Abrasive article and method of forming

Abstract

An abrasive article including a substrate made of a wire, abrasive particles affixed to the substrate, the abrasive particles having a first coating layer overlying the abrasive particles, and a second coating layer different than the first coating layer overlying the first coating layer. The abrasive article further including a bonding layer overlying the substrate and abrasive particles.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a substrate comprising an elongated body having an aspect ratio of length:width of at least about 10:1;   abrasive particles affixed to the substrate;   a discontinuous coating including a metal material defining coated regions comprising a low temperature metal alloy (LTMA) material surrounding and overlying a majority of the abrasive particles and gap region between the abrasive particles.   
     
     
         2 . The abrasive article of  claim 1 , wherein the substrate comprises an inorganic material. 
     
     
         3 . The abrasive article of  claim 1 , wherein the substrate comprises an average length of at least about 50 m. 
     
     
         4 . The abrasive article of  claim 1 , wherein the substrate comprises an average width of not greater than about 1 mm. 
     
     
         5 . The abrasive article of  claim 1 , wherein the substrate consists essentially of a wire. 
     
     
         6 . The abrasive article of  claim 1 , wherein the discontinuous coating layer comprises a material selected from the group of materials consisting of metal, metal alloys, metal matrix composites, and a combination thereof. 
     
     
         7 . The abrasive article of  claim 1 , wherein the discontinuous coating layer comprises a transition metal element. 
     
     
         8 . The abrasive article of  claim 7 , wherein the discontinuous coating layer comprises a metal selected from the group of metals consisting of lead, silver, copper, zinc, tin, titanium, molybdenum, chromium, iron, manganese, cobalt, niobium, tantalum, tungsten, palladium, platinum, gold, ruthenium, and a combination thereof. 
     
     
         9 . The abrasive article of  claim 1 , wherein the discontinuous coating layer has a melting point of not greater than about 450° C. 
     
     
         10 . The abrasive article of  claim 1 , wherein the discontinuous coating layer comprises an average thickness of not greater than about 12 microns. 
     
     
         11 . The abrasive article of  claim 1 , wherein the discontinuous coating layer comprises an average thickness of not greater than about 80% of an average particle size of the abrasive particles. 
     
     
         12 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a material selected from the group of materials consisting of oxides, carbides, nitrides, borides, oxynitrides, oxyborides, diamond, and a combination thereof. 
     
     
         13 . The abrasive article of  claim 1 , wherein the abrasive particles comprise an average particle size of not greater than about 500 microns. 
     
     
         14 . The abrasive article of  claim 1 , wherein the abrasive article further comprises a bonding layer overlying the substrate and abrasive particles. 
     
     
         15 . The abrasive article of  claim 14 , wherein the bonding layer directly contacts the discontinuous coating layer. 
     
     
         16 . The abrasive article of  claim 14 , wherein the bonding layer overlies a majority of an external surface of the substrate and an external surface of the abrasive particles. 
     
     
         17 . The abrasive article of  claim 14 , wherein the bonding layer overlies at least about 90% of the external surfaces of the substrate and abrasive particles. 
     
     
         18 . The abrasive article of  claim 14 , wherein the bonding layer overlies essentially all of the external surfaces of the abrasive particles and the substrate. 
     
     
         19 . The abrasive article of  claim 14 , wherein the bonding layer comprises a material selected from the group of materials consisting of metals, metal alloys, cements, ceramics, composites, and a combination thereof. 
     
     
         20 . The abrasive article of  claim 14 , wherein the bonding layer comprises an average thickness of at least about 10% of an average particle size of the abrasive particles.