Shaped abrasive particles and methods of forming same
A method of forming a shaped abrasive particle includes applying a mixture into a shaping assembly within an application zone and directing an ejection material at the mixture in the shaping assembly under a predetermined force, removing the mixture from the shaping assembly and forming a precursor shaped abrasive particle.
1. A method comprising:
extruding a mixture having a viscosity of at least about 4×10 3 Pa s into an opening in a shaping assembly within an application zone wherein the shaping assembly includes a first portion comprising the opening and a second portion abutting the first portion;
separating the first portion and the second portion; and
removing the mixture from the opening after separating the first portion and the second portion by applying an external force to the mixture in the opening to form a precursor shaped abrasive particle.
2. The method of claim 1 , wherein the mixture comprises a gel comprising a ceramic material and a liquid.
3. The method of claim 1 , wherein the mixture comprises an amount of a ceramic material of at least about 25 wt % for the total weight of the mixture and not greater than about 80 wt % for the total weight of the mixture.
4. The method of claim 1 , wherein the mixture comprises not greater than about 30 wt % organic materials for the total weight of the mixture.
5. The method of claim 1 , wherein the mixture comprises a storage modulus of at least about 1×10 4 Pa.
6. The method of claim 1 , wherein the mixture comprises a change in weight of less than about 5% for a total weight of the mixture for a duration that the mixture is in the opening of the shaping assembly.
7. The method of claim 1 , wherein the mixture comprises a change in volume of less than about 5% for a total volume of the mixture for a duration that the mixture is in the opening of the shaping assembly.
8. The method of claim 1 , wherein an average residence time of the mixture in the opening of the shaping assembly is less than about 18 minutes.
9. The method of claim 1 , wherein the mixture comprises a yield stress of at least about 1.5×10 3 Pa and not greater than about 50×10 3 Pa.
10. The method of claim 1 , wherein the external force comprises a pressure of at least about 10 kPa and not greater than 10,000 kPa.
11. The method of claim 1 , wherein the mixture comprises a coil value of at least about 1800 N.
12. The method of claim 1 , wherein the first portion is configured to receive the mixture.
13. The method of claim 1 , wherein the first portion including the mixture is translated over the surface of the second portion.
14. The method of claim 2 , wherein the gel is a shape-stable material.
15. The method of claim 2 , wherein the gel comprises a ceramic powder material as an integrated network of discrete particles.
16. The method of claim 2 , wherein the ceramic material comprises an oxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, or a combination thereof.
17. The method of claim 2 , wherein the ceramic material comprises alumina.
18. The method of claim 13 , wherein the first portion is translated through the application zone at a rate of at least about 0.5 mm/s.