Modifying the surface of diamond particles

Claim 2

A process for producing diamond abrasive particles having a rough adherent covering which comprises providing milling balls consisting essentially of plastic or elastomer having a diameter ranging from about 1/16 inch to about 1/4 inch, providing particles of a metal compound which is decomposible or reducible at atmospheric pressure at a temperature ranging from about 800° C to 1400° C to produce metal and gaseous product of decomposition, said metal compound being selected from the group consisting of molybdenum sulfide, tungsten sulfide, titanium sulfide, niobium sulfide, tantalum sulfide, chromium chloride, zirconium sulfide, and mixtures thereof, providing diamond particles ranging in size from about 10 microns to 2000 microns, milling said milling balls and said particles of metal compound and diamond mechanically smearing a coating of said metal compound onto the surface of said diamond particles coating said compound on at least 50 percent to about 100 percent of the surface area of said diamond particles, said milling balls having a shape and sufficient elasticity and resiliency to effect said mechanical smearing, recovering the metal compound-coated diamond particles, and firing said metal compound-coated diamond particles in a reducing or inert atmosphere at a temperature ranging from at least about 800° C to 1400° C decomposing or reducing the metal compound and producing said abrasive particles, said abrasive particle consisting essentially of a diamond particle having a rough granular adherent covering consisting essentially of an outside surface coating ranging in composition from said metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range, and a layer of carbide of said metal intermediate said surface coating and said diamond particle chemically bonding said surface coating to said diamond particle, said covering being discontinuous or continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 3

The process according to claim 1 wherein said firing temperature ranges from about 1100° C to 1400° C producing penetration of the diamond surface with tracks of said metal carbide, and wherein said outside surface coating consists essentially of up to a minor amount of said metal and said metal carbide, and wherein said covering is significantly continuous with a significantly uniform fine granular structure with a multitude of furrows distributed therein running significantly parallel to each other.

Claim 4

A process for producing diamond abrasive particles having a rough adherent covering which comprises providing milling balls consisting essentially of plastic or elastomer having a diameter ranging from about 1/16 inch to about 1/2 inch, providing particles of a metal compound which is decomposible or reducible at atmospheric pressure at a temperature ranging from about 800° C to 1400° C to produce metal and gaseous product of decomposition, said metal compound being selected from the group consisting of molybdenum sulfide, tungsten sulfide, titanium sulfide, niobium sulfide, tantalum sulfide, chromium chloride, zirconium sulfide, and mixtures thereof, milling said milling balls and said particles of metal compound producing a coating of said compound on the milling balls, milling the resulting metal compound-coated milling balls with the diamond particles ranging in size from about 10 microns to 2000 microns mechanically smearing a coating of said metal compound onto the surface of said diamond particles coating said compound on at least 50 percent to about 100 percent of the surface area of said diamond particles, said milling balls having a shape and sufficient elasticity and resiliency to effect said mechanical smearing, recovering the metal compound-coated diamond particles, and firing said metal compound-coated diamond particles in a reducing or inert atmosphere at a temperature ranging from at least about 800° C to 1400° C decomposing or reducing the metal compound and producing said abrasive particles, said abrasive particle consisting essentially of a diamond particle having a rough granular adherent covering consisting essentially of an outside surface coating ranging in composition from said metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range, and a layer of carbide of said metal intermediate said surface coating and diamond chemically bonding said surface coating to said diamond, said covering being discontinuous or continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 5

A process for producing diamond abrasive particles having a rough adherent covering which comprises providing milling balls consisting essentially of plastic or elastomer having a diameter ranging from about 1/16 inch to about 1/2 inch, providing particles of a metal compound which is decomposible or reducible at atmospheric pressure at a temperature ranging from about 800° C to 1400° C to produce metal and gaseous product of decomposition, said metal compound being selected from the group consisting of molybdenum sulfide, tungsten sulfide, titanium sulfide, niobium sulfide, tantalum sulfide, chromium chloride, zirconium sulfide, and mixtures thereof, milling said milling balls and said particles of metal compound producing a coating of said compound on the milling balls, milling the resulting metal compound-coated milling balls with the diamond particles ranging in size from about 10 microns to 2000 microns mechanically smearing a coating of said metal compound onto the surface of said diamond particles coating said compound on at least 50 percent to about 100 percent of the surface area of said diamond particles, said milling balls having a shape and sufficient elasticity and resiliency to effect said mechanical smearing, recovering the metal compound-coated diamond particles, and firing said metal compound-coated diamond particles in a reducing or inert atmosphere at a temperature ranging from at least about 800° C to 1400° C decomposing or reducing the metal compound and producing said abrasive particles, said abrasive particle consisting essentially of a diamond particle having a rough granular adherent covering consisting essentially of an outside surface coating ranging in composition from said metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range, and a layer of carbide of said metal intermediate said surface coating and diamond chemically bonding said surface coating to said diamond, said covering being discontinuous or continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 6

A process for producing diamond abrasive particles with a rough adherent covering which comprises providing milling balls consisting essentially of plastic or elastomer having a diameter ranging from about 1/16 inch to about 1/4 inch, providing particles of a metal compound which is decomposible or reducible at atmospheric pressure at a temperature ranging from about 800° C to 1400° C to produce metal and gaseous product of decomposition, said metal compound being selected from the group consisting of molybdenum sulfide, tungsten sulfide, titanium sulfide, niobium sulfide, tantalum sulfide, chromium chloride, zirconium sulfide, and mixtures thereof, providing diamond particles ranging in size from about 10 microns to 2000 microns, milling said milling balls and said particles of metal compound and diamond mechanically smearing a coating of said metal compound onto the surface of said diamond particles coating from at least 50 percent to about 100 percent of the surface area of said diamond particles, said milling balls having a shape and sufficient elasticity and resiliency to effect said mechanical smearing, recovering the metal compound-coated diamond particles, heating said metal compound-coated diamond particles in air to oxidize said metal compound to metal oxide, and firing the resulting metal oxide-coated diamond particles in a reducing atmosphere at a temperature ranging from at least about 800° C to about 1000° C reducing the metal compound and producing said abrasive particles, said abrasive particle consisting essentially of a diamond particle having a rough granular adherent covering consisting essentially of an outside surface coating ranging in composition from said metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range and having a layer of carbide of said metal intermediate said surface coating and said diamond particle chemically bonding said surface coating to said diamond, said covering being discontinuous or continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 7

A process for producing diamond abrasive particles with a rough adherent covering which comprises providing milling balls consisting essentially of plastic or elastomer having a diameter ranging from about 1/16 inch to about 1/4 inch, providing particles of a metal compound which is decomposible or reducible at atmospheric pressure at a temperature ranging from about 800° C to 1400° C to produce metal and gaseous product of decomposition, said metal compound being selected from the group consisting of molybdenum sulfide, tungsten sulfide, titanium sulfide, niobium sulfide, tantalum sulfide, chromium chloride, zirconium sulfide, and mixtures thereof, providing diamond particles ranging in size from about 10 microns to 2000 microns, milling said milling balls and said particles of metal compound and diamond mechanically smearing a coating of said metal compound onto the surface of said diamond particles coating from at least 50 percent to about 100 percent of the surface area of said diamond particles, said milling balls having a shape and sufficient elasticity and resiliency to effect said mechanical smearing, recovering the metal compound-coated diamond particles, heating said metal compound-coated diamond particles in air to oxidize said metal compound to metal oxide, and firing the resulting metal oxide-coated diamond particles in a reducing atmosphere at a temperature ranging from at least about 800° C to about 1000° C reducing the metal compound and producing said abrasive particles, said abrasive particle consisting essentially of a diamond particle having a rough granular adherent covering consisting essentially of an outside surface coating ranging in composition from said metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range and having a layer of carbide of said metal intermediate said surface coating and said diamond particle chemically bonding said surface coating to said diamond, said covering being discontinuous or continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 8

An abrasive particle consisting essentially of diamond particle having a rough adherent flaky granular covering, said covering consisting essentially of an outside surface coating ranging in composition from metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range and a layer of carbide of said metal intermediate said surface coating and said diamond particle bonding said surface coating to said diamond particle, said metal being selected from the group consisting of molybdenum, tungsten, titanium, niobium, tantalum, chromium, zirconium and alloys thereof, said covering ranging in structure from non-uniform to substantially uniform and from discontinuous to continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 9

An abrasive particle consisting essentially of diamond particle having a rough adherent flaky granular covering, said covering consisting essentially of an outside surface coating ranging in composition from metal to a carbide of said metal with all composition ratios of said metal and metal carbide falling within said range and a layer of carbide of said metal intermediate said surface coating and said diamond particle bonding said surface coating to said diamond particle, said metal being selected from the group consisting of molybdenum, tungsten, titanium, niobium, tantalum, chromium, zirconium and alloys thereof, said covering ranging in structure from non-uniform to substantially uniform and from discontinuous to continuous and covering from at least 50 percent to about 100 percent of the surface area of said diamond particle.

Claim 10

An abrasive particle according to claim 5 wherein said outside surface coating consists essentially of up to a minor amount of said metal and said metal carbide, and wherein said covering is significantly continuous with a significantly uniform fine granular structure with a multitude of furrows distributed therein running significantly parallel to each other, said covering also being bonded to the diamond particle by tracks of metal carbide penetrating the diamond surface.