Abrasive article and method for forming same

Abstract

The present disclosure relates to an abrasive article including a body having a bond material including metal and a micro-porosity within the bond material with an average pore size (D50) of not greater than 10 microns and a pore size standard deviation of at least 0.2 microns, and the body further includes abrasive particles contained within the bond material and having an ellipticity of not greater than 1.18 or an average toughness of at least 11257 cycles.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a body comprising:
 a bond material comprising metal and further comprising micro-porosity within the bond material, the micro-porosity comprising an average pore size (D50) of not greater than 10 microns and a pore size standard deviation of at least 0.2 microns; 
 abrasive particles contained within bond material and further comprising at least one of:
 a) an ellipticity of not greater than 1.18; or 
 b) an average toughness of at least 11257 cycles according to ANSIB74.23. 
 
   
     
     
         2 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a material selected from the group consisting of oxides, carbides, nitrides, borides, or any combination thereof. 
     
     
         3 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a superabrasive material. 
     
     
         4 . The abrasive article of  claim 1 , wherein the abrasive particles comprise diamond. 
     
     
         5 . The abrasive article of  claim 1 , wherein the abrasive particles consist essentially of diamond. 
     
     
         6 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a coating. 
     
     
         7 . The abrasive article of  claim 6 , wherein the coating comprises a metal or metal alloy including a transition metal element. 
     
     
         8 . The abrasive article of  claim 6 , wherein the coating comprises titanium. 
     
     
         9 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a particle size distribution including at least one of:
 a D50 of at least 65 microns and not greater than 150 microns;   a D10 of at least 57 microns and not greater than 127 microns; and   a D90 of at least 97 microns and not greater than 165 microns.   
     
     
         10 . The abrasive article of  claim 1 , wherein the abrasive particles comprise a Vickers hardness of at least 2000 kg/mm 2 . 
     
     
         11 . The abrasive article of  claim 1 , wherein the abrasive particles have an average toughness of at least 11850 cycles and not greater than 16000 cycles. 
     
     
         12 . The abrasive article of  claim 1 , wherein the abrasive particles have an ellipticity of at least 1.01 and not greater than 1.17. 
     
     
         13 . The abrasive article of  claim 1 , wherein the body comprises a content of:
 the abrasive particles of at least 2 wt % and not greater than 10 wt % for a total weight of the body;   the bond material of at least 20 wt % and not greater than 95 wt % for the total weight of the body; and   a porosity of at least 0.5 vol % and not greater than 50 vol % for a total volume of the body.   
     
     
         14 . The abrasive article of  claim 1 , wherein the bond material comprises:
 cobalt in a content of at least 0.1 wt % and not greater than 99 wt % for a total weight of the body;   tin in a content of at least 1 wt % and not greater than 15 wt % for the total weight of the body,   tungsten in a content of at least 0.05 wt % and not greater than 20 wt % for the total weight of the body;   copper in a content of not greater than 20 wt % for the total weight of the body; or   any combination thereof.   
     
     
         15 . The abrasive article of  claim 1 , wherein at least 95 wt % of the bond material comprises cobalt, tin and tungsten, and not greater than 5 wt % of the bond material comprises secondary elements selected from the group consisting of aluminum, copper, manganese, lead, silicon, and titanium. 
     
     
         16 . The abrasive article of  claim 1 , wherein the body comprises a first region comprising a first content of abrasive particles and a second region comprising a second content of abrasive particles, wherein the first content and second content are different compared to each other. 
     
     
         17 . The abrasive article of  claim 16 , wherein the first region and the second region are in the form of a layer, wherein the second region is directly contacting the first region. 
     
     
         18 . The abrasive article of  claim 16 , wherein the first region comprises a first content of a first bond material, and wherein the second region comprises a second content of a second bond material, and wherein the second content of the second bond material is different than the first content of the first bond material. 
     
     
         19 . A method for forming an abrasive article including forming a mixture including precursor bond material and abrasive particles; and
 heating the mixture to form a body comprising:
 a bond material comprising metal and further comprising micro-porosity within the bond material, the micro-porosity comprising an average pore size (D50) of not greater than 10 microns and a pore size standard deviation of at least 0.2 microns; 
 abrasive particles contained within bond material and further comprising at least one of:
 a) an ellipticity of not greater than 1.18; or 
 b) an average toughness of at least 11257 cycles. 
 
   
     
     
         20 . The method of  claim 19 , wherein the mixture includes a precursor bond material having an average particle size of not greater than 25 microns.