Abel IP

Shaped Abrasive Particle Including Dopant Material and Method of Forming Same | Publication Date: 7.13.15

Summary:

A particulate material including a shaped abrasive particle having a body including a length, a width, and a thickness, the body having a central region including the geometric center of the body having a first dopant material present in a center dopant amount (DCc), the body further having an upper surface defined by the dimensions of length and width, the upper surface having a second dopant material present in an upper surface dopant amount (DUSc), the body having a dopant amount difference (ΔDc) between the first dopant amount and the second dopant amount.  A method of forming a shaped abrasive particle including extruding a mixture into a form, applying a dopant material to an exterior surface of the form, and forming a precursor shaped abrasive particle from the form.  A particulate material including a shaped abrasive particle having a body including a length (l), a width, (w), and a thickness (t), the body including a first exterior surface having a first dopant amount (D1c) of a first dopant material, a second exterior surface spaced apart from the first exterior surface by at least one edge, the second exterior surface having a second dopant amount (D2c) of a second dopant material, and the body having a dopant amount difference (ΔDc) between the first dopant amount and the second dopant amount.  A particulate material including a shaped abrasive particle having a body including a length, a width, and a height, the body having an upper surface defined by dimensions of the length and width, the upper surface having a dopant material forming a pattern on the upper surface.  A particulate material including a shaped abrasive particle having a body including a length, a width, and a thickness, the body having a central region including the geometric center of the body having a first microstructure, the body further having an upper surface defined by the dimensions of length and width, the upper surface having a second microstructure, the first microstructure being different from the second microstructure.

 

Keywords:

alumina, boehmite, alpha-alumina, alpha alumina, fused brown alumina, alundum, shaped abrasive particle (SAP), SAPS, SAPs, formed abrasive particle, precursor shaped abrasive particle, particulate, particulate material, dopant, dopant material, first dopant, first dopant material, second dopant, second dopant material, dopant amount, dopant amount difference, wt %, wt%, weight percent, vol %, vol%, volume, volume percent, central region, center dopant amount, geometric center, upper surface, exterior surface, upper surface dopant, concentration, polygonal, two-dimensional, two dimensional, two-dimensional shape, plane, length, width, polygons, ellipsoids, numerals, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, complex shapes having a combination of polygonal shapes, triangle, triangular, rectangle, rectangular, quadrilateral, pentagon, hexagon, heptagon, octagon, nonagon, decagon, body, aspect ratio, thickness, midpoint, corner, edge, contour, cross section, cross-section, average, long side, short side, angle, first angle, second angle, quadrilateral, corner truncated, corner-truncated, corner-truncated triangle, corner truncated quadrilateral,  texture, bottom surface, side surface, pattern, patterned surface, feature, protrusions, grooves, ridges, scales, curve, irregularity, regular, oxide, a nitride, a carbide, a boride, an oxycarbide, oxynitride, alkali, alkaline, earth, rare earth, rare-earth, hafnium (Hf), zirconium (Zr), niobium (Nb), tantalum (Ta), molybdenum (Mo), vanadium (V), lithium (Li), sodium (Na), potassium (K), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba), scandium (Sc), yttrium (Y), lanthanum (La), cesium (Ce), praseodymium (Pr), niobium (Nb), nitrate, chloride, sulfate, phosphate, spraying, dipping, depositing, impregnating, transferring, punching, cutting, pressing, crushing, form, forming, extrude, extruding, applying, pressing, forcing, sectioning, perforating, water jet, water-jet, blade, radiation, laser, sheet, direction, altering, embossing, rolling, cutting, engraving, patterning, shaping, drying, printing, screen printing, screen-printing, screen, sinter, sintered, sintering, densifying, tool, die, die opening, opening, belt, translate, translated, translating, exit, exiting, organic, organic material, storage modulus, viscosity, solids, solids content, solids loading, liquid, liquid content, ceramic, ceramic powder, gel, sol gel, sol-gel, seeded gel, seeded-gel, sintered sol gel, sintered sol-gel, seeded sintered, seeded sintered sol gel alumina particles, shape-stable, mixture, blend, blend of abrasive particles, polycrystalline, crushed, crushed abrasive particle, abrasive grain, average particle size, average grain size, body, green body, dishing, flashing, dispersed, uniform, non-uniform, non uniform, distributed, crystalline, grain size, grit size, average grain size, bonded abrasive, coated abrasive, fixed abrasive, substrate, open-coat, closed-coat, particle density, diluent particles, diluents, median particle size, solvent, pH, acid, base, nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, ammonium citrate, cavities, screen printing, mold, dried, water, volatiles, mixture, drying process, humidity, curing, reacting, radiating, planarizing, calcining, sieving.

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Abrasive Articles and Methods for Making and Using Same | Publication Date: 7.9.15

Summary:

An abrasive article including a thin wheel tool having a body including a blend of abrasive particles contained in a bond material, the blend of abrasive particles having a first type of abrasive particle, including a shaped abrasive particle, and a second type of abrasive particle different from the first type of abrasive particle, the second type of abrasive particle including at least one of zirconium, iron, silicon, titanium.  A method of making an abrasive article including making a mixture of a precursor bond material and a blend of abrasive particles, the blend having a first type of abrasive particle, including a shaped abrasive particle, and a second type of abrasive particle including at least one of zirconium, iron, silicon, titanium; and forming a thin wheel tool having a body including the blend of abrasive particles contained in the bond material, the forming including curing a green body at a cure temperature of at least 150ºC for at least 22 hours to form the body.  A thin wheel abrasive article including a body having a first type of abrasive particle and a second type of abrasive particle, the body including an improvement in useable life of at least about 1.2 times as compared to conventional thin wheel abrasive articles incorporating shaped abrasive particles according to a material removal test.

 

Keywords:

alumina, alpha-alumina, alpha alumina, fused brown alumina, alundum, shaped abrasive particle (SAP), SAPS, SAPs, formed abrasive particle, blend, blend of abrasive particles, first abrasive particle, first type of abrasive particle, second abrasive particle, second type of abrasive particle, third abrasive particle, third type of abrasive particle, agglomerated particle, agglomerated abrasive particle, unagglomerated particle, unagglomerated abrasive particle, polycrystalline, crushed, crushed abrasive particle, abrasive grain, average particle size, average grain size, body, green body, dishing, flashing, dispersed, uniform, non-uniform, non uniform, distributed, wt %, wt%, weight percent, vol %, vol%, volume percent, grains, crystalline, grain size, grit size, average grain size, triangular two dimensional shape, polycrystalline, major surface, first major surface, second major surface, exterior surface, width, height, length, weight, aspect ratio, hi, w, l, triangular, quadrilateral, rectangular, trapezoidal, pentagonal, hexagonal, heptagonal, octagonal, ellipsoids, Greek alphabet characters, Latin alphabet characters, Russian alphabet characters, triangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, two dimensional shape, two-dimensional shape, profile ratio, rake angle, zirconia, zirconium, zirconium containing species, zirconium-containing species, iron, iron containing species, iron-containing species, silicon, silicon containing species, silicon-containing species, titanium, titanium containing species, titanium-containing species, oxide, silica, ceria, baria, rare earth, rare-earth, transition metal, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium, potassium, magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium, manganese, nickel, titanium, zinc, nitrides, oxides, carbide, borides, oxynitrides, oxycarbides, diamond, aluminum, yttrium, chromium, strontium, additive, sol gel, sol-gel, seeded gel, seeded-gel, sintered sol gel, sintered sol-gel, seeded sintered, seeded sintered sol gel alumina particles, bonded abrasive, coated abrasive, fixed abrasive, substrate, thin wheel, Type 27 wheel, diameter, volume, thickness, tool, abrasive layer, grinding layer, first abrasive layer, second abrasive layer, reinforcement, fiberglass, fiberglass reinforcement, web, fine back, fine back layer, bond, bond material, precursor bond material, organic bond, polymer, polymeric bond, resin, inorganic, binder, thermoplastic, thermoset, porosity, pore, filler, pyrox, fluoride (PAF), lime, processing aid, lubricant, crosslinking agent, curing agent, antistatic agent, curing, forming, friability, hardness, toughness, density, composition, average density, weighted average density, Moh’s, Moh’s hardness, average Moh’s, Knoop, Knoop hardness, average Knoop hardness, concentration, grinding, grinding performance, material removal, material removal rate (MRR),  life span, lifespan, useable life, useability, grinding energy, specific grinding energy, lifetime, strength, stress, distribution, gel, boehmite, water, singe grit grinding test (SGGT), axis, blend, open-coat, closed-coat, particle density, diluent particles, diluents, median particle size, organic material, solvent, pH, acid, base, nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, ammonium citrate, cavities, tool, die, screen print, screen printing, mold, drying, dried, water, volatiles, mixture, drying process, humidity, precursor, shaping, curing, reacting, radiating, planarizing, calcining, sintering, sieving, doping.

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Abrasive Article Including Shaped Abrasive Particles | Publication Date: 6.2.15

Summary:

A shaped abrasive particle including a body comprising a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, the body having a Shape Index within a range between at least about 0.48 and not greater than about 0.52 and a content of a magnesium-containing species within a range between at least about 1 wt% and not greater than about 4 wt% based on the total weight of the body. A shaped abrasive particle comprising: a body comprising a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, wherein the body comprises a content of a magnesium-containing species within a range between at least about 0.5 wt% and not greater than about 5 wt % based on a total weight of the body, and wherein the body comprises a content of a zirconium-containing species within a range between at least about 1 wt% and not greater than about 5 wt% based on the total weight of the body. A shaped abrasive particle comprising: a body comprising a first major surface, a second major surface, and a side surface extending between the first major surface and the second major surface, wherein the body comprises a substantially triangular two-dimensional shape, a content of a magnesium-containing species within a range between at least about 0.5 wt% and not greater than about 5 wt% based on the total weight of the body, and wherein the body comprises a polycrystalline material including crystalline grains, wherein the average grain size is not greater than about 1 micron.

 

Keywords:

Alumina, Alpha-Alumina, shaped abrasive particle (SAP), SAPS, SAPs, polyhedron, pyramid, ellipsoid, sphere, prism, cylinder, cone, tetrahedron, cube, cuboid, rhomohedron, truncated pyramid, truncated ellipsoid, truncated sphere, truncated cone, pentahedron, hexahedron, heptahedron, aoctahedron, nonahedron, decahedron, Greek alphabet character, Latin alphabet character, Russian alphabet character, volcano shape, monostatic, tip sharpness, sharpness, tip, high tip sharpness, sharpness-shape-strength factor, 3SF, zirconium, zirconium containing species, zirconium-containing species, magnesium, magnesium containing species, magnesium-containing species, bonded abrasive, coated abrasive, fixed abrasive, substrate, wt %, weight percent, grains, crystalline, grain size, average grain size, triangular two dimensional shape, polycrystalline, shape index factor, doping, major surface, first major surface, second major surface, width, height, length, aspect ratio, hi, w, l, fixed, impregnation, implant, implanting, grinding energy, specific grinding energy, lifetime, strength, stress, distribution, gel, boehmite, zirconium basic carbonate (ZBC), supersize, dye, Resin PF Prefere, water, singe grit grinding test (SGGT), axis, flashing, blend, open-coat, closed-coat, particle density, diluent particles, diluents, median particle size, organic material, solvent, pH, acid, base, nitric acid, sulfuric acid, citric acid, chloric acid, tartaric acid, phosphoric acid, ammonium nitrate, ammonium citrate, cavities, tool,  die, screen print, screen printing, mold, drying, dried, water, volatiles, mixture, drying process, humidity, precursor, shaping, curing, reacting, radiating, planarizing, calcining, sintering, sieving, doping, salt, liquid carrier, STIL, Micro Measure 3D Surface Profilometer, Hertzian indentation, axisymmetrical, hafnium, zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium, potassium, magnesium, calcium, strontium, barium, scandium, yttrium, lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium, manganese, nickel, titanium, zinc, grain boundary, grain boundaries, primary phase.

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Method of Using an Abrasive Article Including Shaped Abrasive Particles | Publication Date: 6.2.15

Summary:

A method of removing material from one or more workpieces including moving a coated abrasive article having a plurality of shaped abrasive particles relative to a surface of the one or more workpieces at high material removal rates. A method of removing material from one or more workpieces including moving a coated abrasive article comprising a plurality of shaped abrasive particles relative to a surface of the one or more workpieces at an average material removal rate of at least 6 in3/min/in. A method of conducting a high-speed, high-efficiency grinding operation including removing material from one or more workpieces by moving a coated abrasive article comprising a plurality of shaped abrasive particles relative to a surface of the one or more workpieces at an average material removal rate within a range between at least 6 in3/min/in and not greater than about 25 in3/min/in, wherein removing includes a G-ratio variance for at least two different material removal operations at two different material removal rates within the range of average material removal rates of not greater than about 30%.

Keywords:

Alumina, Alpha-Alumina, shaped abrasive particle (SAP), SAPS, SAPs, polyhedron, pyramid, ellipsoid, sphere, prism, cylinder, cone, tetrahedron, cube, cuboid, rhomohedron, truncated pyramid, truncated ellipsoid, truncated sphere, truncated cone, pentahedron, hexahedron, heptahedron, aoctahedron, nonahedron, decahedron, Greek alphabet character, Latin alphabet character, Russian alphabet character, volcano shape, monostatic, material removal, material removal rate, high material removal rate, average material removal rate, stainless steel, cumulative material removal, cumulative amount of material, hp min/in3, initial material removed, G-ratio, G-ratio variance, length, width, height, aspect ratio, flashing, percent flashing, concave, plane, two-dimensional, body, binder, essentially free of binder, nitrides, oxides, carbides, borides, oxynitrides, diamonds, aluminum oxide, zirconium oxide, titanium oxide, yttrium oxide, chromium oxide, strontium oxide, silicon oxide, seeded, seeded sol-gel, seeded sol gel, batch, first batch, second batch, average particle size, particle color, hardness, friability, toughness, density, specific surface area, surface area, controlled orientation, backing, predetermined rotational orientation, predetermined lateral orientation, predetermined longitudinal orientation, side orientation, side-orientation, coating density, cloth, paper, film, fabric, fleeced fabric, vulcanized fiber, woven material, non-woven material, non woven material, webbing, polymer, resin, phenolic resin, phenolic-latex resin, epoxy resin, polyester resin, urea formaldehyde resin, polyester, polyurethane, polypropylene, epoxy resins, polyurethanes, polyamides, polyacrylates,polymethacrylates, poly vinyl chlorides, polyethylene, polysiloxane, silicones, cellulose acetates, nitrocellulose, natural rubber, starch, shellac, size coat.

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