Abrasive compact with improved machinability
View Patent ↗An abrasive compact may include an ultra-hard phase that may include ultra-hard particles having a Knoop hardness of 5000 KHN or greater, a sinter catalyst, and a reaction phase that may include a catalyst-ceramic compound having a Knoop hardness lower than that of the ultra-hard phase.
1. An abrasive compact, comprising:
an ultra-hard phase comprising ultra-hard particles having a Knoop hardness of 5000 KHN or greater;
a sinter catalyst in absence of aluminum; and
a reaction phase comprising a reaction product between the sinter catalyst and a reactant, wherein the reactant is one or more of hexagonal boron nitride, graphite, a metallic sulphide, an intermetallic sulfide, a metal phosphide, or an intermetallic phosphide, the reaction product has a Knoop hardness lower than that of cubic boron nitride.
2. The abrasive compact of claim 1 , wherein the reaction phase comprises particles that are bonded to the ultra-hard phase.
3. The abrasive compact of claim 1 , wherein the sinter catalyst comprises one or more of Fe, Co, W, Mn, Ni, or a compound thereof.
4. The abrasive compact of claim 1 , wherein: the reactant is pre-coated with the sinter catalyst.
5. The abrasive compact of claim 1 , further comprising an unreacted phase of one or more of hexagonal boron nitride, graphite, a metallic sulphide, an intermetallic sulfide, a metal phosphide, or an intermetallic phosphide.
6. The abrasive compact of claim 1 , wherein, the reaction phase comprises about 0.5 to 20 weight-percent of the abrasive compact.
7. The abrasive compact of claim 1 , wherein:
the reaction phase comprises particles having an average particle size between 0.1 μm to 50 μm.
8. An abrasive compact, comprising:
an ultra-hard phase comprising diamond particles;
a sinter catalyst; and
a reaction product comprising the sinter catalyst and a ceramic component, wherein the reaction product comprises particles which are bonded to the ultra-hard phase, wherein the reaction product has a Knoop hardness lower than that of cubic boron nitride.
9. The abrasive compact of claim 8 , further comprising an unreacted phase of one or more of hexagonal boron nitride, graphite, a metallic sulphide, an intermetallic sulfide, a metal phosphide, or an intermetallic phosphide.
10. The abrasive compact of claim 8 , further comprising a reactant, wherein the reactant is one or more of hexagonal boron nitride, graphite, a metallic sulphide, an intermetallic sulfide, a metal phosphide, or an intermetallic phosphide.
11. The abrasive compact of claim 10 , wherein the reactant is pre-coated with the sinter catalyst.
12. The abrasive compact of claim 11 , wherein the reactant is pre-coated with the sinter catalyst before blending.
13. The abrasive compact of claim 8 , wherein: the ultra-hard phase comprises cubic boron nitride.
14. The abrasive compact of claim 8 , wherein: the sinter catalyst comprises one or more of Fe, Ca, Mn, W, Ni, or their carbon alloys or a compound thereof.
15. The abrasive compact of claim 8 , wherein the reaction product comprises boron containing product.
16. The abrasive compact of claim 15 , wherein the boron containing product further comprises tungsten and cobalt.
17. The abrasive compact of claim 15 , wherein the boron containing product is Co 6 W 6 B 6 .
18. The abrasive compact of claim 15 , wherein the boron containing product is W 2 Co 21 B 6 .
19. The abrasive compact of claim 8 , wherein the reaction product comprises about 0.5 to 20 weight-percent of the abrasive compact.
20. The abrasive compact of claim 8 , wherein the reaction product particles have an average particle size from about 0.1 μm to 50 μm.