Methods of maximizing retention of superabrasive particles in a metal matrix
Methods of making superabrasive tools having improved retention of superabrasive particles in a metal matrix are provided. Such methods may include providing a substrate, providing superabrasive particles, 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, and metallurgically bonding the superabrasive particles to the substrate with the metal matrix.
1 . A method of making a superabrasive tool having improved retention of superabrasive particles in a metal matrix, comprising:
providing a substrate;
providing superabrasive particles;
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; and
metallurgically bonding the superabrasive particles to the substrate with the metal matrix.
2 . The method of claim 1 , wherein without 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 that is sufficient to retain the superabrasive particles in the metal matrix while minimizing 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 includes a member selected from the group consisting of copper, silver, zinc, tin, titanium, silicon, chromium, tungsten, zirconium, and mixtures thereof.
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 includes a member selected from the group consisting of titanium, chromium, silicon, tungsten, and mixtures thereof
15 . The method of claim 7 , wherein the protective material is substantially less reactive with the superabrasive particles than the metal matrix with the superabrasive particles during the chemical bonding of the metal matrix to the superabrasive particles.
16 . The method of claim 7 , further comprising pre-coating the superabrasive particles with a reactive material.
17 . The method of claim 16 , wherein pre-coating the superabrasive particles includes admixing the reactive material with the protective material.
18 . The method of claim 17 , wherein the reactive material is selected from the group consisting of chromium, silicon, titanium, tungsten, and mixtures thereof, including carbides, nitrides, and alloys.
19 . The method of claim 1 , 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 that is sufficient to retain the superabrasive particles in the metal matrix but minimize superabrasive particle degradation.
20 . The method of claim 1 , 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.
21 . The method of claim 20 , wherein the superabrasive particles include diamond.
22 . The method of claim 20 , wherein the superabrasive particles include cubic boron nitride.
23 . The method of claim 1 , wherein the metal matrix is a braze alloy.
24 . The method of claim 23 , wherein the braze alloy includes a nickel alloy having a chromium content of at least about 2 wt %.
25 . A superabrasive tool, comprising:
a substrate; and
a plurality of superabrasive particles metallurgically bonded to the substrate with a metal matrix, at least a portion of each of the plurality of superabrasive particles being chemically bonded to the metal matrix as recited in claim 1 .
26 . The superabrasive tool of claim 25 , wherein the metal matrix includes a protective material which provides improved strength and retention to the superabrasive particles as compared with the metal matrix alone.
27 . The superabrasive tool of claim 25 , wherein the plurality of superabrasive particles includes a member selected from the group consisting of diamond, polycrystalline diamond, cubic boron nitride, polycrystalline cubic boron nitride, and combinations thereof.
28 . The superabrasive tool of claim 26 , 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.
29 . The superabrasive tool of claim 28 , wherein the protective material is copper.
30 . The superabrasive tool of claim 28 , wherein the protective material is tin.
31 . The superabrasive tool of claim 28 , wherein the protective material is zinc.
32 . The superabrasive tool of claim 25 , wherein the substrate is the metal matrix.
33 . The superabrasive tool of claim 25 , wherein the plurality of superabrasive particles are arranged in accordance with a predetermined pattern.
34 . The superabrasive tool of claim 25 , wherein the tool is a member selected from the group consisting of CMP pad dressers, wire saws, chain saws, saw blades, circular saws, frame saws, profile wheels, grinding wheels, drill bits, hole saws, and combinations thereof.
35 . The superabrasive tool of claim 34 , wherein the tool is a CMP pad dresser.