive particles are chemically bonded together with the molten braze. 
   
   
       7 . The method of  claim 1 , wherein the plurality of superabrasive particles are bonded together with a molten braze that has a temperature of less than about 500° C. 
   
   
       8 . The method of  claim 1 , wherein the plurality of superabrasive particles includes diamond. 
   
   
       9 . The method of  claim 8 , wherein the intermediate layer includes a carbide former. 
   
   
       10 . The method of  claim 9 , wherein the carbide former includes a member selected from the group consisting of aluminum (Al), boron (B), chromium (Cr), lithium (Li), magnesium (Mg), molybdenum (Mo), manganese (Mn), nirobium (Nb), silicon (Si), tantalum (Ta), titanium (Ti), vanadium (V), tungsten (W), zirconium (Zr), and combinations thereof. 
   
   
       11 . The method of  claim 9 , wherein the carbide former includes Ti. 
   
   
       12 . The method of  claim 9 , wherein the carbide former includes Si. 
   
   
       13 . The method of  claim 1 , wherein the plurality of superabrasive particles includes cubic boron nitride. 
   
   
       14 . The method of  claim 13 , wherein the intermediate layer includes a nitride former. 
   
   
       15 . The method of  claim 14 , wherein the nitride former includes a member selected from the group consisting of aluminum (Al), boron (B), chromium (Cr), lithium (Li), magnesium (Mg), molybdenum (Mo), manganese (Mn), nirobium (Nb), silicon (Si), tantalum (Ta), titanium (Ti), vanadium (V), tungsten (W), zirconium (Zr), and combinations thereof. 
   
   
       16 . The method of  claim 1 , wherein the braze includes a member selected from the group consisting of Al, Ag, Sb, Zn, Pb, Cd, Cu, Tl, Bi, Sn, In, Ga, and combinations thereof. 
   
   
       17 . The method of  claim 1 , wherein the braze is an alloy including a member selected from the group consisting of Al-Si, Babbit, Cu-Mg, Al-Cu, Al-Mg, Cu-Zn, Al-Ge, Cu-Sn, Al-Sn, Sn-Zn, Sn-Tl, Sn-Pb, Sn-Cu-Ag, and combinations thereof. 
   
   
       18 . The method of  claim 17 , wherein the braze alloy includes Al-Si. 
   
   
       19 . The method of  claim 17 , wherein the braze alloy includes Sn-Cu-Ag. 
   
   
       20 . The method of  claim 1 , further comprising applying a wetting layer to the intermediate layer to improve the wetting between the intermediate layer and the braze. 
   
   
       21 . The method of  claim 20 , wherein the wetting layer includes a member selected from the group consisting of Si, Cu, Ni, Cr, and combinations thereof. 
   
   
       22 . The method of  claim 20 , wherein the intermediate layer is Ti, the wetting layer is Si, and the braze is Al-Si. 
   
   
       23 . The method of  claim 1 , wherein the intermediate layer is Si and the braze is Al-Si. 
   
   
       24 . The method of  claim 1 , wherein the braze is substantially free of Cu. 
   
   
       25 . The method of  claim 2 , wherein the tips of the superabrasive particles are leveled to an RA value of less than about 30 μm. 
   
   
       26 . The method of  claim 2 , wherein the tips of the superabrasive particles are leveled to an RA value of less than about 20 μm. 
   
   
       27 . The method of  claim 2 , wherein the tips of the superabrasive particles are leveled to an RA value of less than about 10 μm. 
   
   
       28 . The method of  claim 2 , wherein the superabrasive particles are leveled to a predetermined height that is along a designated profile. 
   
   
       29 . A low-melting point superabrasive tool, comprising:
 a plurality of superabrasive particles coated with an intermediate layer and bonded together with a braze having a melting temperature of less than about 500° C. said plurality of coated superabrasive particles having tips leveled to an RA value of less than about 40 μm.   
   
   
       30 . (canceled) 
   
   
       31 . The superabrasive tool of  claim 29 , wherein the tips of the superabrasive particles have an RA value of less than about 30 μm. 
   
   
       32 . The superabrasive tool of  claim 29 , wherein the tips of the superabrasive particles have an RA value of less than about 20 μm. 
   
   
       33 . The superabrasive tool of  claim 29 , wherein the tips of the superabrasive particles have an RA value of less than about 10 μm. 
   
   
       34 . The superabrasive tool of  claim 29 , wherein the plurality of superabrasive particles are of substantially the same size. 
   
   
       35 . The superabrasive tool of  claim 29 , wherein the plurality of superabrasive particle are from about 30 microns to about 500 microns in size. 
   
   
       36 . The superabrasive tool of  claim 29 , wherein the plurality of superabrasive particles are from about 100 microns to about 200 microns in size. 
   
   
       37 . The superabrasive tool of  claim 29 , wherein the plurality of superabrasive particles are less than about 100 microns in size. 
   
   
       38 . The superabrasive tool of  claim 29 , wherein the superabrasive tool is a polishing or grinding pad. 
   
   
       39 . The superabrasive tool of  claim 29 , wherein the superabrasive tool is a CMP pad dresser. 
   
   
       40 . The superabrasive tool of  claim 29 , wherein the superabrasive tool is for shaping dental materials. 
   
   
       41 . The superabrasive tool of  claim 29 , wherein the superabrasive particles protrude to a predetermined height that is along a designated profile.