Brazed diamond tools and methods for making the same

US 20030084894A1
Filed: 09/27/2002
Published: 05/08/2003
Est. Priority Date: 04/04/1997
Status: Active Grant

First Claim

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1. A method of making a superabrasive tool, comprising the steps of:

a) providing a substrate; and

b) brazing a plurality of superabrasive particles directly to an exposed surface of the substrate in accordance with a predetermined pattern.

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Abstract

Superabrasive tools and methods for the making thereof are disclosed and described. In one aspect, superabrasive particles are chemically bonded to a matrix support material according to a predetermined pattern by a braze alloy. The brazing alloy may be provided as a powder, thin sheet, or sheet of amorphous alloy. A template having a plurality of apertures arranged in a predetermined pattern may be used to place the superabrasive particles on a given substrate or matrix support material.

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45 Claims

1. A method of making a superabrasive tool, comprising the steps of:
- a) providing a substrate; and
  
  b) brazing a plurality of superabrasive particles directly to an exposed surface of the substrate in accordance with a predetermined pattern.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
- - 2. The method of claim 1, wherein the brazing is accomplished using a brazing alloy that includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon, aluminum and mixtures or alloys thereof.
  - 3. The method of claim 2, wherein the brazing alloy includes between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.
  - 4. The method of claim 3, wherein the material is chromium.
  - 5. The method of claim 2, wherein the brazing alloy is provided as a sheet of amorphous braze.
  - 6. The method of claim 5, wherein prior to the step of brazing, the method further comprises the steps of:
    - a) affixing a plurality of superabrasive particles in a predetermined pattern on the substrate; and
      
      b) placing the sheet of amorphous braze alloy on the superabrasive particles, such that the superabrasive particles are positioned between the sheet of amorphous braze and the exposed surface.
  - 7. The method of claim 5, wherein prior to the step of brazing, the method further comprises the steps of:
    - a) affixing a plurality of superabrasive particles in a predetermined pattern on the sheet of amorphous braze alloy; and
      
      b) placing the sheet of amorphous braze alloy having superabrasive particles affixed thereto on an exposed surface of the substrate, such that the superabrasive particles are disposed between the sheet of amorphous braze and the exposed surface.
  - 8. The method of claim 5, wherein prior to the step of brazing, the method further comprises the steps of:
    - a) placing the sheet of amorphous braze upon an exposed surface of the substrate; and
      
      b) affixing a plurality of superabrasive particles in a predetermined pattern on the sheet of amorphous braze alloy, such that the sheet of amorphous braze is disposed between the superabrasive particles and the exposed surface.
  - 9. The method of claim 1, wherein the step of brazing includes heating the brazing alloy and substrate to a temperature of less than about 1,100°
    - C. which is sufficient to braze the superabrasive particles directly to the substrate.
  - 10. The method of any one of claims 6, 7 or 8 wherein prior to the step of affixing, the method further comprises:
    - a) providing a template having a predetermined pattern of apertures therein;
      
      b) placing the template on the sheet of amorphous braze or substrate prior to affixing the superabrasive particles thereto;
      
      c) filling the apertures with the superabrasive particles; and
      
      d) removing the template, such that the superabrasive particles remain affixed in place on the sheet of amorphous braze or substrate in accordance with the predetermined pattern of the template.
  - 11. The method of claim 10, wherein the superabrasive particles are affixed to the sheet of amorphous braze or substrate using an adhesive.
  - 12. The method of claim 10, wherein each aperture is configured to hold one superabrasive particle.
  - 13. The method of claim 12, wherein some of the apertures are larger than other apertures.
  - 14. The method of claim 2, wherein the brazing alloy is provided as a powder.
  - 15. The method of claim 14, wherein prior to the step of brazing, the method further comprises the step of affixing a plurality of superabrasive particles in a predetermined pattern on the exposed surface of substrate.
  - 16. The method of claim 15, wherein prior to the step of affixing, the method further comprises the steps of:
    - a) mixing the powdered brazing alloy with a carrier agent to form a slurry;
      
      b) applying the slurry to the exposed surface of the substrate;
      
      c) providing a template having a predetermined pattern of apertures therein;
      
      d) placing the template on the brazing alloy;
      
      c) filling the apertures with superabrasive particles; and
      
      d) removing the template, such that the superabrasive particles remain in place on the brazing alloy in accordance with the predetermined pattern of the template during the step of brazing.
  - 17. The method of claim 2, wherein prior to the step of brazing, the method further comprises the steps of:
    - a) affixing the superabrasive particles in a predetermined pattern on an exposed surface of the substrate; and
      
      b) applying a braze alloy to the substrate and the superabrasive particles.
  - 18. The method of claim 17, wherein prior to the step of affixing, the method further comprises the steps of:
    - a) providing a template having a plurality of apertures corresponding to the predetermined pattern;
      
      b) placing the template on the exposed surface of the substrate;
      
      b) filling the apertures with the superabrasive particles; and
      
      c) removing the template, such that the superabrasive particles remain in place on the exposed surface in accordance with the predetermined pattern of the template during the step of brazing.
  - 19. The method of claim 17, wherein prior to the step of affixing, the method further comprises the steps of:
    - a) providing a template having a plurality of apertures corresponding to the predetermined pattern;
      
      b) placing the template on a transfer sheet;
      
      b) filling the apertures with the superabrasive particles;
      
      c) removing the template, such that the superabrasive particles remain in place on the transfer sheet in accordance with the predetermined pattern of the template; and
      
      d) transferring the superabrasive particles to the exposed surface of the substrate using the transfer sheet, such that the superabrasive particles become affixed to the exposed surface of the substrate in accordance with the predetermined pattern.
  - 20. The method of claim 19, wherein the superabrasive particles are affixed to the exposed surface of the substrate by applying an adhesive to the exposed surface prior to pressing the transfer of the superabrasive particles thereto with the transfer sheet, wherein the adhesive on the substrate is stronger than forces holding the superabrasive particles in place on the transfer sheet.
  - 21. The method of either claim 18 or 19, wherein the brazing alloy is provided as a sheet of amorphous braze.
  - 22. The method of either claim 18 or 19, wherein the brazing alloy is provided as a powder.

23. A method of making a superabrasive tool, comprising the steps of:
- a) providing a substrate having an exposed surface;
  
  b) providing a sheet of amorphous braze alloy having between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum;
  
  c) affixing a plurality of superabrasive particles on the exposed surface of the substrate in accordance with a predetermined pattern;
  
  d) applying the sheet of amorphous braze alloy on the superabrasive particles affixed to the exposed surface of the substrate; and
  
  e) heating the sheet of amorphous braze alloy to a temperature below about 1,100°
  
  C. that is sufficient to melt the sheet and braze the superabrasive particles directly to the exposed surface of the substrate.

24. A method of making a superabrasive tool, comprising the steps of:
- a) providing a substrate having an exposed surface;
  
  b) affixing a plurality of superabrasive particles in accordance with a predetermined pattern on the exposed surface of the substrate;
  
  c) applying to the substrate and the superabrasive particles a powdered brazing alloy, having between about 2% and about 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum; and
  
  d) heating the brazing alloy to a temperature below about 1,100°
  
  C. that is sufficient to melt the alloy and braze the superabrasive particles directly to the exposed surface of the substrate

25. A method of making a superabrasive tool, comprising:
- a) providing a matrix support material; and
  
  b) brazing a plurality of superabrasive particles directly to an exposed surface of the matrix support material using a sheet of amorphous brazing alloy.
- View Dependent Claims (26, 27, 28, 29, 30)
- - 26. The method of claim 25, wherein the brazing is accomplished using a brazing alloy that includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.
  - 27. The method of claim 26, further comprising:
    - a) affixing the superabrasive particles on the exposed surface of the matrix support material; and
      
      b) applying the sheet of amorphous braze on the superabrasive particles.
  - 28. The method of claim 27, wherein the superabrasive particles are affixed to the matrix support material using an adhesive.
  - 29. The method of claim 27, further comprises:
    - a) providing a plurality of sheets of amorphous braze;
      
      b) providing a plurality of matrix support material having exposed surfaces;
      
      c) affixing the superabrasive particles on the plurality of matrix support material;
      
      d) applying the plurality of sheets on the superabrasive particles to form a plurality of individual superabrasive segments;
      
      e) placing the individual superabrasive segments adjacent to one another to form a three-dimensional tool precursor; and
      
      e) consolidating the tool precursor to form a three-dimensional abrasive tool segment.
  - 30. The method of claim 29, wherein the step of affixing further comprises placing the superabrasive particles in a predetermined pattern.

31. A method of making a superabrasive tool, comprising:
- a) providing a plurality of sheets of amorphous braze;
  
  b) providing a plurality of matrix support material layers having exposed surfaces;
  
  c) affixing the superabrasive particles on the plurality of amorphous braze sheets in a predetermined pattern;
  
  d) applying the plurality of amorphous braze sheets having superabrasive particles thereon to the exposed surfaces of the matrix support material to form a plurality of individual superabrasive segments;
  
  e) assembling the individual superabrasive segments into a tool precursor having a three-dimensional arrangement of superabrasive particles in accordance with a predetermined pattern; and
  
  f) consolidating the tool precursor by heating it to a temperature sufficient to melt the braze alloy and sinter the matrix support material.

32. A superabrasive tool comprising:
- a) a solid metal substrate;
  
  b) a plurality of superabrasive particles; and
  
  c) a sheet of amorphous braze alloy chemically bonding the plurality of superabrasive particles to the solid metal substrate.
- View Dependent Claims (33, 34, 35, 36, 37, 38)
- - 33. The superabrasive tool of claim 32, wherein the brazing alloy includes a material selected from the group consisting of titanium, vanadium, chromium, zirconium, molybdenum, tungsten, manganese, iron, silicon and aluminum.
  - 34. The superabrasive tool of claim 32, wherein the brazing alloy includes between about 2% and 50% by weight of a material selected from the group consisting of chromium, manganese, titanium, silicon and aluminum.
  - 35. The superabrasive tool of claim 32, wherein the predetermined pattern is a grid.
  - 36. The superabrasive tool of claim 32, wherein the predetermined pattern consists of superabrasive particles positioned substantially along an exterior edge of the superabrasive tool.
  - 37. The superabrasive tool of claim 32, wherein the predetermined pattern comprises an exterior portion concentration of superabrasive particles that is higher than an interior portion concentration of superabrasive particles.
  - 38. The superabrasive tool of claim 32, wherein the predetermined pattern is a uniform grid.

39. A superabrasive tool precursor comprising:
- a) a metal support matrix;
  
  b) a plurality of superabrasive particles placed in contact with the metal support matrix; and
  
  c) a sheet of amorphous braze alloy placed in contact with the plurality of superabrasive particles.
- View Dependent Claims (41, 42, 43, 44, 45)
- - 41. The superabrasive tool precursor of either claim 39 or 40, wherein the plurality of superabrasive particles are arranged in accordance with a predetermined pattern.
  - 42. The superabrasive tool precursor of either claim 39 or 40, wherein the sheet of amorphous braze alloy has a predetermined thickness.
  - 43. The superabrasive tool precursor of either claim 39 or 40, wherein the tool precursor is configured for use as a CMP pad dresser.
  - 44. The superabrasive tool precursor of either claim 39 or 40, wherein the superabrasive particles have a size from about 100 to 350 micrometers.
  - 45. The superabrasive tool precursor of either claim 39 or 40, wherein the superabrasive particles extend a predetermined height above the metal support matrix.

40. A superabrasive tool precursor comprising:
- a) a metal support matrix;
  
  b) a sheet of amorphous braze alloy placed in contact with the metal support matrix; and
  
  c) a plurality of superabrasive particles placed on the sheet of amorphous braze.

Specification

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Current Assignee
Chien-Min Sung, Kinik Company
Original Assignee
Kinik Company
Inventors
Sung, Chien-Min

Granted Patent

US 7,124,753 B2
Time in Patent Office

Days
Field of Search
US Class Current

125/12
CPC Class Codes

B01J 2203/061   Graphite

B01J 2203/062   Diamond

B01J 2203/0645   Boronitrides

B01J 2203/0655   Diamond

B01J 2203/066   Boronitrides

B01J 2203/068   Crystal growth

B01J 2203/0685   Crystal sintering

B01J 3/062   characterised by the compos...

B22F 1/05   Metallic powder characteris...

B22F 1/08   Metallic powder characteris...

B22F 2003/1046   with separating means for a...

B22F 2005/001   Cutting tools, earth boring...

B22F 2207/03   of the metallic binder phas...

B22F 2999/00   Aspects linked to processes...

B22F 3/004   Filling molds with powder f...

B23D 61/028   of special material

B23D 61/04   with inserted saw teeth , i...

B23D 61/18   Sawing tools of special typ...

B23D 65/00   Making tools for sawing mac...

B23K 35/0233   Sheets, foils B23K35/0244 t...

B23P 15/28 : cutting tools sawing tools ...

B24B 53/017 : Devices or means for dressi...

B24B 53/12 : Dressing tools; Holders the...

B24D 18/00 : Manufacture of grinding too...

B24D 2203/00 : Tool surfaces formed with a...

B24D 3/06 : metallic or mixture of meta...

B24D 3/08 : for close-grained structure...

B24D 5/066 : with segments mounted axial...

B24D 7/02 : Wheels in one piece

B24D 7/066 : Grinding blocks; their moun...

B24D 99/005 : Segments of abrasive wheels

B28D 1/041 : with cylinder saws, e.g. tr...

C04B 35/52 : based on carbon, e.g. graphite

C22C 1/051 : Making hard metals based on...

C22C 21/06 : with magnesium as the next ...

C22C 2204/00 : End product comprising diff...

C22C 26/00 : Alloys containing diamond o...

C22C 45/00 : Amorphous alloys making amo...

E21B 10/5676 : having a cutting face with ...

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Brazed diamond tools and methods for making the same

First Claim

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Abstract

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45 Claims

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Brazed diamond tools and methods for making the same

First Claim

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