US4824442A
Expired / Lapsed
US
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Method of manufacturing composite thermostable abrasive products
Assignee: Industrielle de Combustible Nucleaire Ste
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Filing: 1988-06-14
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Granted: 1989-04-25
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Expires: 2008-06-14
Abstract
Abstract For preparing a composite abrasive product having an active part, formed by a compact containing grains of ultra-hard product representing more than 80% per volume of the compact, each grain being bonded directly to its neighbors so that the compact has a polycrystalline structure, and by a hard and refractory support bonded to the compact, formed essentially of a refractory carbide such tungsten carbide, characterized in that: a layer of ultra-hard product grains (PCD or CBN) is placed in contact with components generating an ultra-hard ceramic binder phase in the cell. The powder layer is covered with a thin layer of tungsten coated with a carbide supplying material and, finally, with a tungsten carbide support. The cell containing the stack thus formed is brought to a temperature and a pressure sufficient to cause plastic phase sintering of the ultra-hard product grains with each other and bonding of the compact to the support.
Inventors
- 👤 Jean-Michel Cerceau
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 23:29
CPC Classifications
B; B22; B22F; B22F7/00; B22F7/06; B01; B01J; B01J3/00; B01J3/06; B01J3/062; B24; B24D; B24D3/00; B24D3/007; B24D3/02; B24D3/04; B24D3/06; B24D3/14; C; C22; C22C; C22C26/00; B01J2203/00; B01J2203/06; B01J2203/0605; B01J2203/062; B01J2203/065; B01J2203/0655; B01J2203/066; B01J2203/0675; B01J2203/0685
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
155 words
Method for producing a composite abrasive body having; an active compact containing grains of ultra-hard product representing more than 80% per volume of the compact, said grains mutually bonded directly so that the compact has a polycrystalline structure; and a hard refractory support bonded to the compact, formed essentially of a refractory metal carbide, comprising the steps of: placing, within a cell, a layer of grains of particulate ultra-hard product in contact with material of such nature as to generate a ultra-hard ceramic binder phase; placing a thin layer of tungsten coated with carbon supplying material over said layer of grains; placing a tungsten carbide support over said thin layer to constitute a stack; and bringing the cell containing the stack to a temperature and a pressure and for a time sufficient to cause mutual plastic phase sintering of the ultra-hard product grains and to bond the compact generated by the layers to the support.
Claim 2
Dependent Claim
155 words
Method for producing a composite abrasive body having; an active compact containing grains of ultra-hard product representing more than 80% per volume of the compact, said grains mutually bonded directly so that the compact has a polycrystalline structure; and a hard refractory support bonded to the compact, formed essentially of a refractory metal carbide, comprising the steps of: placing, within a cell, a layer of grains of particulate ultra-hard product in contact with material of such nature as to generate a ultra-hard ceramic binder phase; placing a thin layer of tungsten coated with carbon supplying material over said layer of grains; placing a tungsten carbide support over said thin layer to constitute a stack; and bringing the cell containing the stack to a temperature and a pressure and for a time sufficient to cause mutual plastic phase sintering of the ultra-hard product grains and to bond the compact generated by the layers to the support.
Claim 3
Dependent Claim
20 words
Method according to claim 1, wherein the thin layer a tungsten disk of from 200 to 400 μm in thickness.
Claim 4
Dependent Claim
25 words
Method according to claim 2, wherein the carbon supplying material is a coating of substantially pure carbon with a thickness of 30 to 300 μm.
Claim 5
Dependent Claim
21 words
Method according to claim 3, wherein the coating is deposited on the tungsten layer by vacuum vaporization or vapor phase deposition.
Claim 6
Dependent Claim
124 words
Method for producting a composite abrasive body, comprising the steps of: constituting a stack consisting of a mass predominantly of grains of ultra-high particulate material selected from diamond and CBN and of a material of such nature as to form a hard ceramic binder phase, a tungsten disk having a thickness of from 200 to 400 μm coated with carbon on its surface remote from said mass, and a support of pre-sintered refractory metal having a thickness much in excess of the thickness of said mass, and bringing said stack to a temperature and a pressure and for a time sufficient to cause mutual plastic phase sintering of the ultra-hard product grains and to bond the compact generated by the layers to the support.
Claim 7
Dependent Claim
124 words
Method for producting a composite abrasive body, comprising the steps of: constituting a stack consisting of a mass predominantly of grains of ultra-high particulate material selected from diamond and CBN and of a material of such nature as to form a hard ceramic binder phase, a tungsten disk having a thickness of from 200 to 400 μm coated with carbon on its surface remote from said mass, and a support of pre-sintered refractory metal having a thickness much in excess of the thickness of said mass, and bringing said stack to a temperature and a pressure and for a time sufficient to cause mutual plastic phase sintering of the ultra-hard product grains and to bond the compact generated by the layers to the support.
Claim 8
Dependent Claim
34 words
Method according to claim 5, wherein said material forming a binder phase essentially consists of a mixture of nickel and iron intimately mixed with said grains and of a silicon disk supporting said mass.
Claim 9
Dependent Claim
29 words
Method according to claim 5, wherein said ultra-high material is CBN and said material for forming a binder phase consists of a mixture of powdered silicon, aluminum and diamond.
Claim 10
Dependent Claim
100 words
Abrasive product having: an abrasive body which consists of a predominant proportion of an ultra-hard product and a binder phase for thermostability of the body; a sintered tungsten carbide support containing cobalt as a binder; and a bonding interface between said body and support whose composition varies progressively and steadily from a zone formed of tungsten carbide bonded directly to the support and having a stoechiometric composition substantially corresponding to the formula WC, a transition zone to the composition W 2 C and a transition zone to a residual metal tungsten layer having a metallurgical bond with the ultra-hard product.
Claim 11
Dependent Claim
100 words
Abrasive product having: an abrasive body which consists of a predominant proportion of an ultra-hard product and a binder phase for thermostability of the body; a sintered tungsten carbide support containing cobalt as a binder; and a bonding interface between said body and support whose composition varies progressively and steadily from a zone formed of tungsten carbide bonded directly to the support and having a stoechiometric composition substantially corresponding to the formula WC, a transition zone to the composition W 2 C and a transition zone to a residual metal tungsten layer having a metallurgical bond with the ultra-hard product.
Claim 12
Dependent Claim
12 words
Abrasive product according to claim 8, wherein the bonding interface is thermostable.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-04-24 | 1992-10-24 | 1993-04-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-04-24 | 1996-10-24 | 1997-04-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-04-24 | 2000-10-24 | 2001-04-25 | $7700.00 | Window Closed / Lapsed |