Methods of making metal bond and vitreous bond abrasive articles, and abrasive article precursors
The present disclosure provides methods of making a vitreous bond abrasive article and a metal bond abrasive article. The methods include sequential steps. Step a) includes a subprocess including sequentially: i) depositing a layer of loose powder particles in a confined region; and ii) selectively applying heat via conduction or irradiation, to heat treat an area of the layer of loose powder particles. The loose powder particles include abrasive particles and organic compound particles, as well as vitreous bond precursor particles or metal particles. The layer of loose powder particles has substantially uniform thickness. Step b) includes independently carrying out step a) a number of times to generate an abrasive article preform comprising the bonded powder particles and remaining loose powder particles. Step c) includes separating remaining loose powder particles from the abrasive article preform. Step d) includes heating the abrasive article preform to provide the vitreous bond abrasive article comprising the abrasive particles retained in a vitreous bond material, or to provide the metal bond abrasive article. A method of making a metal bond abrasive optionally includes infusing an abrasive article preform with a molten lower melting metal and solidifying the molten lower melting metal to provide the metal bond abrasive article. The present disclosure further provides a vitreous bond abrasive article precursor and a metal bond abrasive article precursor.
1. A method of making a vitreous bond abrasive article, the method comprising sequential steps:
a) a subprocess comprising sequentially:
i) depositing a layer of loose powder particles in a confined region, wherein the loose powder particles comprise vitreous bond precursor particles, abrasive particles, and organic compound particles, and wherein the layer of loose powder particles has substantially uniform thickness; and
ii) selectively applying heat to an area of the layer of loose particles, the heat being applied via conduction or irradiation, wherein the heat is sufficient to cause the organic compound particles to form a temporary bond;
b) independently carrying out step a) a plurality of times to generate an abrasive article preform comprising the bonded powder particles and remaining loose powder particles, wherein in each step a), the loose powder particles are independently selected;
c) separating substantially all of the remaining loose powder particles from the abrasive article preform, wherein the abrasive article preform comprises temporarily bonded powder particles in the area of each layer that received heat; and
d) heating the abrasive article preform to provide the vitreous bond abrasive article, the vitreous bond abrasive article comprising the abrasive particles retained in a vitreous bond material.
2. The method of claim 1 , wherein the abrasive particles comprise at least one of diamond particles or cubic boron nitride particles.
3. The method of claim 1 , wherein the abrasive particles comprise metal oxide ceramic particles.
4. The method of claim 1 , wherein the vitreous bond abrasive article includes at least one cooling channel.
5. The method of claim 1 , wherein the vitreous bond abrasive article is selected from the group consisting of a unitary structured abrasive disc, an abrasive grinding bit, abrasive segments, abrasive rims, an abrasive wheel, and a rotary dental tool.
6. The method of claim 1 , wherein the organic compound particles have a melting point between 50 degrees Celsius and 250 degrees Celsius, inclusive.
7. The method of claim 1 , wherein the organic compound particles are selected from waxes, sugars, dextrins, thermoplastics having a melting point of no greater than 250 degrees Celsius, acrylates, methacrylates, and combinations thereof.
8. The method of claim 1 , wherein the organic compound particles are present in an amount of 2.5 weight percent to 30 weight percent of the loose powder particles.
9. The method of claim 1 , wherein step d) further comprises burning out the organic compound material.
10. The method of claim 1 , wherein in step ii) the heat is applied using a single tip.