Note: Descriptions are shown in the official language in which they were submitted.
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
ABRASIVE ARTICLE HAVING REVERSIBLE INTERCHANGEABLE ABRASIVE
SEGMENTS
BACKGROUND
Field of the Disclosure
The following is generally directed to abrasive tools and processes for
forming same, and more
particularly, to abrasive tools utilizing abrasive segments attached to a base
and methods of
assembling such tools.
Description of the Related Art
Tools necessary for furthering infrastructure improvements, such as building
additional roads and
buildings, are vital to the continued economic expansion of developing
regions. Additionally,
developed regions have a continuing need to replacing aging infrastructure
with new and
expanded roads and buildings.
The construction industry utilizes a variety of tools for cutting and grinding
of construction
materials. Cutting and grinding tools are required for to remove or refinish
old sections of roads.
Additionally, quarrying and preparing finishing materials, such as stone slabs
used for floors and
building facades, require tools for drilling, cutting, and polishing.
Typically, these tools include
abrasive segments bonded to a base element or core, such as a plate or a
wheel. As with other
industries, improvements to these abrasive tools are always sought.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure may be better understood, and its numerous features and
advantages made
apparent to those skilled in the art by referencing the accompanying drawings.
FIG. 1 includes a first plan view of an abrasive article in accordance with an
embodiment.
FIG. 2 includes a second plan view of an abrasive article in accordance with
an embodiment.
FIG. 3 includes a first plan view of a segment in accordance with an
embodiment.
FIG. 4 includes a second plan view of a segment in accordance with an
embodiment.
FIG. 5 includes a cross-sectional view of a segment taken along line 5-5 in
FIG. 3 in accordance
with an embodiment.
FIG. 6 includes a perspective view of another abrasive article in accordance
with an embodiment.
FIG. 7 includes a detailed view of an abrasive article taken at circle 8 in
FIG. 7 in accordance with
an embodiment.
FIG. 8 includes a perspective view of another abrasive article in accordance
with an embodiment.
FIG. 9 includes a detailed view of an abrasive article taken at circle 9 in
FIG. 8 in accordance with
an embodiment.
FIG. 10 includes a perspective view of another abrasive article in accordance
with an
embodiment.
FIG. 11 includes a detailed view of an abrasive article taken at circle 11 in
FIG. 10 in accordance
with an embodiment.
- 1 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
FIG. 12 includes a perspective view of another abrasive article in accordance
with an
embodiment.
FIG. 13 includes a detailed view of an abrasive article taken at circle 13 in
FIG. 12 in accordance
with an embodiment.
FIG. 14 includes a perspective view of another abrasive article in accordance
with an
embodiment.
FIG. 15 includes a detailed view of an abrasive article taken at circle 15 in
FIG. 14 in accordance
with an embodiment.
The use of the same reference symbols in different drawings indicates similar
or identical items.
DETAILED DESCRIPTION
According to an embodiment, the abrasive article herein can include a core and
a plurality of
abrasive segments affixed to the core. The abrasive article can be a cutting
tool for cutting
construction materials, such as a saw for cutting concrete. Alternatively, the
abrasive article can
be a grinding tool such as for grinding concrete or fired clay or removing
asphalt.
In general, the abrasive article can include a first segment and a second
segment. The first
segment can include a first segment indicia on a first face and second segment
indicia on a second
face opposite the first face. The second segment can include second segment
indicia on a first
face and first segment indicia on a second face opposite the first face. The
first segment and the
second segment can be arranged with respect to each other on the core to
define first abrasive
article indicia that includes the first segment indicia of the first segment
and the second segment
indicia of the second segment and second abrasive article indicia that
includes the second segment
indicia of the first segment and the first segment indicia of the second
segment.
In a particular aspect, the first segment and the second segment can include a
single segment type.
The single segment type can have first segment indicia on a first face and
second segment indicia
on a second face opposite the first face. Further, the single segment type can
be reversible around
a periphery of the core to define first abrasive article indicia and second
abrasive article indicia
opposite the first abrasive article indicia.
FIG. 1 illustrates an exemplary abrasive article designated 100. As depicted,
the abrasive article
100 can include a core 102. A plurality of segments 104 can extend outwardly
from a perimeter,
or circumference, of the core 102. The segments 104 can be formed separately
from the core, as
described herein, and affixed to the core via a brazing procedure, a welding
procedure, a
mechanical coupling, etc. In a particular aspect, each adjacent pair of
segments 104 can be
separated by a gap, such as a gullet 106.
Each gullet can include a first portion 108 that extends from the outer
periphery, or
circumference, of the adjacent segments 104 toward a center 110 of the core
102. As illustrated,
the center 110 of the core 102 is also the center of the abrasive article 100.
The first portion 108
of the gullet 106 can extend to a second portion 112 of the gullet 106 that is
formed in the core
- 2 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
102. The second portion 112 can extend from an outer periphery of the core 102
toward the
center 110 of the core 102. Further, the second portion 112 can terminate in a
generally circular
end 114. The circular end 114 can be a bore formed through core 102.
The first portion 108 of the gullet can include an open space between two
adjacent segments 104
that is defined by a leading edge 116 of a first segment in the pair of
segments and a trailing edge
118 of a second segment in the pair of segments 104. The second portion 112 of
the gullet 106
can include a slot cut into the core 102. The first portion 108 of the gullet
106 and the second
portion 112 of the gullet 106 can be substantially aligned along the same
axis. Further, the end
114 can include a center that lies along the central axis of the first portion
108 and the second
portion 112 of the gullet 106.
In a particular aspect, the first portion 108 of the gullet 106 can have a
first width and the second
portion 112 of each gullet 106 can include a second width. The first width can
be greater than the
second width. The end 114 of the gullet 106 can have a diameter and the
diameter can be greater
than the first width.
In a particular aspect, as illustrated in FIG. 1 and FIG. 2, the segments 104
are all identical to each
other and can be arranged on the core 102 to form a first abrasive article
indicia 120 around the
outer periphery of the core 102 on a first side of the abrasive article 100
and a second abrasive
article indicia 122 around the outer periphery of the core 102 on a second
side of the abrasive
article 100 opposite the first side. For example, the segments 104 and the
abrasive article indicia
120, 122 can be arranged in a ring around the core 102. The first abrasive
article indicia 120 can
be substantially identical to the second abrasive article indicia 122.
Moreover, the first abrasive
article indicia 120 can be offset with respect to the second abrasive article
indicia 122.
Specifically, if the first abrasive article indicia 120, shown in FIG. 1, was
overlaid on the second
abrasive article indicia 120, shown in FIG. 2, the first abrasive article
indicia 120 would be
angularly distanced, or angularly rotated, with respect to the second abrasive
article indicia 120
and the first abrasive article indicia 120 would not be aligned with the
second abrasive article
indicia 120 so as to block out the second abrasive article indicia 120. In
other words, if the
abrasive article 100 is rotated about an axis 124 passing through the center
110 of the abrasive
article 100, the pattern formed around the outer periphery of the core 102 of
the abrasive article
100 rotates, or otherwise shifts, from side-to-side by one segment.
In a particular aspect, the first abrasive article indicia 120 can be offset
with respect to the second
abrasive article indicia 122 by at least one segment 104 so that a first
orientation of the first
abrasive article indicia 120 is angularly distanced, i.e., rotated, with
respect to a second
orientation of the second abrasive article indicia 122 on the core 102. As
illustrated in FIG. 1 and
FIG. 2, the abrasive article can be generally round and the first abrasive
article indicia 120 can be
angularly offset from the second abrasive article indicia 122 by at least one
segment arc length.
- 3 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
As illustrated in FIG. 1 and FIG. 2, the first abrasive article indicia 120
and the second abrasive
article indicia 122 each includes a plurality of first segment indicia 130 and
a plurality of second
segment indicia 130. The plurality of first segment indicia 130 and the
plurality of second
segment indicia 132 can be arranged in a pattern to define the first abrasive
article indicia 120 and
the second abrasive article indicia 122. Specifically, the first segment
indicia 130 and the second
segment indicia 132 can be arranged in a ring around the core 102. Further,
the first segment
indicia 130 and the second segment indicia 132 can alternate relative to each
other around the
core 102. In another aspect, each of the first abrasive article indicia 130
and the second abrasive
article indicia 132 can include a company name, a product name, a product
identifier, a company
logo, a product logo, a design, or a combination thereof.
As shown in FIG. 3 and FIG. 4, each segment 104 can include a first face 140
and a second face
142 that is different from and opposite to the first face 140. In particular,
the first face 140 and
the second face 142 are spaced a distance from each other and are
substantially parallel to each
other. The first segment indicia 130 can be formed in the first face 140 of
the segment 104 and
the second segment indicia 130 can be formed in the second face 142 of the
segment 104 opposite
the first face. In particular, the second segment indicia 142 can be different
from the first segment
indicia 140.
FIG. 3 and FIG. 4 indicate that the first segment indicia 130 can include a
continuous portion 150
that extends continuously along the segment from a leading edge 152 of the
segment 104 to a
trailing edge 154 of the segment 104. Moreover, the first segment indicia 130
can include at least
one other portion 156 located within an area bounded by the continuous portion
150, the leading
edge 152 of the segment 104, the trailing edge 154 of the segment 104, and an
outer perimeter of
the core 102 (or the inner periphery 158 of the segment 104 which is adjacent
to, and extends
along, the outer perimeter of the core 102).
The second segment indicia 132 of each segment 104 can include a continuous
portion 160 that
can extend continuously along the segment 104 from the leading edge 152 of the
segment 104 to
the trailing edge 154 of the segment 104. The second segment indicia 132 of
each segment 104
can also include at least one other portion 162 that is located within an area
bounded by the
continuous portion 160, the leading edge 152 of the segment 104, the trailing
edge 154 of the
segment 104, and an outer perimeter of the core 102 or an inner periphery 158
of the segment.
In a particular aspect, the continuous portion 150 of the first segment
indicia 130 is the same
shape as the continuous portion 160 of the second segment indicia 132.
However, the at least one
other portion 156 of the first segment indicia 130 can be different that the
at least one other
portion 162 of the second segment indicia 132.
As depicted in FIG. 3 and FIG. 4, the segment 104 can include a first relief
portion 170 formed in
the first face 140 of the segment. The first relief portion 170 can be formed
by pressing a portion
of the material of the segment 104 into the segment 104 away from the first
face 140. This can be
- 4 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
performed during a molding process. The molding process can include pressing a
green segment
using a hot pressing operation, a cold pressing operation, or some other
pressing operation. In a
particular aspect, the first relief portion 170 can at least partially
surround the first segment indicia
130.
Further, the first relief portion can include a substantially uniform first
depth, Di, that is measured
perpendicularly into the segment 104 from the first face 140 of the segment
104. In one aspect, Di
can be > 5% of the segment thickness, T, measured from the first face 140 to
the second face 142.
For example, Di can be > 10% T, or > 15% T. In another aspect, Di can be < 30%
T, such as <
25% T, or < 20% T. Further, Di can be within a range between and including any
of the % of T
values above.
Each segment 104 can also include a second relief portion 172 formed in the
second face 132 in
the same manner as the first relief portion 170. The second relief portion 172
can at least partially
surround the second segment indicia 132. Also, the second relief portion 172
includes a second
depth, D2, that is measured perpendicularly into the segment 104 from the
second face 142 of the
segment 104. In one aspect, D2 can be > 5% T, such as > 10% T, or > 15% T. In
another aspect,
D2 can be < 30% T, such as < 25% T, or < 20% T. Further, D2 can be within a
range between and
including any of the % of T values above. Moreover, Di = D2 5%D2, such as D2
4% D2, D2
3% D2, D2 2% D2, or D2 1% D2. In another aspect, Di = D2.
In a particular aspect, the relief portions 170, 172 can be established by
removing material from
the first face 130 and second face 132 of the segment 104. In such an aspect,
the material
removed from each face 130, 132 of the segment 104 should be substantially the
same in order to
maintain balance and prevent vibration of the abrasive article 100 during use.
If Di = D2, the
same volume of material can be removed from each face 130, 132, or compressed,
by removing or
compressing material over the same total area of each face 130, 132.
Accordingly, the first face
130 of the segment 104 can include an overall surface area, AF1, before the
first relief portion 170
is formed. After the first relief portion 170 is formed, the resulting first
segment indicia 130 can
have a first segment indicia surface area, Asll. Similarly, the second face
132 of the segment can
include an overall surface area, AF2, before the second relief portion 172 is
formed. After the
second relief portion 172 is formed, the resulting second segment indicia 132
can have a second
segment indicia surface area As12.
In a particular aspect, AsI1 can be < 45% An, such as < 40% An, or < 35% AFI.
Further, AsI1 can
be > 10% AF1, such as > 15% AF1, > 20% AF1, or > 25% An. ASH can be in a range
between and
including any of the area values described above.
Similarly, AsI2 can be < 45% AF2, such as < 40% AF2, or < 35% A. Moreover,
As12 can be >
10% AF2, such as > 15% AF2, > 20% AF2, or > 25% A. AsI2 can be in a range
between and
including any of the area values described above.
- 5 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
Additionally, in a particular aspect, AsI1 can = As12 5% ASI2, such as As12
4% ASI2, AS12 3%
AsI2, ASI2 2% AS12, or As12 1% Asm. Further, ASTI can = Al2.S
Referring now to FIG. 6 and FIG. 7, another abrasive article is illustrated
and is designated 600.
The abrasive article 600 can include a core 602. A plurality of segments 604
can extend
outwardly from a perimeter, or circumference, of the core 602. Each adjacent
pair of segments
604 can be separated by a gap, such as a gullet 606.
In a particular aspect, as illustrated in FIG. 6 and FIG. 7, the segments 604
are all identical to each
other and can be arranged on the core 602 to form a first abrasive article
indicia 620 around the
outer periphery of the core 602 on a first side of the abrasive article 600
and a second abrasive
article indicia (not shown) around the outer periphery of the core 602 on a
second side of the
abrasive article 600 opposite the first side. The first abrasive article
indicia 620 can be
substantially identical to the second abrasive article indicia. Moreover, the
first abrasive article
indicia 620 can be offset with respect to the second abrasive article indicia.
As illustrated in FIG. 6 and FIG. 7, the first abrasive article indicia 620
can include a plurality of
first segment indicia 630 and a plurality of second segment indicia 632. The
plurality of first
segment indicia 630 and the plurality of second segment indicia 632 can be
arranged in a pattern,
e.g., a ring, to define the first abrasive article indicia 620 and the second
abrasive article indicia.
Each of the first abrasive article indicia 630 and the second abrasive article
indicia 632 can
include a company name, a product name, a product identifier, a company logo,
a product logo, a
design, or a combination thereof.
FIG. 8 and FIG. 9 depict another abrasive article 800. The abrasive article
800 can include a core
802. A plurality of segments 804 can extend outwardly from a perimeter, or
circumference, of the
core 802. Each adjacent pair of segments 804 can be separated by a gap, such
as a gullet 806.
As illustrated in FIG. 8 and FIG. 9, the segments 804 are all identical to
each other and can be
arranged on the core 802 to form a first abrasive article indicia 820 around
the outer periphery of
the core 802 on a first side of the abrasive article 800 and a second abrasive
article indicia (not
shown) around the outer periphery of the core 802 on a second side of the
abrasive article 800
opposite the first side. The first abrasive article indicia 820 can be
substantially identical to the
second abrasive article indicia. Moreover, the first abrasive article indicia
820 can be offset with
respect to the second abrasive article indicia.
The first abrasive article indicia 820 can include a plurality of first
segment indicia 830 and a
plurality of second segment indicia 832. The plurality of first segment
indicia 830 and the
plurality of second segment indicia 832 can be arranged in a pattern, e.g., a
ring, to define the first
abrasive article indicia 820 and the second abrasive article indicia. Each of
the first abrasive
article indicia 830 and the second abrasive article indicia 832 can include a
company name, a
product name, a product identifier, a company logo, a product logo, a design,
or a combination
thereof.
- 6 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
Referring to FIG. 10 and FIG. 11, yet another abrasive article 1000 is
depicted. As illustrated, the
abrasive article 1000 can include a core 1002. A plurality of segments 1004
can extend outwardly
from a perimeter, or circumference, of the core 1002. Each adjacent pair of
segments 1004 can be
separated by a gap, such as a gullet 1006.
As indicated in FIG. 10 and FIG. 11, the segments 1004 are all identical to
each other and can be
arranged on the core 1002 to form a first abrasive article indicia 1020 around
the outer periphery
of the core 1002 on a first side of the abrasive article 1000 and a second
abrasive article indicia
(not shown) around the outer periphery of the core 1002 on a second side of
the abrasive article
1000 opposite the first side. The first abrasive article indicia 1020 can be
substantially identical
to the second abrasive article indicia. Moreover, the first abrasive article
indicia 1020 can be
offset with respect to the second abrasive article indicia.
In a particular aspect, the first abrasive article indicia 1020 can include a
plurality of first segment
indicia 1030 and a plurality of second segment indicia 1032. The plurality of
first segment indicia
1030 and the plurality of second segment indicia 1032 can be arranged in a
pattern, e.g., a ring, to
define the first abrasive article indicia 1020 and the second abrasive article
indicia. Each of the
first abrasive article indicia 1030 and the second abrasive article indicia
1032 can include a
company name, a product name, a product identifier, a company logo, a product
logo, a design, or
a combination thereof.
Referring now to FIG. 12 and FIG. 13, yet another abrasive article 1200 is
illustrated. The
abrasive article 1200 can include a core 1202. A plurality of segments 1204
can extend outwardly
from a perimeter, or circumference, of the core 1202. Each adjacent pair of
segments 1204 can be
separated by a gap, such as a gullet 1206.
As illustrated in FIG. 12 and FIG. 13, the segments 1204 are all identical to
each other and can be
arranged on the core 1202 to form a first abrasive article indicia 1220 around
the outer periphery
of the core 1202 on a first side of the abrasive article 1200 and a second
abrasive article indicia
(not shown) around the outer periphery of the core 1202 on a second side of
the abrasive article
1200 opposite the first side. The first abrasive article indicia 1220 can be
substantially identical
to the second abrasive article indicia. In a particular aspect, the first
abrasive article indicia 1220
can be offset with respect to the second abrasive article indicia.
Additionally, the first abrasive article indicia 1220 can include a plurality
of first segment indicia
1230 and a plurality of second segment indicia 1232. The plurality of first
segment indicia 1230
and the plurality of second segment indicia 1232 can be arranged in a pattern,
e.g., a ring, to
define the first abrasive article indicia 1220 and the second abrasive article
indicia. Each of the
first abrasive article indicia 1230 and the second abrasive article indicia
1232 can include a
company name, a product name, a product identifier, a company logo, a product
logo, a design, or
a combination thereof.
- 7 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
FIG. 14 and FIG. 15 illustrate still another abrasive article 1400. The
abrasive article 1400 can
include a core 1402 and a plurality of segments 1404 can extend outwardly from
a perimeter, or
circumference, of the core 1402. Each adjacent pair of segments 1404 can be
separated by a gap,
such as a gullet 1406.
In a particular aspect, the segments 1404 are all identical to each other and
can be arranged on the
core 1402 to form a first abrasive article indicia 1420 around the outer
periphery of the core 1402
on a first side of the abrasive article 1400 and a second abrasive article
indicia (not shown) around
the outer periphery of the core 1402 on a second side of the abrasive article
1400 opposite the first
side. The first abrasive article indicia 1420 can be substantially identical
to the second abrasive
article indicia. Moreover, the first abrasive article indicia 1420 can be
offset with respect to the
second abrasive article indicia.
As illustrated in FIG. 14 and FIG. 15, the first abrasive article indicia 1420
can include a plurality
of first segment indicia 1430 and a plurality of second segment indicia 1432.
The plurality of first
segment indicia 1430 and the plurality of second segment indicia 1432 can be
arranged in a
pattern, e.g., a ring, to define the first abrasive article indicia 1420 and
the second abrasive article
indicia. Each of the first abrasive article indicia 1430 and the second
abrasive article indicia 1432
can include a company name, a product name, a product identifier, a company
logo, a product
logo, a design, or a combination thereof.
In a particular aspect, the core of each abrasive article described herein can
be in the form of a
ring, a ring section, a plate, or a disc depending upon the intended
application of the abrasive
article. The core can be made of a metal or metal alloy. For instance, the
base can be made of
steel, and particularly, a heat treatable steel alloys, such as 25CrMo4, 75Cr
1, C60, or similar steel
alloys for a core having a thin cross section or simple construction steel
like St 60 or similar for a
thick core. The core can have a tensile strength of at least about 600 N/mm2.
The core can be
formed by a variety of metallurgical techniques known in the art.
In an exemplary embodiment, an abrasive segment includes abrasive particles
embedded in a
bond matrix. The bond matrix can include a metal matrix having a network of
interconnected
pores. The abrasive particles can include an abrasive material having a Mohs
hardness of at least
about 7. In particular instances, the abrasive particles can include a
superabrasive material, such
as diamond or cubic boron nitride. The abrasive particles can have a particle
size of not less than
about 400 US mesh, such as not less than about 100 US mesh, such as between
about 25 and 80
US mesh. Depending on the application, the size can be between about 30 and 60
US mesh.
The abrasive particles can be present in an amount between about 2 vol% to
about 50 vol%.
Additionally, the amount of abrasive particles may depend on the application.
For example, an
abrasive segment for a grinding or polishing tool can include between about
3.75 and about 50
vol% abrasive particles of the total volume of the abrasive segment.
Alternatively, an abrasive
segment for a cutting-off tool can include between about 2 vol% and about 6.25
vol% abrasive
- 8 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
particles of the total volume of the abrasive segment. Further, an abrasive
segment for core
drilling can include between about 6.25 vol% and about 20 vol% abrasive
particles of the total
volume of the abrasive segment.
The metal matrix can include a metal element or metal alloy including a
plurality of metal
elements. For certain abrasive segments, the metal matrix can include metal
elements such as
iron, tungsten, cobalt, nickel, chromium, titanium, silver, and a combination
thereof. In particular
instances, the metal matrix can include a rare earth element such as cerium,
lanthanum,
neodymium, and a combination thereof.
In one particular example, the metal matrix can include a wear resistant
component. For example,
in one embodiment, the metal matrix can include tungsten carbide, and more
particularly, may
consist essentially of tungsten carbide.
In certain designs, the metal matrix can include particles of individual
components or pre-alloyed
particles. The particles can be between about 1.0 microns and about 250
microns.
As noted above, the abrasive segment can be formed such that an infiltrant is
present within the
interconnected network of pores within the body of the abrasive segment. The
infiltrant can
partially fill, substantially fill, or even completely fill the volume of the
pores extending through
the volume of the abrasive segment. In accordance with one particular design,
the infiltrant can
be a metal or metal alloy material. For example, some suitable metal elements
can include
copper, tin, zinc, and a combination thereof.
In particular instances, the infiltrant can be a bronzing material made of a
metal alloy, and
particular a copper-tin metal alloy, such that it is particularly suited for
welding according to
embodiments herein. For example, the bronzing material can consist essentially
of copper and
tin. Certain bronzing materials can incorporate particular contents of tin,
such as not greater than
about 20%, not greater than about 15%, not greater than about 12%, or even not
greater than
about 10% of the total amount of materials within the composition. In
accordance with an
embodiment, the bronzing material can include an amount of tin within a range
between about 5%
and about 20%, such as between about 8% and about 15%, or even between about
8% and about
12%.
Moreover, certain bronzing materials can be used as infiltrant material, and
can have an amount of
copper of at least about 80%, at least about 85%, or even at least about 88%
of the total amount of
materials within the composition. Some bronzing materials can utilize an
amount of copper
within a range between about 80% and about 95%, such as between about 85% and
about 95%, or
even between about 88% and about 93%.
Additionally, the bronzing material may contain a particularly low content of
other elements, such
as zinc to facilitate proper formation of the abrasive article according to
the forming methods of
the embodiments herein. For example, the bronzing material may utilize not
greater than about
- 9 -
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
10%, such as not greater than about 5%, or even not greater than about 2%
zinc. In fact, certain
bronzing materials can be essentially free of zinc.
The abrasive segment may be manufactured, such that abrasive particles can be
combined with a
metal matrix to form a mixture. The metal matrix can include a blend of
particles of the
components of the metal matrix or can be pre-alloyed particles of the metal
matrix. In an
embodiment, the metal matrix can conform to the formula (WC)wW,,FeyCrzX(i-w-x-
y-z), wherein
0<w<0.8, 0<x<0.7, 0<y<0.8, 0<z<0.05, w+x+y+z<1, and X can include other metals
such as
cobalt and nickel. In another embodiment, the metal matrix can conform to the
formula
(WC)wWxFeyCrzAgvX(i-v-w-x-y-z), wherein 0<w<0.5, 0<x<0.4, 0<y<1.0, 0<z<0.05,
0<v<0.1,
v+w+x+y+z<1, and X can include other metals such as cobalt and nickel.
The mixture of metal matrix and abrasive particles can be formed into an
abrasive preform by a
pressing operation, particularly a cold pressing operation, to form a porous
abrasive segment. The
cold pressing can be carried out at a pressure of between about 50 kN/cm2 (500
MPa) to about
250 kN/cm2 (2500 MPa). The resulting porous abrasive segment can have a
network of
interconnected pores. In an example, the porous abrasive segment can have a
porosity between
about 25 and 50 vol%.
The resulting porous abrasive segment can then be subject to an infiltration
process, wherein the
infiltrant material is disposed within the body of the abrasive segment, and
particularly, disposed
within the interconnected network of pores within the body of the abrasive
segment. The
infiltrant may be drawn into the pores of the cold pressed abrasive segment
via capillary action.
After the infiltration process, the resulting densified abrasive segment can
be not less than about
96% dense. The amount of infiltrant that infiltrates the abrasive segment can
be between about 20
wt% and 45 wt% of the densified abrasive segment.
The abrasive segment can include a backing region, disposed between the
abrasive segment and
the base, i.e., the core, which facilitates the joining of the abrasive
segment and the base.
According to one embodiment, the backing region can be a distinct region from
the abrasive
segment and the base. Still, the backing region can be initially formed as
part of the abrasive
segment, and particularly may be a distinct region of the abrasive segment
that has particular
characteristics facilitating the joining of the abrasive segment and the base.
For example,
according to one embodiment, the backing region can have a lesser percentage
(vol%) of abrasive
particles as compared to the amount of abrasive particles within the abrasive
segment. In fact, in
certain instances, the backing region can be essentially free of abrasive
particles. This may be
particularly suitable for forming methods utilizing a beam of energy (e.g., a
laser) used to weld
the abrasive segment to the base.
At least a portion of the backing region can include a bonding composition.
The bonding
composition can include a metal or metal alloy. Some suitable metal materials
can include
- 10-
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
transition metal elements, including for example, titanium, silver, manganese,
phosphorus,
aluminum, magnesium, chromium, iron, lead, copper, tin, and a combination
thereof.
In particular instances, the bonding composition can be similar to the
infiltrant, such that the
bonding composition and the infiltrant are different from each other by not
greater than a single
elemental species. In even more particular instances, the bonding composition
can be the same as
the infiltrant. According to embodiments herein, the bonding composition can
be related to the
infiltrant composition in having a certain degree of commonality of elemental
species.
Quantitatively, an elemental weight percent difference between the bonding
composition and the
infiltrant composition does not exceed 20 weight percent. Elemental weight
percent difference is
defined as the absolute value of the difference in weight content of each
element contained in the
bonding composition relative to the infiltrant composition. Other embodiments
have closer
compositional relationships between the bonding composition and the
composition of the
infiltrant. The elemental weight percent difference between the bonding
composition and the
infiltrant composition may, for example, not exceed 15 weight percent, 10
weight percent, 5
weight percent, or may not exceed 2 weight percent. An elemental weight
percent difference of
about zero represents the same composition making up the backing region and
the infiltrant. The
foregoing elemental values may be measured by any suitable analytical means,
including
microprobe elemental analysis, and ignores alloying that might take place
along areas in which
the infiltrant contacts the metal matrix.
The backing region can include at least about 90 wt% infiltrant, such as at
least about 95 wt%
infiltrant, such as at least about 98 wt% infiltrant. The infiltrant can be
continuous throughout the
backing region and the densified abrasive segment. In certain instances, the
backing region can
be formed primarily of the infiltrant material, and in more particular
instances, can consist
essentially of the infiltrant material. Still, in other embodiments, the
backing region can be an
infiltrated region, like the abrasive segment. Accordingly, the backing region
can include a
network of interconnected pores formed between a matrix metal, and wherein the
infiltrant
material substantially fills the interconnected pores. The backing region can
contain similar
amounts of matrix metal and infiltrant. Notably, the backing region may be
essentially free of
abrasive particles. In such embodiments wherein the backing region includes
interconnected
pores substantially filled with the infiltrant, the infiltrant material can
act as a bronzing material in
forming a joint (e.g., a welded joint) between the base and the abrasive
segment.
In one embodiment, the backing region can be formed of the bronzing material
described herein.
In fact, certain backing regions can consist essentially of a copper-tin
bronzing material having
about 88% copper and 12% tin or 90% copper and 10% tin.
In general, an abrasive article as described herein can be made by forming a
plurality of segments.
Each of the plurality of segments can include first segment indicia on a first
face and second
segment indicia on a second face that is opposite the first face. While each
of the plurality of
-11-
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
segments is identically constructed, the first segment indicia on a single
segment are different
from the second segment indicia on the segment. The segments can be configured
to establish
first abrasive article indicia on a first side of the abrasive article and
second abrasive article
indicia on a second side of the abrasive article opposite the first side. The
first abrasive article
indicia and the second abrasive article indicia can include at least one first
segment indicia and at
least one second segment indicia. The shape of the abrasive article indicia,
i.e., the generally
sinusoidal or wave-shape, around the periphery of the abrasive article can
serve to pump cutting
fluid into and out of a cutting area as the abrasive article rotates. This
pumping action can aid in
cooling the cutting area and cleaning the cutting area of swarf or debris. In
addition, the abrasive
article indicia can serve as an identifier of the abrasive article, the
manufacturer of the abrasive
article, etc.
The method of making the abrasive article can include affixing a first of the
plurality of segments
to a core such that the first segment indicia is facing a first direction and
the second segment
indicia is facing a second direction opposite the first direction and affixing
a second of the
plurality of segments to a core such that the second segment indicia is facing
the first direction
and the first segment indicia is facing the second direction. In this aspect,
the first segment is
rotated 180 with respect to the second segment.
Affixing the segments to the core can include welding the abrasive segments to
the core. In
particular, the welding process can include impinging a beam of energy at the
base of each
segment. More particularly in the instance of a segment having a backing
region, welding can
include impinging a beam of energy at the backing region between the abrasive
segment and the
core. In particular instances, the beam of energy can be a laser, such that
each abrasive segment is
attached to the core via a laser welded bond joint. The laser may be a Roffin
laser source
commonly available from Dr. Fritsch, GmbH.
In one aspect, each segment can be formed by pressing a green segment in a
mold and curing the
green segment. The pressing can include hot pressing or cold pressing. In
another aspect,
forming each segment can include sintering a green segment, e.g., using an
electro-discharge
sintering process. In yet another aspect, forming each segment can include the
infiltration method
described herein.
The abrasive article described herein can also be made by forming a plurality
of segments in
which each segment includes first segment indicia on a first face and second
segment indicia on a
second face. While the segments are identical, the first segment indicia are
different from the
second segment indicia. This method can also include arranging the segments to
establish a first
abrasive article indicia on a first side of the abrasive article and a second
abrasive article indicia
on a second side of the abrasive article. The first abrasive article indicia
and the second abrasive
article indicia comprise at least one first segment indicia and at least one
second segment indicia.
Further, the first abrasive article indicia and the second abrasive article
indicia are identical.
- 12-
CA 02877751 2014-12-22
WO 2014/005079
PCT/US2013/048696
However, the first abrasive article indicia are angularly offset with respect
to the second abrasive
article indicia.
According to an embodiment, the abrasive article includes a carrier element,
e.g., a core, and an
abrasive component. The abrasive article can be a cutting tool for cutting
construction materials,
such as a saw for cutting concrete. Alternatively, the abrasive article can be
a grinding tool such
as for grinding concrete or fired clay or removing asphalt. In particular, the
following
embodiments have formulated a method for the welding of infiltrated abrasive
segments onto a
base for use in an abrasive article.
In the foregoing, reference to specific embodiments and the connections of
certain components is
illustrative. It will be appreciated that reference to components as being
coupled or connected is
intended to disclose either direct connection between said components or
indirect connection
through one or more intervening components as will be appreciated to carry out
the methods as
discussed herein. As such, the above-disclosed subject matter is to be
considered illustrative, and
not restrictive, and the appended claims are intended to cover all such
modifications,
enhancements, and other embodiments, which fall within the true scope of the
present invention.
Thus, to the maximum extent allowed by law, the scope of the present invention
is to be
determined by the broadest permissible interpretation of the following claims
and their
equivalents, and shall not be restricted or limited by the foregoing detailed
description.
The Abstract of the Disclosure is provided to comply with Patent Law and is
submitted with the
understanding that it will not be used to interpret or limit the scope or
meaning of the claims. In
addition, in the foregoing Detailed Description of the Drawings, various
features may be grouped
together or described in a single embodiment for the purpose of streamlining
the disclosure. This
disclosure is not to be interpreted as reflecting an intention that the
claimed embodiments require
more features than are expressly recited in each claim. Rather, as the
following claims reflect,
inventive subject matter may be directed to less than all features of any of
the disclosed
embodiments. Thus, the following claims are incorporated into the Detailed
Description of the
Drawings, with each claim standing on its own as defining separately claimed
subject matter.
- 13 -
