Core drill bit binder materials

Abstract

Ag-free or low-Ag binder alloys are provided that can be used as binders for abrasive materials such as core drill bits. The alloys comprise, or consist of, Cu, Sn and Ni, with Cu preferably the plurality or majority component. Methods of manufacturing abrasive materials comprising the binder alloys, such as infiltration processes, are also disclosed.

1 . A binder alloy comprising 1-33 wt % Ni, 11-38 wt % Sn, and Cu, wherein Cu is the plurality or majority component, and wherein the binder alloy comprises less than 10 wt % Ag, and less than 20 wt % Zn. 
     
     
         2 . The binder alloy of  claim 1  satisfying at least one of the following formulas:
   17-33 wt % Ni,12-24 wt % Sn,  (A1)
 
   4-8 wt % Ni,15-29 wt % Sn,  (A2)
 
   7-13 wt % Ni,20-28 wt % Sn,  (A3)
 
   1-3 wt % Ni,14-27 wt % Sn, or  (A4)
 
   6-12 wt % Ni,11-21 wt % Sn  (A5)
 
 
       comprising less than 5 wt % Ag, less than 5 wt % Zn, and a balance of Cu. 
     
     
         3 . An abrasive article comprising an abrasive material in a matrix comprising the binder alloy of  claim 1 . 
     
     
         4 . An abrasive article comprising an abrasive material in a matrix comprising the binder alloy of  claim 2 . 
     
     
         5 . The binder alloy of  claim 2  having a mushy zone of 150K or less. 
     
     
         6 . The binder alloy of  claim 2 , comprising a matrix microstructure comprising a CuSn gamma phase, wherein the CuSn gamma phase comprises 0.1% to 70% of the matrix microstructure 
     
     
         7 . The abrasive article of  claim 3 , wherein the abrasive article is a core drill bit. 
     
     
         8 . The drill core bit of  claim 7  having Vickers hardness HV 0.3  of 250 or greater. 
     
     
         9 . The drill core bit of  claim 7  having TRS of 200 MPa or greater. 
     
     
         10 . A process for manufacturing an abrasive article comprising:
 placing an abrasive particulate material into a mold;   melting a binder alloy according to  claim 1  to obtain a molten binder;   allowing the molten binder to enter the mold and contact the particulate material to obtain a coated particulate material; and   cooling the coated particulate material to obtain the abrasive article.   
     
     
         11 . The binder alloy of  claim 1  comprising 17-33 wt % Ni and 12-24 wt % Sn. 
     
     
         12 . The binder alloy of  claim 11  comprising 17-33 wt % Ni, 12-24 wt % Sn, and the balance copper. 
     
     
         13 . The binder alloy of  claim 1  comprising 21-29 wt % Ni and 15-21 wt % Sn. 
     
     
         14 . The binder alloy  claim 13  comprising 21-29 wt % Ni, 15-21 wt % Sn, and the balance copper. 
     
     
         15 . A process for manufacturing an abrasive article comprising:
 placing an abrasive particulate material into a mold;   melting a binder alloy according to  claim 11  to obtain a molten binder;   allowing the molten binder to enter the mold and contact the particulate material to obtain a coated particulate material; and   cooling the coated particulate material to obtain the abrasive article.   
     
     
         16 . A process for manufacturing an abrasive article comprising:
 placing an abrasive particulate material into a mold;   melting a binder alloy according to  claim 13  to obtain a molten binder;   allowing the molten binder to enter the mold and contact the particulate material to obtain a coated particulate material; and   cooling the coated particulate material to obtain the abrasive article.