Abrasive slicing tool for electronics industry

Abstract

A bond matrix for metal bonded abrasive tools includes a metal bond system, porosity and an optional filler. Tools according to embodiments of the invention exhibit long tool life, produce an acceptable quality of cut and can have self-dressing properties. The bond matrix can be used, for example, in abrasives tools configured for the electronics industry, such as 1A8 wheels for slicing ball grid arrays (BGAs) and other such slicing operations.

What is claimed is: 
     
         1 . A method for producing a metal bonded abrasive tool, the method comprising:
 a. combining abrasive grains and a metal bond composition including nickel, tin metal and a pre-alloyed bronze;   b. forming the combined abrasive grains and metal bond composition into a shaped body; and   c. densifying the shaped body to produce the metal bonded abrasive tool, wherein the metal bonded abrasive tool has less than 20% porosity.   
     
     
         2 . The method of  claim 1 , further comprising pressing the shaped body. 
     
     
         3 . The method of  claim 1 , wherein densifying is by sintering at a temperature within the range of from about 400° C. to about 1100° C. 
     
     
         4 . The method of  claim 1 , wherein the abrasive grains, the metal bond composition or both are further combined with a filler. 
     
     
         5 . The method of  claim 4 , wherein the filler is selected from the group consisting of tungsten carbide, silicon carbide, alumina, graphite, hexagonal boron nitride and any combination thereof. 
     
     
         6 . The method of  claim 1 , wherein the abrasive grains, the metal bond composition or both are further combined with a pore inducer. 
     
     
         7 . The method of  claim 1 , wherein the pre-alloyed bronze is essentially devoid of intrinsic porosity. 
     
     
         8 . The method of  claim 1 , wherein the metal bond composition consists essentially of nickel, tin and bronze. 
     
     
         9 . The method of  claim 1 , wherein the metal bond composition consists of nickel, tin and bronze. 
     
     
         10 . A method for manufacturing a metal bonded abrasive article, the method comprising:
 a. forming a shaped body that includes a combination of abrasive grains and a metal bond system, said metal bond system including:
 (i) a first component that is a metal or metal alloy having a melting point within the range of from about 1100° C. to about 1600° C.; 
 (ii) a second component having a melting point of less than about 700° C., said component being capable of forming a transient liquid phase that is entirely or partially soluble in the metal or the metal alloy; and 
 (iii) a third component that is pre-alloyed, has a melting point of less than about 800° C., said third component being present in a phase that is essentially continuous in structure; and 
   b. densifying the shaped body to form the metal bonded abrasive article, wherein the metal bonded abrasive article has a porosity of less than about 20 volume %.   
     
     
         11 . The method of  claim 10 , wherein the abrasive grains are selected from the group including diamond, cubic boron nitride, alumina, silicon carbide, boron carbide and any combination thereof. 
     
     
         12 . The method of  claim 10 , wherein the shaped body further includes a filler. 
     
     
         13 . The method of  claim 12 , wherein the filler is selected from the group consisting of carbides, oxides, sulfides, nitrides, borides, graphite and any combinations thereof. 
     
     
         14 . The method of  claim 12 , wherein the filler has a melting point greater than about 1200° C. 
     
     
         15 . The method of  claim 12 , wherein, the abrasive grains are present in an amount within the range of from about 5 to about 40 volume % %; the metal bond system is present in an amount within the range of from about 26 to about 95 volume %; and the filler is present in an amount within the range of from about 0 to about 15 volume %, based on the total volume of the metal bonded abrasive article. 
     
     
         16 . The method of  claim 10 , wherein the second component is entirely soluble within the first component. 
     
     
         17 . The method of  claim 10 , wherein the metal or metal alloy is nickel, cobalt or Iron. 
     
     
         18 . The method of  claim 10 , wherein the second component is selected from the group consisting of tin, zinc, aluminum, indium, bismuth, antimony and any combinations thereof. 
     
     
         19 . The method of  claim 10 , wherein the third component is copper-tin, copper-zinc, copper-tin-phosphorus or copper-tin-zinc. 
     
     
         20 . The method of any of  claim 10 , wherein the metal bond system consists of components (i), (ii) and (iii).