Bonded abrasive article and method of forming
An abrasive article includes a body having abrasive grains contained within a bond material comprising a metal or metal alloy, wherein the body comprises a ratio of V AG /V BM of at least about 1.3, wherein V AG is the volume percent of abrasive grains within the total volume of the body and V BM is the volume percent of bond material within the total volume of the body.
1. An abrasive article comprising:
a body, wherein the body comprises:
abrasive grains contained within a bond material comprising a metal,
at least about 1 vol % and not greater than about 40 vol % of an active bond composition of the total volume of the bond material, wherein the active bond composition comprises a precipitated phase and an interfacial phase and wherein the interfacial phase is dispersed as a distinct phase throughout the bond material, and
a porosity of at least about 5 vol % and not greater than about 35 vol. %.
2. The abrasive article of claim 1 , wherein the bond material comprises an average fracture toughness (K 1c ) within a range between about 0.6 MPa m 0.5 and about 4.0 MPa m 0.5 .
3. The abrasive article of claim 2 , wherein the bond material comprises an average fracture toughness (K 1c ) within a range between about 0.6 MPa m 0.5 and about 3.0 MPa m 0.5 .
4. The abrasive article of claim 1 , wherein the ratio of V P /V BM is within a range between about 1.5 and about 9.0, wherein V P is a volume percent of particulate material including abrasive grains and fillers within a total volume of the body and V BM is a volume percent of bond material within the total volume of the body.
5. The abrasive article of claim 4 , wherein the ratio of V P /V BM is within a range between about 1.7 and about 6.0, wherein V P is a volume percent of particulate material including abrasive grains and fillers within a total volume of the body and V BM is a volume percent of bond material within the total volume of the body.
6. The abrasive article of claim 1 , wherein the body comprises a ratio of V AG /V BM of at least about 1.3, wherein V AG is a volume percent of abrasive grains within the total volume of the body and V BM is a volume percent of bond material within the total volume of the body.
7. The abrasive article of claim 6 , wherein the ratio of V AG /V BM is within a range between about 1.3 and about 9.0.
8. The abrasive article of claim 1 , wherein the active bond composition comprises a compound including a metal.
9. The abrasive article of claim 1 , wherein the active bond composition comprises a compound selected from the group consisting of carbides, nitrides, oxides and a combination thereof.
10. The abrasive article of claim 1 , wherein the active bond composition comprises a metal element selected from the group of metal elements consisting of titanium, vanadium, chromium, zirconium, hafnium, tungsten, and a combination thereof.
11. The abrasive article of claim 1 , wherein a majority of the porosity is interconnected porosity defining a network of interconnected pores extending through the volume of the body.
12. The abrasive article of claim 1 , wherein the bond material comprises at least one transition metal element.
13. The abrasive article of claim 12 , wherein the bond material comprises a metal selected from the group of metals consisting of copper, tin, silver, molybdenum, zinc, tungsten, iron, nickel, antimony, and a combination thereof.
14. The abrasive article of claim 13 , wherein the bond material comprises a metal alloy including copper and tin.
15. The abrasive article of claim 1 , wherein the body comprises a bimodal distribution of abrasive grains including fine grains having a fine average grit size and coarse grains having a coarse average grit size, wherein the coarse grit size is greater than the fine average grit size.
16. The abrasive article of claim 4 , wherein the fillers comprise a material selected from the group of materials consisting of oxides, carbides, borides, silicides, nitrides, oxynitrides, oxycarbides, silicates, graphite, silicon, inter-metallics, ceramics, hollow-ceramics, fused silica, glass, glass-ceramics, hollow glass spheres, and a combination thereof.
17. The abrasive article of claim 4 , wherein the fillers comprise a fracture toughness (K 1c ) of not greater than about 10 MPa m 0.5 .
18. The abrasive article of claim 4 , wherein the fillers comprise not greater than about 75 vol % of the total volume of the body.
19. The abrasive article of claim 1 , wherein the abrasive grains comprise a coating.