Abrasive articles including aggregates of silicon carbide in a vitrified bond

Abstract

The present disclosure relates to abrasive articles that include abrasive aggregates of silicon carbide with a vitrified bond, and methods of making and using such abrasive articles and abrasive aggregates. In particular, the abrasive aggregates can possess a combination of beneficial properties and comprise a vitreous binder composition having a specific composition, sintering temperature, glass transition temperature, or a combination thereof.

What is claimed is: 
     
         1 . An abrasive article, comprising:
 a substrate; and   an abrasive composition disposed on the substrate, wherein the abrasive composition comprises a polymeric binder composition and a plurality of abrasive aggregates dispersed in the polymeric binder composition, wherein each of the plurality of abrasive aggregates comprises a vitreous binder composition and a plurality of silicon carbide abrasive grit particles joined by the vitreous binder, wherein the vitreous binder composition comprises not less than 1 wt. % and not greater than 10 wt. % of the weight of each of the plurality of abrasive aggregates, and wherein the silicon carbide abrasive grit particles comprise not less than 90 wt. % and not greater than 99 wt. % of the weight of each of the plurality of abrasive aggregates.   
     
     
         2 . The abrasive article of  claim 1 , wherein the vitreous binder composition comprises a sintering temperature (Ts) in a range of 700° C. to 1100° C. 
     
     
         3 . The abrasive article of  claim 2 , wherein the vitreous binder composition comprises a sintering temperature (Ts) in a range of 800° C. to 1000° C. 
     
     
         4 . The abrasive article of  claim 1 , wherein the vitreous binder composition comprises a glass transition temperature (Tg) in a range of 490° C. to 900° C. 
     
     
         5 . The abrasive article of  claim 4 , wherein the vitreous binder composition comprises a glass transition temperature (Tg) in a range of 500° C. to 800° C. 
     
     
         6 . The abrasive article of  claim 1 , wherein the vitreous binder composition comprises:
 40 wt. % to 65 wt. % of one or more acid oxides;   15 wt. % to 30 wt. % of one or more amphoteric oxides; and   15 wt. % to 25 wt. % of one or more basic oxides and neutral oxides.   
     
     
         7 . The abrasive article of  claim 6 , wherein the one or more acid oxides comprises silicon dioxide (silica) (SiO 2 ), manganese (IV) oxide (MnO 2 ), molybdenum trioxide (molybdite) (MoO 3 ), phosphorus pentoxide (P 2 O 5 ), titanium dioxide (titania) (TiO 2 ), vanadium (V) oxide (V 2 O 5 ), zirconium dioxide (ZrO 2 ), or any combination thereof. 
     
     
         8 . The abrasive article of  claim 6 , wherein the one ore more amphoteric oxides comprises cobalt (II) oxide (CoO), copper (II) oxide (cupric oxide)(CuO), nickel (II) oxide (NiO), strontium oxide (strontia) (SrO), magnesium oxide (magnesia) (MgO), calcium oxide (calcia) (CaO), lithium oxide (lithia) (Li 2 O), barium oxide (baria) (BaO), zinc oxide (calamine)(ZnO), sodium oxide (Na 2 O), potassium oxide (potash) (K 2 O), or any combination thereof. 
     
     
         9 . The abrasive article of  claim 6 , wherein the one or more basic and neutral oxides comprises boron trioxide (boria) (B 2 O 3 ), chromium (III) oxide (chromia) (Cr 2 O 3 ), yttrium (III) oxide (yttria) (Y 2 O 3 ), iron (III) oxide (Fe 2 O 3 ), aluminum oxide (alumina) (Al 2 O 3 ), or any combination thereof. 
     
     
         10 . The abrasive article of  claim 1 , wherein the plurality of abrasive aggregates comprises bubbles dispersed in the vitreous binder at the interface of the vitreous binder and the silicon carbide abrasive grit particles. 
     
     
         11 . The abrasive article of  claim 1 , wherein the plurality of silicon carbide abrasive grit particles comprises a size in a range of not less than 1 micron and not greater than 2000 microns. 
     
     
         12 . The abrasive article of  claim 11 , wherein the plurality of abrasive aggregates comprises a size in a range of not less than 10 microns and not greater than 4000 microns. 
     
     
         13 . The abrasive article of  claim 1 , wherein the plurality of abrasive aggregates comprises a loose packed density in a range of not less than 0.5 g/cm 3  to not greater than 3.5 g/cm 3 . 
     
     
         14 . The abrasive article of  claim 1 , wherein the plurality of abrasive aggregates comprises a porosity in a range of 5% to 85% as measured by mercury porosimetry. 
     
     
         15 . The abrasive article of  claim 1 , wherein the abrasive composition comprises:
 5 wt. % to 60 wt. % polymeric composition; and   15 wt. % to 80 wt. % abrasive aggregates.   
     
     
         16 . The abrasive article of  claim 1 , wherein the abrasive composition comprises:
 5 wt. % to 60 wt. % polymeric composition;   15 wt. % to 80 wt. % abrasive aggregates; and   0 wt. % to 30 wt. % of a filler.   
     
     
         17 . The abrasive article of  claim 1 , wherein the abrasive composition comprises 50 wt. % to 99 wt. % of the abrasive article. 
     
     
         18 . The abrasive article of  claim 17 , wherein the substrate comprises 1 wt. % to 50 wt. % of the abrasive article. 
     
     
         19 . The abrasive article of  claim 1 , wherein the abrasive composition comprises a make coat. 
     
     
         20 . The abrasive article of  claim 19 , further comprising: a size coat is disposed over the make coat.