Methods of maximizing retention of superabrasive particles in a metal matrix
Methods of maximizing retention of superabrasive particles in a metal matrix are disclosed. The superabrasive particles may be chemically bonded with the metal matrix to a degree which holds the superabrasive particles in the metal matrix without substantially degrading the superabrasive particles. Substantially degrading the superabrasive particles can be avoided by protecting the superabrasive particles from over-bonding during the chemical bonding process.
1 . A method of maximizing retention of superabrasive particles in a metal matrix comprising:
chemically bonding the superabrasive particles with the metal matrix to a degree which holds the superabrasive particles in the metal matrix without substantially degrading the superabrasive particles.
2 . The method of claim 1 , wherein avoiding substantially degrading the superabrasive particles further includes protecting the superabrasive particles from over-bonding during the chemical bonding process.
3 . The method of claim 2 , wherein protecting the superabrasive particles from over-bonding further comprises:
moderating chemical bonding between the superabrasive particles and the metal matrix to a degree which is sufficient to retain the superabrasive particles in the metal matrix but minimize superabrasive particle degradation.
4 . The method of claim 3 , wherein superabrasive particle degradation includes conversion of the superabrasive particles to a different material.
5 . The method of claim 4 , wherein the different material is a member selected from the group consisting of non-diamond forms of carbon, carbides, nitrides, borides, and combinations thereof.
6 . The method of claim 4 , wherein moderating chemical bonding further includes moderating a relative amount of a reactive element in the metal matrix.
7 . The method of claim 4 , wherein moderating chemical bonding further includes diluting the metal matrix with a protective material which moderates chemical bonding between the superabrasive particles and the metal matrix.
8 . The method of claim 7 , wherein diluting the metal matrix further comprises coating the superabrasive particles with the protective material prior to chemically bonding with the metal matrix.
9 . The method of claim 7 , wherein diluting the metal matrix further comprises admixing the protective material with the metal matrix prior to chemically bonding to the superabrasive particles.
10 . The method of claim 7 , wherein the protective material is selected from the group consisting of copper, silver, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.
11 . The method of claim 10 , wherein the protective material is copper.
12 . The method of claim 10 , wherein the protective material is silver.
13 . The method of claim 10 , wherein the protective material is zinc.
14 . The method of claim 10 , wherein the protective material is selected from the group consisting of titanium, chromium, silicon, tungsten, and mixtures thereof, including carbides, nitrides, and alloys.
15 . A method of making a superabrasive tool having improved retention of superabrasive particles in a metal matrix as recited in claim 1 , comprising:
providing superabrasive particles; and
incorporating the superabrasive particles into a superabrasive tool.
16 . The method of claim 15 , wherein providing superabrasive particles includes providing superabrasive particles coated with a protective material which moderates chemical bonding between the superabrasive particles and the metal matrix to a degree which is sufficient to retain the superabrasive particles in the metal matrix but minimize superabrasive particle degradation.
17 . The method of claim 16 , wherein superabrasive particle degradation includes conversion of the superabrasive particles to a different material.
18 . The method of claim 17 , wherein the different material is a member selected from the group consisting of non-diamond forms of carbon, carbides, nitrides, borides, and combinations thereof.
19 . The method of claim 16 , wherein the protective material is selected from the group consisting of copper, gold, silver, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof, including carbides, nitrides, and alloys.
20 . The method of claim 19 , wherein the protective material is copper.
21 . The method of claim 19 , wherein the protective material is silver.
22 . The method of claim 19 , wherein the protective material is zinc.
23 . The method of claim 19 , wherein the protective material is selected from the group consisting of titanium, chromium, silicon, tungsten, and mixtures thereof, including carbides, nitrides, and alloys.
24 . The method of claim 15 , wherein the superabrasive particles include a member selected from the group consisting of diamond, polycrystalline diamond, cubic boron nitride, polycrystalline cubic boron nitride, and combinations thereof.
25 . The method of claim 24 , wherein the superabrasive particles include diamond.
26 . The method of claim 24 , wherein the superabrasive particles include cubic boron nitride.
27 . The method of claim 15 , wherein incorporating the superabrasive particles into the superabrasive tool further includes chemically bonding a portion of each superabrasive particle to the metal matrix.
28 . The method of claim 15 , wherein the metal matrix is a braze alloy.
29 . The method of claim 15 , further comprising arranging the superabrasive particles in a predetermined pattern, wherein the superabrasive particles are bonded together to substantially conform to the predetermined pattern.