Structured abrasive articles and methods of making the same

1. A structured abrasive article comprising a plurality of shaped abrasive composites disposed on and secured to a major surface of a backing, wherein the shaped abrasive composites comprise magnetizable abrasive particles retained in and dispersed throughout an organic binder, wherein, on a respective basis, each of the magnetizable abrasive particles has a ceramic body with a magnetizable layer substantially completely enclosing the respective ceramic body, and wherein a majority of the magnetizable abrasive particles are aligned substantially perpendicular to the major surface of the backing.

2. The structured abrasive article of claim 1 , wherein the ceramic body comprises alpha alumina.

3. The structured abrasive article of claim 1 , wherein the ceramic body is a precisely-shaped ceramic body.

4. The structured abrasive article of claim 1 , wherein the shaped abrasive composites comprise precisely-shaped abrasive composites.

5. The structured abrasive article of claim 1 , wherein the shaped abrasive composites are pyramidal.

6. The structured abrasive article of claim 1 , wherein the shaped abrasive composites are close-packed.

7. The structured abrasive article of claim 1 , wherein the magnetizable abrasive particles have an average aspect ratio of at least 3.

8. A method of making a structured abrasive article, the method comprising the consecutive steps:

a) providing a production tool having a mold surface defining a plurality of precisely-shaped cavities;

b) filling at least a majority of the precisely-shaped cavities with a slurry comprising magnetizable abrasive particles dispersed throughout a curable organic binder precursor material, wherein, on a respective basis, the magnetizable abrasive particles each comprise a ceramic body having a magnetizable layer disposed on at least a portion thereof, wherein the magnetizable abrasive particles have an average aspect ratio of at least 3;

c) contacting a major surface of a backing with the mold surface of the production tool while the slurry is disposed within said at least a majority of the precisely-shaped cavities;

d) orienting the magnetizable abrasive particles by means of a magnetic field;

e) at least partially curing the curable organic binder precursor material to form shaped abrasive composites disposed on the major surface of the backing; and

f) separating the shaped abrasive composites from the production tool.

9. The method of claim 8 , wherein steps d) and e) are carried out concurrently.

10. The method of claim 8 , wherein steps d) and e) are carried out sequentially.

11. The method of claim 8 , wherein the magnetizable abrasive particles comprise a ceramic body having a having an outer surface with a magnetizable layer disposed on at least a portion thereof.

12. A method of making a structured abrasive article, the method comprising the steps:

a) contacting a major surface of a backing with a malleable composition comprising magnetizable abrasive particles dispersed throughout a curable organic binder precursor, wherein, on a respective basis, the magnetizable abrasive particles each comprise a ceramic body having a magnetizable layer disposed on at least a portion thereof, wherein the magnetizable abrasive particles have an average aspect ratio of at least 3;

b) orienting the magnetizable abrasive particles by means of a magnetic field;

c) at least partially curing the curable organic binder precursor to form shaped abrasive composites disposed on the major surface of the backing.

13. The method of claim 12 , wherein steps a) and b) are carried out concurrently.

14. The method of claim 12 , wherein steps b) and c) are carried out concurrently.

15. The method of claim 12 , wherein steps a) and b) are carried out sequentially.

16. The method of claim 12 , wherein steps b) and c) are carried out sequentially.

17. The method of claim 12 , wherein the ceramic body is a precisely-shaped ceramic body.