Methods of making metal bond and vitreous bond abrasive articles, and abrasive article precursors

Abstract

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. Also, methods including receiving, by a manufacturing device having a processor, a digital object specifying data for an abrasive article, and generating the abrasive article with the manufacturing device.

1 . A vitreous bond abrasive article precursor comprising abrasive particles bonded together by a vitreous bond precursor material and an organic compound, wherein the vitreous bond abrasive article precursor further comprises at least one of:
 at least one tortuous cooling channel extending at least partially through the vitreous bond abrasive article precursor; or   at least one arcuate cooling channel extending at least partially through the vitreous bond abrasive article precursor.   
     
     
         2 . The vitreous bond abrasive precursor of  claim 1 , wherein the abrasive particles comprise at least one of silicon carbide, boron carbide, silicon nitride, or metal oxide ceramic particles. 
     
     
         3 . A method of making a metal 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 higher melting metal particles, abrasive particles, and organic compound particles, and wherein the layer of loose powder particles has substantially uniform thickness; and 
 ii) selectively applying heat via conduction or irradiation, to heat treat an area of the layer of loose powder particles; 
   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;   d) infusing the abrasive article preform with a molten lower melting metal, wherein at least some of the higher melting metal particles do not completely melt when contacted by the molten lower melting metal; and   e) solidifying the molten lower melting metal to provide the metal bond abrasive article.   
     
     
         4 . The method of  claim 3 , wherein the higher melting metal particles have a melting point that is at least 50 degrees Celsius higher than the temperature of the molten lower melting metal. 
     
     
         5 . The method of  claim 3 , further comprising, between steps c) and d), burning off at least a portion of the organic compound material. 
     
     
         6 . A method of making a metal 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 metal particles, abrasive particles, and organic compound particles, and wherein the layer of loose powder particles has substantially uniform thickness; 
 ii) selectively applying heat via conduction or irradiation, to heat treat an area of the layer of loose powder particles; 
   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 the abrasive article preform has a predetermined shape, and 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; and   d) heating the abrasive article preform to provide the metal bond abrasive article.   
     
     
         7 . The method of  claim 6 , wherein the metal particles comprise a combination of higher melting metal particles and lower melting metal particles, wherein the higher melting metal particles have a melting point that is at least 50 degrees Celsius higher than the temperature of the molten lower temperature metal. 
     
     
         8 . A metal bond abrasive article precursor comprising metallic particles and abrasive particles bonded together by an organic compound material, wherein the metal bond abrasive article precursor further comprises at least one of:
 at least one tortuous cooling channel extending at least partially through the metal bond abrasive article precursor;   at least one arcuate cooling channel extending at least partially through the metal bond abrasive article precursor.