Molten braze-coated superabrasive particles and associated methods
A superabrasive particle coated with a solidified coating of a molten braze alloy that is chemically bonded to the superabrasive particle, where the molten braze alloy includes a substantially less-reactive protective material, is disclosed and described. In one aspect, the molten braze alloy may coat at least about 80% of an outer surface of the superabrasive particle. Various methods for making and using such a coated superabrasive particle are additionally disclosed and described.
1 . A method for preserving the strength of a superabrasive particle having a braze alloy coating bonded thereto by application of the braze alloy coating in a molten state, comprising:
protecting said superabrasive particle with a protective material that is substantially less-reactive with the superabrasive particle than the braze alloy during application of the braze alloy coating to the superabrasive particle.
2 . The method of claim 1 , wherein the superabrasive particle is diamond.
3 . The method of claim 1 , wherein the superabrasive particle is cubic boron nitride.
4 . The method of claim 1 , wherein protecting the superabrasive particle is accomplished by coating the substantially less-reactive protective material on the superabrasive particle prior to the application of the braze alloy coating.
5 . The method of claim 1 , wherein protecting the superabrasive particle is accomplished by admixing the substantially less-reactive protective material in the braze alloy coating.
6 . The method of claim 1 , wherein the substantially less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.
7 . The method of claim 6 , wherein the substantially less-reactive protective material is copper.
8 . The method of claim 6 , wherein the substantially less-reactive protective material is tin.
9 . The method of claim 6 , wherein the substantially less-reactive protective material is zinc.
10 . A method for coating a superabrasive particle having improved strength, a braze alloy coating bonded thereto by application of the braze alloy coating in a molten state, comprising steps of:
providing a superabrasive particle;
protecting the superabrasive particle as recited in claim 1 , while coating the superabrasive particle with a molten braze alloy; and
allowing the coating to solidify.
11 . The method of claim 10 , wherein the superabrasive particle is diamond.
12 . The method of claim 10 , wherein the superabrasive particle is cubic boron nitride.
13 . The method of claim 10 , wherein the step of protecting the superabrasive particle is accomplished by coating the substantially less-reactive protective material on the superabrasive particle prior to the application of the braze alloy coating.
14 . The method of claim 10 , wherein the step of protecting the superabrasive particle is accomplished by admixing the substantially less-reactive protective material in the braze alloy coating.
15 . The method of claim 10 , wherein the substantially less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.
16 . The method of claim 15 , wherein the substantially less-reactive protective material is copper.
17 . The method of claim 15 , wherein the substantially less-reactive protective material is tin.
18 . The method of claim 15 , wherein the substantially less-reactive protective material is zinc.
19 . The method of claim 10 , further comprising the step of pre-coating the superabrasive particle with a reactive material.
20 . The method of claim 19 , wherein the step of pre-coating the superabrasive particle includes admixing the reactive material with the substantially less-reactive protective material.
21 . The method of claim 19 , wherein the reactive material is selected from the group consisting of chromium, silicon, titanium, tungsten, and mixtures thereof, including carbides, nitrides, and alloys.
22 . The method of claim 21 , wherein the reactive material is titanium.
23 . The method of claim 21 , wherein the reactive material is tungsten carbide.
24 . The method of claim 21 , wherein the reactive material is silicon carbide.
25 . The method of claim 21 , wherein the reactive material is chromium.
26 . A method of making a superabrasive tool precursor, comprising steps of:
providing a superabrasive particle; and
coating the superabrasive particle as recited in claim 10 .
27 . The method of claim 26 , further comprising the step of metallurgically bonding together a plurality of coated superabrasive particles with the braze alloy coating.
28 . The method of claim 27 , wherein the step of metallurgically bonding together a plurality of coated superabrasive particles forms a one dimensional structure.
29 . The method of claim 27 , wherein the step of metallurgically bonding together a plurality of coated superabrasive particles forms a two dimensional structure.
30 . The method of claim 27 , wherein the step of metallurgically bonding together a plurality of coated superabrasive particles forms a three dimensional structure.
31 . The method of claim 27 , further comprising the step of arranging the plurality of coated superabrasive particles in a predetermined pattern, wherein the coated superabrasive particles are bonded together to substantially conform to said predetermined pattern.
32 . A method of making a superabrasive tool, comprising:
providing a support matrix;
providing a tool precursor made by the method recited in claim 26; and
metallurgically bonding the tool precursor to the support matrix.
33 . The method of claim 32 , wherein the support matrix comprises a consolidated metal powder.
34 . The method of claim 33 , wherein the support matrix is porous.
35 . The method of claim 32 , wherein the support matrix comprises a solid metal substrate.
36 . The method of claim 32 , further comprising the step of metallurgically bonding a plurality of tool precursors to the support matrix.
37 . The method of claim 36 , further comprising the step of arranging the plurality of tool precursors such that the coated superabrasive particles substantially conform to a predetermined pattern.
38 . The method of claim 32 , wherein the step of metallurgically bonding a tool precursor to the support matrix forms a layer.
39 . The method of claim 38 , further comprising the step of metallurgically bonding together a plurality of layers.
40 . A superabrasive tool precursor comprising:
at least one superabrasive particle bonded with a braze alloy coating, said braze alloy coating including a substantially less-reactive protective material, said braze alloy coating including the substantially less-reactive protective material providing improved strength to the coated superabrasive particle as compared with the braze alloy alone.
41 . The superabrasive tool precursor of claim 40 , wherein the superabrasive particle is diamond.
42 . The superabrasive tool precursor of claim 40 , wherein the superabrasive particle is cubic boron nitride.
43 . The superabrasive tool precursor of claim 40 , wherein the substantially less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.
44 . The method of claim 43 , wherein the substantially less-reactive protective material is copper.
45 . The method of claim 43 , wherein the substantially less-reactive protective material is tin.
46 . The method of claim 43 , wherein the substantially less-reactive protective material is zinc.
47 . The superabrasive tool precursor of claim 40 , wherein the at least one coated superabrasive particle is a plurality of coated superabrasive particles metallurgically bonded together by the braze alloy coating.
48 . The tool precursor of claim 47 , wherein the bonded plurality of coated superabrasive particles forms a one dimensional structure.
49 . The tool precursor of claim 47 , wherein the bonded plurality of coated superabrasive particles forms a two dimensional structure.
50 . The tool precursor of claim 47 , wherein the bonded plurality of coated superabrasive particles forms a three dimensional structure.
51 . The tool precursor of claim 47 , wherein the bonded plurality of coated superabrasive particles are each arranged and held in accordance with a predetermined pattern.
52 . A superabrasive tool, comprising:
a support matrix; and
a tool precursor as recited in claim 40 metallurgically bonded to the support matrix.
53 . The superabrasive tool of claim 52 , wherein the support matrix comprises a consolidated metal powder.
54 . The superabrasive tool of claim 53 , wherein the support matrix is porous.
55 . The superabrasive tool of claim 52 , wherein the support matrix comprises a solid metal substrate.
56 . The superabrasive tool of claim 52 , further comprising a plurality of tool precursors metallurgically bonded to the support matrix.
57 . The superabrasive tool of claim 56 , wherein the plurality of tool precursors are arranged such that the coated superabrasive particles substantially conform to a predetermined pattern.
58 . The superabrasive tool of claim 52 , wherein the support matrix and tool precursor form a layer.
59 . The superabrasive tool of claim 58 , further comprising a plurality of layers metallurgically bonded together.
60 . The superabrasive tool of claim 59 , wherein the substrate of each layer comprises a solid metal, and each tool precursor is porous.
61 . The superabrasive tool of claim 60 , wherein the coated superabrasive particles of each tool precursor are arranged in accordance with a predetermined pattern.
62 . The superabrasive tool of claim 61 , wherein the pores in each tool precursor occur in accordance with a predetermined pattern.
63 . The superabrasive tool of claim 60 , wherein the tool is a saw segment.
64 . The superabrasive tool of claim 63 , wherein the saw segment is a reciprocating saw.
65 . The superabrasive tool of claim 63 , wherein the saw segment is a circular saw.
66 . A superabrasive tool comprising:
a plurality of superabrasive particles bonded together with a braze alloy coating, said braze alloy coating including a substantially less-reactive protective material, said braze alloy coating including the substantially less-reactive protective material providing improved strength to the coated superabrasive particle as compared with the braze alloy alone; and
a plurality of spacer particles chemically bonded to the molten braze alloy.
67 . The superabrasive tool of claim 66 , wherein the superabrasive particle is diamond.
68 . The superabrasive tool of claim 66 , wherein the superabrasive particle is cubic boron nitride.
69 . The superabrasive tool of claim 66 , wherein the less-reactive protective material is selected from the group consisting of copper, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.
70 . The superabrasive tool of claim 69 , wherein the less-reactive protective material is copper.
71 . The superabrasive tool of claim 69 , wherein the less-reactive protective material is tin.
72 . The superabrasive tool of claim 69 , wherein the less-reactive protective material is zinc.
73 . The superabrasive tool of claim 66 , wherein the braze alloy is porous.
74 . The superabrasive tool of claim 66 , wherein the coated superabrasive particles are arranged in accordance with a predetermined pattern.
75 . The superabrasive tool of claim 66 , wherein the spacer particles are arranged in accordance with a predetermined pattern.
76 . The superabrasive tool of claim 73 , wherein braze alloy pores occur in accordance with a predetermined pattern.
77 . The superabrasive tool of claim 66 , wherein the spacer particles include particles of SiC.