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 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.

6 . The method of claim 1 , wherein the braze alloy is a sheet of amorphous braze alloy.

7 . 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.

8 . 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 a transfer sheet of amorphous braze alloy; and

b) applying the transfer sheet to the substrate.

9 . The method of claim 1 , wherein the superabrasive particles are placed in a predetermined pattern.

10 . The method of claim 9 , wherein the predetermined pattern is a uniform grid.

11 . A superabrasive tool comprising:

a) a solid metal substrate;

b) a plurality of superabrasive particles; and

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

12 . The superabrasive tool of claim 11 , wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.

13 . The superabrasive tool of claim 11 , 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.

14 . The superabrasive tool of claim 11 , wherein bonding of the superabrasive particles avoids damage to the superabrasive particles.

15 . The superabrasive tool of claim 11 , wherein superabrasive particles are oriented in a predetermined pattern.

16 . The superabrasive tool of claim 15 , wherein the predetermined pattern consists of superabrasive particles positioned substantially along an exterior edge of the superabrasive tool.

17 . The superabrasive tool of claim 15 , wherein the predetermined pattern comprises an exterior portion concentration of superabrasive particles that is higher than an interior portion concentration of superabrasive particles.

18 . The superabrasive tool of claim 15 , wherein the predetermined pattern is a uniform grid.

19 . The super abrasive tool of claim 11 , further comprising a layer of overlay material affixed to a working surface of the brazing alloy to create a smooth working surface.

20 . 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 layer of amorphous braze alloy placed in contact with either the plurality of superabrasive particles or the metal support matrix.