Brazed diamond tools and methods for making the same
Superabrasive tools and methods for the making thereof are disclosed and described. In one aspect, superabrasive particles are chemically bonded to a matrix support material according to a predetermined pattern by a braze alloy. The brazing alloy may be provided as a powder, thin sheet, or sheet of amorphous alloy. A template having a plurality of apertures arranged in a predetermined pattern may be used to place the superabrasive particles on a given substrate or matrix support material.
1. A superabrasive dresser comprising:
a tool substrate;
a metal matrix layer including a braze alloy attached to the substrate; and
a plurality of superabrasive particles positively planted in the matrix layer at specific locations according to a predetermined pattern, wherein the particles protrude above the metal matrix layer to a uniform height.
2. The dresser of claim 1 , wherein the particles are spaced apart from one another at a distance that is from about 2.7 to about 5.4 times the diameter of each particle.
3. The dresser of claim 1 , wherein the predetermined pattern is a uniform pattern.
4. The dresser of claim 1 , wherein the superabrasive particles are diamond.
5. The dresser of claim 1 , wherein the space between particles is a distance of about 2 mm.
6. A method for making a superabrasive dresser, comprising:
providing a tool substrate;
providing a metal matrix layer including a brazing alloy;
positively planting a plurality of superabrasive particles in the metal matrix layer at specific positions such that the plurality of superabrasive particles are held in the metal matrix layer according to a predetermined pattern, wherein the particles protrude above the metal matrix layer to a uniform height; and
consolidating the metal matrix layer such that the superabrasive particles are held in the metal matrix sheet in the predetermined pattern and the metal matrix layer is attached to the tool substrate.
7. The method of claim 6 , wherein arranging the plurality of superabrasive particles includes:
placing a template with a plurality of apertures formed therein on the metal matrix;
filling the apertures of the template with superabrasive particles;
pressing the superabrasive particles at least partially into the metal matrix; and
removing the template.
8. The method of claim 6 , wherein the template is configured to hold only one superabrasive particle in each aperture.
9. The method of claim 6 , wherein the predetermined pattern is a uniform pattern.
10. The method of claim 6 , wherein the particles are spaced apart from one another at a distance that is from about 2.7 to about 5.4 times the diameter of each particle.
11. The method of claim 6 , wherein the space between particles is a distance of about 2 mm.
12. The method of claim 6 , wherein the superabrasive particles are diamond.
13. A superabrasive dresser comprising:
a tool substrate;
a consolidated metal matrix layer including a braze alloy attached to the substrate; and
a plurality of superabrasive particles positively planted and bonded in the matrix layer at specific locations, wherein the particles protrude above the metal matrix layer to a uniform height, and wherein the particles are spaced apart from one another at a distance that is from about 2.7 to about 5.4 times the diameter of each particle.