Abrasive articles and methods of forming

Abstract

An abrasive article includes a bonded abrasive body including a bond material and abrasive particles contained in the bond material. The bonded abrasive body may include improved bond post count, a ratio of bond post count to bond content, or any combination thereof. In an embodiment, the bond material can include a total content of an alkali metal oxide greater than 6 wt % for a total weight of the bond material, a total content of an alkaline earth metal oxide less than 5 wt % for a total weight of the bond material, or a combination thereof.

What is claimed is: 
     
         1 . An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material,
 wherein:
 the abrasive particles have an average particle size (D50) of 1 to 5 microns; and 
 the bond material has a content of at least 1 vol % and at most 14 vol % for a total volume of the bonded abrasive body; and 
   wherein:
 when the content of the bond material is at least 1 vol % and at most 6 vol %, the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 200; and 
 when the content of the bond material is at least 7 vol % and at most 14 vol %, the ratio of the average bond post count to the content of the bond material is greater than 158. 
   
     
     
         2 . The abrasive article of  claim 1 , wherein the content of the bond material is from 5 vol % to 6 vol %, and the average bond post count is greater than 1100 and at most 2700. 
     
     
         3 . The abrasive article of  claim 1 , wherein the content of the bond material is from 1 vol % to 4 vol %, and the average bond post count is at least 680 and at most 1700. 
     
     
         4 . The abrasive article of  claim 1 , wherein the content of the bond material is at least 7 vol % and at most 14 vol %, and the average bond post count is at least 1050 and at most 2700. 
     
     
         5 . The abrasive article of  claim 1 , wherein the bond material comprises a total content of an alkali metal oxide greater than 6 wt % for a total weight of the bond material. 
     
     
         6 . The abrasive article of  claim 1 , wherein the bond material comprises a total content of an alkaline earth metal oxide less than 5 wt % for a total weight of the bond material. 
     
     
         7 . The abrasive article of  claim 1 , wherein the bond material comprises aluminum oxide (Al 2 O 3 ) and one or more alkali metal oxides, wherein a weight content ratio of a content of aluminum oxide to a total content of alkali metal oxides is at least 1.6 and at most 5.7. 
     
     
         8 . The abrasive article of  claim 1 , wherein the bonded abrasive body comprises for a total weight of the bond material:
 a content of aluminum oxide (Al 2 O 3 ) of at least 23 wt % and at most 64 wt %;   a total content of an alkali metal oxide of greater than 6 wt % and at most 22.0 wt %;   a content of boron oxide (B 2 O 3 ) of at least 5 wt % and at most 21 wt %; and   a content of silicon dioxide (SiO 2 ) of at least 18 wt % and at most 55 wt %.   
     
     
         9 . The abrasive article of  claim 8 , wherein the bonded abrasive body comprises for the total volume of the bonded abrasive body, a porosity of at least 26 vol % and at most 68 vol % and a content of abrasive particles of at least 26 vol % and at most 60 vol %. 
     
     
         10 . An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material,
 wherein:
 the abrasive particles have an average particle size (D50) of 6 to 8 microns; and 
 the bond material has a content of at least 1 vol % and at most 14 vol % for a total volume of the bonded abrasive body; and 
   wherein:
 when the content of the bond material is at least 1 vol % and at most 6 vol %, the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 200; and 
 when the content of the bond material is of at least 7 vol % and at most 14 vol %, the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 150. 
   
     
     
         11 . The abrasive article of  claim 10 , wherein the content of the bond material is at least 1 vol % and at most 6 vol % and the average bond post count is greater than 650 and at most 1900. 
     
     
         12 . The abrasive article of  claim 10 , wherein the content of the bond material is at least 7 vol % and at most 14 vol % and the average bond post count is greater than 1350. 
     
     
         13 . The abrasive article of  claim 10 , wherein the bonded abrasive body comprises for a total weight of the bond material:
 a content of aluminum oxide (Al 2 O 3 ) of at least 23 wt % and at most 64 wt %;   a total content of an alkali metal oxide (A 2 O) of greater than 6 wt % and at most 22.0 wt %;   a content of boron oxide (B 2 O 3 ) of at least 5 wt % and at most 21 wt %;   a content of silicon dioxide (SiO 2 ) of at least 18 wt % and at most 55 wt %; and   a total content of an alkaline earth metal oxide of less than 5 wt %.   
     
     
         14 . The abrasive article of  claim 10 , wherein the bonded abrasive body comprises for a total volume of the bonded abrasive body porosity of at least 26 vol % and at most 68 vol % and a content of abrasive particles of at least 26 vol % and at most 60 vol %. 
     
     
         15 . The abrasive article of  claim 10 , wherein the bond material comprises a weight content ratio of alumina to sodium oxides (Al 2 O 3 /Na 2 O), wherein the weight content ratio is at most 7.7 and at least 2.8. 
     
     
         16 . An abrasive article, comprising a bonded abrasive body including abrasive particles contained in a bond material comprising an inorganic material,
 wherein:
 the abrasive particles have an average particle size (D50) of 9 to 25 microns; and 
 the bond material has a content of at least 1 vol % and at most 14 vol % for a total volume of the body; 
   wherein:
 when the content of the bond material is at least 1 vol % and at most 6 vol %, the bonded abrasive body comprises a ratio of an average bond post count to the content of the bond material of greater than 180; and 
 when the content of the bond material is at least 7 vol % and at most 14 vol %, the bonded abrasive body comprises a ratio of bond post count to the content of the bond material of greater than 125. 
   
     
     
         17 . The abrasive article of  claim 16 , wherein the content of the bond material is at least 1 vol % and at most 6 vol % and the average bond post count is at least 610 and at most 1860. 
     
     
         18 . The abrasive article of  claim 16 , wherein the content of the bond material is at least 7 vol % and at most 14 vol % and the average bond post count is at least 1200 and at most 1960. 
     
     
         19 . The abrasive article of  claim 16 , wherein the bonded abrasive body comprises for a total weight of the bond material:
 a content of aluminum oxide (Al 2 O 3 ) of at least 23 wt % and at most 64 wt %;   a content of boron oxide (B 2 O 3 ) of at least 5 wt % and at most 21 wt %; and   a content of silicon dioxide (SiO 2 ) of at least 18 wt % and at most 55 wt %.   
     
     
         20 . The abrasive article of  claim 16 , wherein the bonded abrasive body comprises a weight content ratio of a total content of an alkali metal oxide to a total content of an alkaline earth metal oxide of at least 5 and at most 20.