Abrasive article and method of forming

Abstract

An abrasive article including a substrate having an elongated body, a tacking layer overlying the substrate, a first type of abrasive particle overlying the tacking layer, a second type of abrasive particle different than the first type of abrasive particles overlying the tacking layer, and a bonding layer overlying at least a portion of one of the first type of abrasive particle and the second type of abrasive particle and the tacking layer.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a substrate;   a tacking film overlying the substrate;   abrasive particles bonded to the tacking film, and   a bonding layer overlying the abrasive particles and the tacking film.   
     
     
         2 . The abrasive article of  claim 1 , wherein the tacking film comprises a transition metal element. 
     
     
         3 . The abrasive article of  claim 2 , wherein the tacking film comprises a metal alloy of tin and lead. 
     
     
         4 . The abrasive article of  claim 2 , wherein the tacking film comprises tin. 
     
     
         5 . The abrasive article of  claim 1 , wherein the tacking film comprises an average thickness of not greater than about 80% of an average particle size of the abrasive particles. 
     
     
         6 . The abrasive article of  claim 1 , wherein the tacking film comprises an average thickness of at least about 11% of an average particle size of the abrasive particles. 
     
     
         7 . The abrasive article of  claim 1 , wherein the tacking film has a melting point of not greater than about 450° C. 
     
     
         8 . The abrasive article of  claim 1 , wherein the tacking film is in direct contact with a surface of the substrate. 
     
     
         9 . The abrasive article of  claim 8 , wherein the tacking film is bonded directly to a surface of the substrate. 
     
     
         10 . The abrasive article of  claim 1 , wherein the tacking film overlies a majority of an external surface of the substrate. 
     
     
         11 . The abrasive article of  claim 10 , wherein the tacking film overlies essentially the entire external surface of the substrate. 
     
     
         12 . The abrasive article of  claim 1 , wherein the abrasive article comprises a ratio C/ttl of at least about 2, where C represents the concentration of abrasive particles in particles per mm of substrate and ttl represents the tacking layer thickness in percent of the average abrasive particle size. 
     
     
         13 . The abrasive article of  claim 1 , wherein the substrate comprises a material selected from the group consisting of metal, metal alloys, ceramic, glass, and a combination thereof. 
     
     
         14 . The abrasive article of  claim 1 , wherein the substrate comprises an elongated body having an aspect ratio of length:width of at least about 10:1. 
     
     
         15 . The abrasive article of  claim 1 , wherein the substrate comprises an average length of at least about 50 m. 
     
     
         16 . The abrasive article of  claim 1 , wherein the substrate comprises an average width of not greater than about 1 mm. 
     
     
         17 . The abrasive article of  claim 1 , wherein the substrate consists essentially of a wire. 
     
     
         18 . The abrasive article of  claim 17 , wherein a core of the substrate comprises a plurality of filaments braided together. 
     
     
         19 . The abrasive article of  claim 1 , wherein the bonding layer comprises an average thickness of at least about 1 micron and not greater than about 60 microns. 
     
     
         20 . The abrasive article of  claim 1 , further comprising an abrasive particle concentration of at least about 10 particles per mm of substrate.