Abrasive segment comprising abrasive aggregates including silicon carbide particles

Abstract

An abrasive article can include an abrasive segment. The abrasive segment can have a body that includes a plurality of abrasive aggregates. In addition, the abrasive aggregates can include a plurality of silicon carbide particles bonded together by a binder material phase. The abrasive aggregates can be contained within a bond material that includes a magnesia-based cement. In an embodiment, the binder material phase can include a vitreous phase material and a crystalline phase material. In particular instances, the binder material phase can include a certain porosity. In another embodiment, the abrasive segment can be formed from a mixture of abrasive aggregates including silicon carbide and a magnesia-based bond material.

1 . An abrasive article, comprising:
 an abrasive segment having a body including a plurality of abrasive aggregates comprising a plurality of silicon carbide particles bonded together by a binder material phase, the abrasive aggregates being contained within a bond material comprising a magnesia-based cement.   
     
     
         2 . The abrasive article of  claim 1 , wherein the magnesia-based cement comprises magnesium oxide, magnesium chloride, or both. 
     
     
         3 . The abrasive article of  claim 1 , wherein the abrasive segment comprises no greater than about 30 wt % silicon carbide for a total weight of the abrasive segment. 
     
     
         4 . (canceled) 
     
     
         5 . The abrasive article of  claim 1 , wherein the abrasive segment comprises at least about 70 wt % magnesia-based cement for a total weight of the abrasive segment. 
     
     
         6 . (canceled) 
     
     
         7 . The abrasive article of  claim 1 , wherein the abrasive article comprises a porosity less than about 5 vol % of a total volume of the abrasive segment. 
     
     
         8 . The abrasive article of  claim 1 , wherein the abrasive aggregates are uniformly distributed throughout a volume of the magnesia-based cement. 
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . The abrasive article of  claim 1 , wherein the abrasive segment is generally prismatic. 
     
     
         32 . The abrasive article of  claim 1 , wherein the body of the abrasive segment is bonded to a substrate. 
     
     
         33 . The abrasive article of  claim 32 , wherein the substrate comprises a metal or a metal alloy. 
     
     
         34 . (canceled) 
     
     
         35 . (canceled) 
     
     
         36 . The abrasive article of  claim 32 , wherein the substrate comprises an organic material. 
     
     
         37 . (canceled) 
     
     
         38 . The abrasive article of  claim 36 , wherein the organic material comprises a polymer. 
     
     
         39 . A method of making an abrasive segment, the method comprising:
 forming a mixture of abrasive aggregates including silicon carbide particles and a magnesia-based binder material; and   forming the abrasive segment from the mixture.   
     
     
         40 . (canceled) 
     
     
         41 . The method of  claim 39 , wherein forming the abrasive segment comprises curing the mixture at a temperature of at least about 20° C. and no greater than about 100° C. 
     
     
         42 . (canceled) 
     
     
         43 . (canceled) 
     
     
         44 . The method of  claim 41 , wherein the mixture cures for at least about 1 week and no greater than about 8 weeks. 
     
     
         45 . (canceled) 
     
     
         46 . An abrasive article, comprising:
 an abrasive segment comprising a body comprising a plurality of abrasive aggregates dispersed within a magnesia-based bond material wherein each abrasive aggregate comprises a plurality of silicon carbide particles bonded together in binder material, the binder material comprising a vitreous phase material and a crystalline phase material.   
     
     
         47 . (canceled) 
     
     
         48 . The abrasive segment of  claim 46 , further comprising:
 an average aggregate-to-aggregate distance between two adjacent abrasive aggregates of the plurality of abrasive aggregates; and   an average particle-to-particle distance between two adjacent silicon carbide particles, wherein the particle-to-particle distance is less than the aggregate-to-aggregate distance.   
     
     
         49 . The abrasive segment of  claim 48 , wherein the particle-to-particle distance is less than 20% of the aggregate-to-aggregate distance. 
     
     
         50 . (canceled) 
     
     
         51 . (canceled) 
     
     
         52 . (canceled) 
     
     
         53 . The abrasive article of  claim 1 , wherein the plurality of abrasive aggregates includes a plurality of pores formed in a boundary between adjacent silicon carbide particles. 
     
     
         54 . The abrasive article of  claim 53 , wherein the pores comprise an average pore size of at least about 1 micron and no greater than about 10 microns. 
     
     
         55 . (canceled) 
     
     
         56 . The abrasive article of  claim 53 , wherein the pores are substantially aligned along the boundary.