# US 9,434,050 B2 · Methods of fabricating abrasive elements using SP2-carbon-containing particles

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- Number: US 9,434,050 B2
- Document ID: US9434050B2
- Status: Granted
- Kind: B2
- Application number: 13/912,433
- Filed: 2013-06-07
- Published: 2013-10-17
- Granted: 2016-09-06
- Earliest claimed: 2006-07-31
- Assignees: US Synthetic Corporation
- Applicants: US Synthetic Corporation
- Inventors: Michael A Vail
- Web page: https://patentgrep.com/patent/US9434050B2

## CPC

- B24D 3/10: for porous or cellular structure, e.g. for use with diamonds as abrasives
- B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)}
- B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites
- C04B 35/52: based on carbon, e.g. graphite
- C04B 35/645: Pressure sintering
- C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes}
- E21B 10/567: with preformed cutting elements mounted on a distinct support, e.g. polycrystalline inserts
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- C04B 2235/427: Diamond
- C04B 2235/5436: micrometer sized, i.e. from 1 to 100 micron
- C04B 2235/5454: nanometer sized, i.e. below 100 nm
- C04B 2235/5472: Bimodal, multi-modal or multi-fraction
- C04B 2235/77: Density
- C22C 29/06: based on carbides, but not containing other metal compounds
- B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS

## Abstract

In an embodiment, a method of forming an abrasive element is disclosed. The method includes sintering a powder mixture including a plurality of superabrasive particles, a plurality of sp2-carbon-containing particles, and a metallic constituent to form the abrasive element.

## Claims

### Claim 1

A method of forming an abrasive element, comprising:
sintering a powder mixture including a plurality of superabrasive particles, a plurality of sp2-carbon-containing particles, and a metallic constituent to form the abrasive element; and
wherein the plurality of sp2-carbon-containing particles are present in the powder mixture in an amount greater than zero weight percent to about 5 weight percent of the powder mixture.

### Claim 2 (depends on 1)

The method of claim 1 wherein the plurality of superabrasive particles includes at least one of diamond, carbide, or boron nitride.

### Claim 3 (depends on 1)

The method of claim 1 wherein the plurality of superabrasive particles includes diamond particles.

### Claim 4 (depends on 1)

The method of claim 1 wherein the plurality of superabrasive particles includes carbide.

### Claim 5 (depends on 4)

The method of claim 4 wherein the carbide includes silicon carbide.

### Claim 6 (depends on 1)

The method of claim 1 wherein the plurality of sp2-carbon-containing particles includes at least one of ultra-dispersed diamond particles or nanocrystalline diamond.

### Claim 7 (depends on 1)

The method of claim 1 wherein the plurality of sp2-carbon-containing particles are present in the powder mixture in an amount greater than zero weight percent to about 4 weight percent of the powder mixture.

### Claim 8 (depends on 1)

The method of claim 1 wherein the plurality of sp2-carbon-containing particles are present in the powder mixture in an amount greater than 0.1 weight percent to about 1.5 weight percent of the powder mixture.

### Claim 9 (depends on 1)

The method of claim 1 wherein the plurality of sp2-carbon-containing particles are present in the powder mixture in an amount greater than 0.1 weight percent to about 1 weight percent of the powder mixture.

### Claim 10 (depends on 1)

The method of claim 1, further comprising attaching the abrasive element to a substrate.

### Claim 11 (depends on 1)

The method of claim 1 wherein the metallic constituent includes iron, nickel, cobalt, or alloys thereof.

### Claim 12 (depends on 1)

The method of claim 1 wherein the metallic constituent includes a catalyst material.

### Claim 13 (depends on 1)

The method of claim 1 wherein the abrasive element forms a component of a superabrasive cutting element.

### Claim 14 (depends on 1)

The method of claim 1 wherein sintering a powder mixture including a plurality of superabrasive particles, a plurality of sp2-carbon-containing particles, and a metallic constituent to form the abrasive element includes subjecting the powder mixture to a high-pressure/high-temperature process.

### Claim 15

A method of forming a superabrasive element, comprising:
sintering a powder mixture including a plurality of diamond particles, a plurality of sp2-carbon-containing particles, a plurality of carbide particles, and a metallic constituent to form the superabrasive element;
wherein the plurality of sp2-carbon-containing particles are present in the powder mixture in an amount greater than zero weight percent to about 45 weight percent of the powdered mixture.

### Claim 16 (depends on 15)

The method of claim 15 wherein the plurality of sp2-carbon-containing particles includes at least one of ultra-dispersed diamond particles or nanocrystalline diamond.

### Claim 17 (depends on 15)

The method of claim 15 wherein the plurality of sp2-carbon-containing particles comprises greater than zero weight percent to about 1 weight percent of the powder mixture.

### Claim 18 (depends on 15)

The method of claim 15 wherein the plurality of sp2-carbon-containing particles comprises greater than zero weight percent to about 2 weight percent of the powder mixture.

### Claim 19 (depends on 15)

The method of claim 15 wherein the plurality of carbide particles includes silicon carbide.

### Claim 20 (depends on 15)

The method of claim 15 wherein the metallic constituent includes iron, nickel, cobalt, or alloys thereof.