Brazed diamond tools by infiltration
DC
First Claim
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1. A method of forming a diamond impregnated tool comprising the steps of:
- a) providing an amount of a matrix support material comprising a mixture of a powder and an organic binder;
b) shaping said matrix support material;
c) forming a plurality of holes in the shaped matrix support material which are sufficient to receive diamond particles;
d) distributing an amount of diamond particles into the holes; and
e) infiltrating the shaped matrix support material with a diamond braze which comprises a metal alloy containing between 2 and 50 percent of an element selected from the group consisting of chromium, manganese, silicon, and aluminum.
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Abstract
The present invention describes a diamond tool with diamond bonded chemically by a braze that contains either Cr, Mn, SI, or Al or mixtures or alloys thereof. The diamond tool is made by infiltrating the braze into a matrix metal that contains diamond in either form of grits or polycrystalline bodies.
213 Citations
12 Claims
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1. A method of forming a diamond impregnated tool comprising the steps of:
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a) providing an amount of a matrix support material comprising a mixture of a powder and an organic binder;
b) shaping said matrix support material;
c) forming a plurality of holes in the shaped matrix support material which are sufficient to receive diamond particles;
d) distributing an amount of diamond particles into the holes; and
e) infiltrating the shaped matrix support material with a diamond braze which comprises a metal alloy containing between 2 and 50 percent of an element selected from the group consisting of chromium, manganese, silicon, and aluminum. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
a) cold pressing the matrix support material.
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6. The method according to claim 1, wherein step (b) comprises the steps of:
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a) pressing the matrix support material in a mold; and
b) heating the molded matrix support material to a temperature sufficient to allow sintering of the matrix support material into a porous unit having a porosity sufficient to allow infiltration of a brazing composition.
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7. The method according to claim 1, wherein the diamond braze material is free of interfering metals selected from the group consisting of zinc, lead and tin.
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8. The method according to claim 1, wherein the braze contains at least 5 percent by weight of a carbide former selected from the group consisting of chromium, manganese, silicon, their alloys, and mixtures thereof.
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9. The method according to claim 1, wherein the matrix support material and diamond particles are subjected to a vacuum of at least 10−
- 3 torr during step (e).
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10. The method according to claim 1, wherein the amount of diamond particles is less than 50 percent of the diamond impregnated tool.
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11. The method of claim 1, wherein step (b) further comprises the steps of:
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a) forming the matrix support material into a sheet; and
b) cutting the sheet.
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12. The method of claim 11, wherein the sheet is formed by rolling the matrix support material between two metal rolls.
Specification
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Litigation Data
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Current AssigneeChien-Min Sung, Kinik Company
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Original AssigneeKinik Company
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InventorsSung, Chien-Min
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Primary Examiner(s)MARCHESCHI, MICHAEL A
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Application NumberUS09/185,897Time in Patent Office846 DaysField of Search512/95, 512/93, 513/07, 513/09, 451/540, 451/542US Class Current51/295CPC Class CodesB01J 2203/0645 BoronitridesB01J 2203/066 BoronitridesB01J 2203/0685 Crystal sinteringB22F 2005/001 Cutting tools, earth boring...B22F 2998/00 Supplementary information c...B22F 3/26 Impregnating making ferrous...B24D 18/00 Manufacture of grinding too...B24D 3/08 for close-grained structure...B24D 5/12 Cut-off wheelsB24D 99/005 Segments of abrasive wheelsB28D 1/12 Saw-blades or saw-discs spe...C04B 35/52 based on carbon, e.g. graphiteC22C 1/1015 by preparing or treating a ...C22C 1/1036 starting from a meltC22C 26/00 Alloys containing diamond o...
