Flexible bilayered sheet, one layer of which contains abrasive particles in a volatilizable organic binder and the other layer of which contains alloy particles in a volatilizable binder, method for producing same and coating produced by heating same

A method for forming a self-supporting flexible bilayered sheet comprising a base layer and a top layer, the method comprising:

• (a) forming a solution of an organic binder in an organic solvent, the binder comprising from 53 to 58.5 weight percent of polyvinyl butyral, 39.5 to 43.8 weight percent of a phthalate plasticizer and 2.0 to 2.7 weight percent of a deflocculant;
• (b) forming first and second slurries of abrasive particles and metallic matrix particles in said solution, respectively;
• (c) tape casting said first and second slurries;
• (d) removing the organic solvent from the tape cast layers to leave first and second flexible self-supporting sheets;
• and
• (e) attaching the second sheet to the top of the first sheet to form a flexible self-supporting bilayered sheet.