Methods of forming abrasive articles
An abrasive article, comprising a polycrystalline material comprising abrasive grains and a filler material having an average negative coefficient of thermal expansion (CTE) within a range of temperatures between about 70 K to about 1500 K. A method of forming an abrasive article, comprising preparing an abrasive material, preparing a filler material having an average negative coefficient of thermal expansion (CTE) within a range of temperatures between about 150 K to about 1500 K, and forming a polycrystalline material comprising grains of the abrasive material and the filler material.
1. A method of forming an abrasive article, comprising:
preparing an abrasive material;
preparing a filler material having an average negative coefficient of thermal expansion (CTE) within a range of temperatures between about 150 K to about 1500 K;
forming a green body comprising the abrasive material and the filler material; and
subjecting the green body to a high temperature, high pressure process to form a polycrystalline material comprising grains of the abrasive material and the filler material.
2. The method of claim 1 , wherein preparing the filler material comprises preparing a precursor filler material.
3. A method of forming an abrasive article, comprising:
preparing an abrasive material;
preparing a filler material having an average negative coefficient of thermal expansion (CTE) within a range of temperatures between about 150 K to about 1500 K, wherein preparing the filler material comprises preparing a precursor filler material, wherein preparing the filler material comprises forming a precursor filler material comprising a suspension of particles of the filler material in a liquid;
forming a green body comprising the abrasive material and the filler material; and
subjecting the green body to a high temperature, high pressure process to form a polycrystalline material comprising grains of the abrasive material and the filler material.
4. The method of claim 3 , wherein forming the suspension comprises combining a passivation agent with the filler material.
5. The method of claim 2 , wherein preparing the precursor filler material comprises forming a powder material.
6. The method of claim 5 , wherein forming the powder material comprises a process selected from the group consisting of deposition, spraying, precipitation, and combinations thereof.
7. The method of claim 5 , wherein forming the powder material comprises forming a powder material comprising a coating overlying a core material.
8. The method of claim 7 , wherein forming a powder material comprising a coating overlying a core material comprises forming a passivation agent over the core material.
9. The method of claim 7 , wherein forming a coating comprises disposing a passivation agent over the core material.
10. The method of claim 7 , wherein forming a coating overlying a core material comprises a process selected from the group consisting of deposition, spraying, precipitation, plating, mixing, adsorption, absorption, and combinations thereof.
11. The method of claim 5 , wherein forming the powder material comprises forming an agglomerate.
12. A method of forming an abrasive article, comprising:
preparing an abrasive material;
preparing a filler material having an average negative coefficient of thermal expansion (CTE) within a range of temperatures between about 150 K to about 1500 K;
forming a green body comprising the abrasive material and the filler material;
subjecting the green body to a high temperature, high pressure process to form a polycrystalline material comprising grains of the abrasive material and the filler material; and
annealing the polycrystalline material.
13. The method of claim 12 , wherein the annealing process is conducted after heating the polycrystalline material to a first temperature higher than an annealing temperature.
14. The method of claim 12 , wherein annealing comprises applying an annealing temperature less than a forming temperature for an annealing duration.
15. The method of claim 14 , wherein annealing comprises maintaining a temperature within a range between about 400° C. and about 700° C.
16. The method of claim 14 , wherein annealing comprises maintaining the annealing temperature for an annealing duration of at least about 30 minutes.