Brazed diamond tools and methods for making the same

1 . A method of making a superabrasive tool, comprising the steps of:

a) providing a substrate; and

b) brazing a plurality of superabrasive particles directly to an exposed surface of the substrate in accordance with a predetermined pattern with a brazing alloy.

2 . The method of claim 1 , wherein the brazing is accomplished using a brazing alloy that includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon, aluminum and mixtures or alloys thereof.

3 . The method of claim 2 , wherein the brazing alloy includes between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.

4 . The method of claim 3 , wherein the material is chromium.

5 . The method of claim 1 , wherein prior to the step of brazing, the method further comprises the steps of:

a) affixing a plurality of superabrasive particles in a predetermined pattern either on the substrate or the brazing alloy in the form of a sheet of amorphous braze alloy; and

b) placing the sheet of amorphous braze alloy on an exposed surface of the substrate, such that the superabrasive particles are positioned between the sheet of amorphous braze and the exposed surface.

6 . The method of claim 1 , wherein prior to the step of brazing, the method further comprises the steps of:

a) placing the brazing alloy in the form of a sheet of amorphous braze alloy upon an exposed surface of the substrate; and

b) affixing a plurality of superabrasive particles in a predetermined pattern on the sheet of amorphous braze alloy, such that the sheet of amorphous braze is disposed between the superabrasive particles and the exposed surface.

7 . The method of claim 1 , wherein the step of brazing includes heating the brazing alloy and substrate to a temperature of less than about 1,100° C. which is sufficient to braze the superabrasive particles directly to the substrate.

8 . The method of claim 1 , wherein prior to the step of affixing, the method further comprises:

a) providing a template having a predetermined pattern of apertures therein;

b) placing the template on the brazing alloy or substrate prior to affixing the superabrasive particles thereto;

c) filling the apertures with the superabrasive particles; and

d) removing the template, such that the superabrasive particles remain affixed in place on the brazing alloy or substrate in accordance with the predetermined pattern of the template.

9 . The method of claim 8 , wherein the superabrasive particles are affixed to the brazing alloy or substrate using an adhesive.

10 . The method of claim 8 , wherein each aperture is configured to hold only one superabrasive particle.

11 . The method of claim 10 , wherein some of the apertures are larger than other apertures.

12 . The method of claim 1 , wherein prior to the step of affixing, the method further comprises the steps of:

a) mixing a powdered brazing alloy with a carrier agent to form a slurry;

b) applying the slurry to an exposed surface of the substrate;

c) providing a template having a predetermined pattern of apertures therein;

d) placing the template on the brazing alloy;

e) filling the apertures with superabrasive particles; and

f) removing the template, such that the superabrasive particles remain in place on the brazing alloy in accordance with the predetermined pattern of the template during the step of brazing.

13 . The method of claim 1 , wherein prior to the step of brazing, the method further comprises the steps of:

a) affixing the superabrasive particles in a predetermined pattern on an exposed surface of the substrate; and

b) applying the braze alloy to the substrate and the superabrasive particles.

14 . The method of claim 1 , wherein prior to the step of brazing, the method further comprises the steps of:

a) providing a template having a plurality of apertures corresponding to the predetermined pattern;

b) placing the template on a transfer sheet;

c) filling the apertures with the superabrasive particles;

d) removing the template, such that the superabrasive particles remain in place on the transfer sheet in accordance with the predetermined pattern of the template; and

e) transferring the superabrasive particles to the exposed surface of the substrate or the brazing alloy using the transfer sheet, such that the superabrasive particles become affixed to the substrate in accordance with the predetermined pattern.

15 . The method of claim 14 , wherein the superabrasive particles are affixed to the exposed surface of the substrate by applying an adhesive to the exposed surface prior to pressing the transfer of the superabrasive particles thereto with the transfer sheet, wherein the adhesive on the substrate is stronger than forces holding the superabrasive particles in place on the transfer sheet.

16 . A method of making a superabrasive tool, comprising:

a) providing a matrix support material; and

b) brazing a plurality of superabrasive particles directly to an exposed surface of the matrix support material using a sheet of amorphous brazing alloy.

17 . The method of claim 16 , wherein the step of brazing includes heating the brazing alloy and substrate to a temperature of less than about 1,100° C. which is sufficient to braze the superabrasive particles directly to the substrate.

18 . The method of claim 16 , wherein the brazing is accomplished using a brazing alloy that includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.

19 . The method of claim 16 , wherein the superabrasive particles are placed in a predetermined pattern.

20 . A superabrasive tool comprising:

a) a solid metal substrate;

b) a plurality of superabrasive particles; and

c) a sheet of amorphous braze alloy chemically bonding the plurality of superabrasive particles to the solid metal substrate.

21 . The superabrasive tool of claim 20 , wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.

22 . The superabrasive tool of claim 20 , wherein the brazing alloy includes between about 2% and 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.

23 . The superabrasive tool of claim 20 , wherein bonding of the superabrasive particles avoids damage to the superabrasive particles.

24 . The superabrasive tool of claim 20 , wherein superabrasive particles are oriented in a predetermined pattern.

25 . The superabrasive tool of claim 24 , wherein the predetermined pattern consists of superabrasive particles positioned substantially along an exterior edge of the superabrasive tool.

26 . The superabrasive tool of claim 24 , wherein the predetermined pattern comprises an exterior portion concentration of superabrasive particles that is higher than an interior portion concentration of superabrasive particles.

27 . The superabrasive tool of claim 24 , wherein the predetermined pattern is a uniform grid.

28 . A superabrasive tool precursor comprising:

a) a metal support matrix;

b) a plurality of superabrasive particles placed on the metal support matrix; and

c) a sheet of amorphous braze alloy placed in contact with either the plurality of superabrasive particles or the metal support matrix.

29 . The superabrasive tool precursor of claim 28 , wherein the plurality of superabrasive particles are arranged in accordance with a predetermined pattern.

30 . The superabrasive tool precursor of claim 28 , wherein the superabrasive particles extend a predetermined height above the metal support matrix.

31 . The superabrasive tool precursor of claim 28 , wherein the sheet of amorphous braze has a liquidus temperature of less than 1,100° C.