Abrasive article including shaped abrasive particles

Abstract

Various shaped abrasive particles are disclosed. Each shaped abrasive particle includes a body having at least one major surface and another surface extending from the major surface.

What is claimed is: 
     
         1 . A method for forming shaped abrasive particles comprising:
 forming a mixture comprising a precursor ceramic material;   extruding the mixture through a shaped opening to form an extrusion having a cross-sectional shape corresponding to the shaped opening;   cutting the extrusion into green particles; and   drying the green particles to form shaped abrasive particles.   
     
     
         2 . The method of  claim 1 , wherein drying comprises dropping the green particles through a vertical air dryer to form precursor shaped abrasive particles. 
     
     
         3 . The method of  claim 1 , wherein the method further includes collecting the shaped abrasive particles in a collection receptacle. 
     
     
         4 . The method of  claim 2 , wherein the vertical air dryer comprises an updraft fan. 
     
     
         5 . The method of  claim 2 , wherein the shaped abrasive particles exit the dryer and land onto a conveyor belt. 
     
     
         6 . The method of  claim 1 , wherein the shaped abrasive particles are translated to a post-forming process including surface shaping, curing, reacting, radiating, planarizing, calcining, sintering, sieving, doping, drying, and a combination thereof. 
     
     
         7 . The method of  claim 1 , wherein the shaped abrasive particles are translated through an application zone wherein a dopant material is applied. 
     
     
         8 . The method of  claim 1 , wherein the method further includes sintering the shaped abrasive particles. 
     
     
         9 . The method of  claim 1 , wherein the shaped abrasive particles have substantially the same arrangement of surfaces and edges relative to each other. 
     
     
         10 . The method of  claim 1 , wherein the shaped abrasive particles have a two-dimensional shape, as viewed in a plane defined by the length and width of the body, including a polygonal shape, ellipsoidal shape, a numeral, a Greek alphabet character, a Latin alphabet character, a Russian alphabet character, a complex shape utilizing a combination of polygonal shapes and a combination thereof. 
     
     
         11 . The method of  claim 1 , wherein the precursor ceramic material comprises an oxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, and a combination thereof. 
     
     
         12 . The method of  claim 1 , wherein the precursor ceramic material comprises alumina. 
     
     
         13 . The method of  claim 1 , wherein the mixture has a viscosity of at least about 2×103 Pa s. 
     
     
         14 . The method of  claim 1 , wherein drying is conducted at a drying temperature of not greater than about 300° C. 
     
     
         15 . The method of  claim 1 , wherein the shaped abrasive particles comprises at least about 80 wt % alpha alumina. 
     
     
         16 . The method of  claim 1 , wherein the shaped abrasive particles consist essentially of alpha alumina. 
     
     
         17 . The method of  claim 1 , wherein the shaped abrasive particles are essentially free of a binder material. 
     
     
         18 . The method of  claim 1 , wherein the shaped abrasive particles are incorporated into a fixed abrasive article. 
     
     
         19 . The method of  claim 18 , wherein the fixed abrasive article is selected from a coated abrasive, bonded abrasive, or non-woven abrasive. 
     
     
         20 . The method of  claim 10 , wherein the shaped abrasive particles are triangular.