Superabrasive wire saw and associated methods of manufacture
OwnerChien-Min Sunginventor
Life of this patent
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Abstract
A superabrasive wire saw having a plurality of individual coated superabrasive particles attached to a wire with an organic binder is disclosed and described. The superabrasive particle can be coated with a solidified coating of a molten braze alloy that is chemically bonded to the superabrasive particle. The organic binder can optionally contain filler materials and/or an organometallic coupling agent to improve the retention of coated superabrasive particles. The resulting superabrasive wire saws can be produced having diameters of less than 0.5 mm which significantly reduce kerf loss. Various methods for making and using such a superabrasive wire saw are additionally disclosed and described.
Claims31
A superabrasive wire saw, comprising a wire and a superabrasive layer having a plurality of individual coated superabrasive particles attached to the wire with an organic binder, said coated superabrasive particles comprising a superabrasive particle and a solidified coating of a molten braze alloy chemically bonded to the superabrasive particle.
A method of forming a superabrasive wire saw, comprising the steps of:
- a) coating superabrasive particles with a braze alloy in a molten liquid state and solidifying the braze alloy around the superabrasive particle, such that the braze alloy becomes chemically bonded with the superabrasive particle to form coated superabrasive particles;
- b) forming a mixture of coated superabrasive particles and organic binder over at least a portion of a wire;
- and
- c) curing the organic binder to secure the coated superabrasive particles to the wire to form a superabrasive wire saw.
A method of forming a superabrasive wire saw, comprising the steps of:
- a) coating superabrasive particles with a braze alloy in a molten liquid state and solidifying the braze alloy around the superabrasive particle, such that the braze alloy becomes chemically bonded with the superabrasive particle to form coated superabrasive particles having an average surface roughness of from about 3 μm to about 10 μm, said braze alloy has a melting temperature below a thermal stability limit of the superabrasive particle and contains at least about 1% of a reactive element selected from the group consisting of Al, B, Cr, Li, Mg, Mo, Mn, Nb, Si, Ta, Ti V, W, Zr, and mixtures thereof and wets at least about 40% of the superabrasive particle surface;
- b) forming a mixture of coated superabrasive particles and organic binder over at least a portion of a metal wire, such that the coated superabrasive particles are in a single layer;
- and
- c) curing the organic binder to secure the coated superabrasive particles to the metal wire to form a superabrasive wire saw;
- wherein the steps of coating the superabrasive particles, forming a mixture, and curing the organic binder are performed continuously as the metal wire is translated through a processing area.
Dependencies are inferred from the claim text.