Magnetizable abrasive particle and method of making the same
A magnetizable abrasive particle is presented. The magnetizable abrasive particle has a ceramic particle having an outer surface. The magnetizable abrasive particle also has a magnetic coating layer applied to the outer surface of the ceramic particle prior to sintering. The sintered magnetizable particle is responsive to a magnetic field.
1. A method of making magnetizable abrasive particles, comprising:
forming a ceramic particle precursor from a sol-gel precursor material, the sol-gel precursor material comprising alpha-alumina, wherein forming comprises drying the sol-gel precursor material in a shaped mold cavity;
applying a coating directly to a surface of the ceramic particle precursor, wherein the, coating comprises a magnetically responsive material; and
firing the coated ceramic particle precursor to create a sintered ceramic particle and wherein, after firing, the magnetically responsive material is responsive to a magnetic field.
2. The method of claim 1 , and further comprising:
removing solvent from the ceramic particle precursor.
3. The method of claim 2 , wherein removing solvent comprises a pre-firing process.
4. The method of claim 1 , wherein firing the magnetic coated ceramic particle causes a reaction layer to form between the applied coating layer and a ceramic particle layer.
5. The method of claim 4 , wherein the reaction layer comprises alumina, zinc, iron or nickel.
6. The method of claim 1 , wherein the magnetically responsive coating comprises ferrite.
7. The method of claim 1 , wherein the magnetic coating is a unitary coating.
8. The method of claim 1 , wherein the magnetically responsive coating is substantially limited to a single side of the ceramic particle precursor.
9. The method of claim 1 , wherein the magnetically responsive coating comprises a soft magnetic material.
10. The method of claim 1 , wherein coating comprises applying a slurry of the magnetically responsive material.
11. The method of claim 10 , wherein the ferrite magnetically responsive material comprises a nickel zinc ferrite material.
12. The method of claim 1 , wherein the ceramic particle precursor is formed within a tool having a mold cavity, such that the ceramic particle precursor has a shape that is a negative image of the mold cavity.
13. The method of claim 1 , wherein the ceramic particle precursor is a fully dense ceramic particle.
14. The method of claim 13 , wherein coating comprises applying the magnetic coating as a slurry while the ceramic particle precursor is in the mold cavity.
15. The method of claim 1 , wherein firing comprises sintering the ceramic particle precursors at a temperature above 1250° C.
16. The method of claim 1 , wherein the magnetically responsive material cannot be converted into a non-magnetic state during firing; wherein firing comprises heating the coated ceramic particle precursor in an oven to temperatures above 1250° C.
17. The method of claim 16 , wherein the magnetically responsive material has a formula of: XO·M m Fe 2-m O 3 (m<1) where X is a divalent cation and M is a trivalent cation, or a formula of X 3 A 5 O 12 , where X and A are metals.