Patent Description:
The construction industry utilizes a variety of tools for cutting and grinding of construction materials. Cutting and grinding tools are required to remove or refinish old sections of roads. Additionally, quarrying and preparing finishing materials, such as stone slabs used for floors and building facades, require tools for drilling, cutting, and polishing. Typically, these tools include abrasive segments bonded to a core, such as a plate or a wheel. Abrasive segments are typically formed individually and then bonded to the core by sintering, brazing, welding, and the like. Breakage of the bond between the abrasive segment and the core can require replacement of the abrasive segment and/or the core, resulting in down time and lost productivity. Additionally, the breakage can pose a safety hazard when portions of the abrasive segment are ejected at high speed from the work area. Industry continues to look for improved formation of abrasive tools.

<CIT> discloses a cutting element and <CIT> discloses an abrasive article and a method of forming an abrasive article respectively.

According to the present invention, a process is defined in claim <NUM>.

The following is generally directed to a process of forming an abrasive tool having at least one abrasive component bonded to a core. An abrasive component can be an abrasive segment or a continuous rim. In particular, the process can include a single pressing step that can allow formation of a plurality of precursor abrasive components on a core. The process may not necessarily require a separate step, such as laser welding, sintering, or brazing, to facilitate attachment of a component to a core. The process can include infiltrating at least one precursor abrasive component on the core to form an abrasive tool having at least one abrasive component bonded to the core. After reading the present disclosure, a skilled artisan would appreciate embodiments provide a streamlined process of forming abrasive tools. Furthermore, the process allows formation of abrasive tools that comply with safety standards, such as EN13236. <NUM> for blades in hand held applications. An exemplary abrasive tool can include a cut-off blade or core drill.

<FIG> includes a flow chart illustrating a process for forming an exemplary abrasive article. The process can start at step <NUM>, forming a bond material composition. The bond material composition can include a metal element, such as a transition metal element, an alloy, or a combination thereof. Exemplary metal element or ally can include iron, iron alloy, tungsten, cobalt, nickel, chromium, titanium, silver, and any combination thereof. Alternatively or additionally, the bond material composition can include a rare earth element, such as cerium, lanthanum, and neodymium. As desired in certain applications, the bond material composition can include a wear resistant component such as tungsten carbide. A skilled artisan would understand that a desired bond material composition may vary to suit different applications. According to an embodiment, the bond material composition can be in the form of powder. For instance, the bond material composition can include a blend of particles of individual components or pre-alloyed particles. The particles can be between <NUM> microns and <NUM> microns.

At step <NUM>, a mixture including the bond material composition and abrasive particles can be formed. The abrasive particles can include a superabrasive, such as diamond, cubic boron nitride (CBN), or any combination thereof. In a particular embodiment, the superabrasive material can consist of diamond, cubic boron nitride (cBN), or any combination thereof.

In an embodiment, other materials, such as a filler, can be added to the mixture. Filler can be added to modify a property of the finally formed abrasive article or facilitate a forming process. For instance, filler including SiC, Al<NUM>O<NUM>, or the like can be added to improve wear resistance of the abrasive tool. In a further embodiment, filler can include graphite. Filler may or may not be present in the finally-formed abrasive article. Filler can be in the form of powder, granules, particles, or a combination thereof.

According to an embodiment, the mixture can include filler in a content that can facilitate improved formation of an abrasive article. For instance, filler can have a content of at least <NUM> wt. % for the total weight of the mixture, such as at least <NUM> wt. %, at least <NUM> wt%, or at least <NUM> wt. In another instance, filler can have a content of at most <NUM> wt. % for the total weight of the mixture, such as at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. In a further embodiment, the content of filler can be in a range including any of the minimum or maximum percentages noted herein. For instance, the mixture can include a filler content of at least <NUM> wt% and at most <NUM> wt.

According to an embodiment, the mixture can include the bond material composition in a content that can facilitate improved formation of an abrasive article. For example, the mixture can include at least <NUM> wt. % of the bond material composition for a total weight of the mixture, such as at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, or at least <NUM> wt. In another example, the mixture can include at most <NUM> wt. % of the bond material composition for a total weight of the mixture, such as at most <NUM> wt. %, at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. After reading the instant disclosure, a skilled artisan would understand that the content of the bond material composition may vary as desired by different applications. In a further example, the mixture can include at least <NUM> wt. % and at most <NUM> wt. % of the bond material composition for a total weight of the mixture.

According to an embodiment, the mixture can include abrasive particles in a content that can facilitate improved formation of an abrasive article. For example, the mixture can include at least <NUM> wt. % of abrasive particles for a total weight of the mixture, such as at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, or at least <NUM> wt. In another example, the mixture can include at most <NUM> wt. % of abrasive particles for a total weight of the mixture, such as at most <NUM> wt. %, at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. After reading the present disclosure, a skilled artisan would also understand that that the content of abrasive particles may vary as desired by different operations. In a further embodiment, the mixture can include at least <NUM> wt. % and at most <NUM> wt. % of abrasive particles for a total weight of the mixture.

In an embodiment, the abrasive particles can have an average particle size that can facilitate improved formation of an abrasive article. For example the average particle size can be at least <NUM> microns, such as at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, at least <NUM> microns, or at least <NUM> microns. In another embodiment, the abrasive particles can have an average particle size of at most <NUM> microns, such as at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, at most <NUM> microns, or at most <NUM> microns. It is to be appreciated that the abrasive particles can have an average particle size within a range including any of the minimum and maximum values disclosed herein. For instance, the average particle size of the abrasive particles can be within a range including at least <NUM> microns and at most <NUM> microns. Abrasive particle size can vary depending on applications of the abrasive articles. For example, coarse abrasive particles may be desired for certain applications requiring abrasive particles including diamond.

At step <NUM>, forming at least one precursor abrasive component, such as a precursor abrasive segment or a continuous rim, on a core can be performed. As used herein, precursor is intended to describe an article or a part of an article that is not finally formed. A precursor abrasive component can be understood to be an uninfiltrated abrasive component. According to the present invention, forming at least one precursor abrasive component on a core includes shaping the mixture obtained at step <NUM> into a body and simultaneously joining the body to a core. In an embodiment, a shaping device capable of providing a desired shape, such as a mold, can be used. The mixture can be disposed in a mold, and for instance, in a region that has the desired shape for an abrasive segment or a continuous rim. In some applications, the mold can include a plurality of segments to facilitate shaping and forming a plurality of precursor abrasive segments.

According to another embodiment, a core can be placed in the mold and in contact with the mixture. Depending on the application, a core can be in the form of a ring, a ring section, a plate, a cup wheel body, or a disc, such as a solid metal disk. A core can include heat treatable steel alloys, such as 25CrMo4, 75Cr1, C60, steel 65Mn, or similar steel alloys for cores with thin cross sections or simple construction steel like St <NUM> or similar for thick cores. A core can have a tensile strength of at least about <NUM> N/mm<NUM>. A suitable core can be formed by a variety of metallurgical techniques known in the art.

According to another embodiment, a pressure can be applied to the mixture to facilitate shaping and joining the precursor abrasive component to the core. According to an embodiment, forming at least one precursor abrasive component on a core can include a single operation of pressing. Pressing can include hot pressing, cold pressing, isostatic pressing, or the like. In a particular embodiment, pressing can include cold pressing. Unlike certain conventional processes, cold pressing can be performed to shape the mixture into at least one precursor abrasive component having a green body and simultaneously join the green body directly to the core to form an abrasive article preform. The term, green, as used herein to describe a body, is intended to refer to a body that is not finally formed. For instance, a green body can be understood to be an uninfiltrated body of a precursor abrasive component. More particularly, forming at least one precursor abrasive component on a core can include a single operation of cold pressing. In a particular embodiment, a single cold pressing operation can be performed to form a precursor continuous rim on a core and simultaneously join the rim directly to the core. In another particular embodiment, a single cold pressing operation can be performed to form a plurality of precursor abrasive segments and simultaneously join the plurality of abrasive segments directly to the core.

<FIG> includes an illustration of an exemplary abrasive article preform <NUM> including a plurality of precursor abrasive segments <NUM> directly attached to a core <NUM>. Each precursor abrasive segment <NUM> can include a body <NUM>.

According to at least one embodiment, pressing, such as cold pressing, can be carried out at a certain pressure that can facilitate improved formation of an abrasive article. For instance, the pressure can be at least <NUM> MPa, at least <NUM> MPa, at least <NUM> MPa, at least <NUM> MPa, at least <NUM> MPa, at least <NUM> MPa, or at least <NUM> MPa. In another instance, pressing can be performed at a pressure of at most <NUM> MPa, such as at most <NUM> MPa, at most <NUM> MPa, at most <NUM> MPa, at most <NUM> MPa, or at most <NUM> MPa. It is to be appreciated pressing can be performed at a pressure in a range including any of the minimum and maximum values disclosed herein. For instance, pressing can be performed at a pressure including at least <NUM> MPa and at most <NUM> MPa, such as in a range including at least <NUM> MPa and at most <NUM> MPa, or in a range including at least <NUM> MPa and at most <NUM> MPa. In another embodiment, pressing can be performed at a pressure including at least <NUM> MPa and at most <NUM> MPa.

According to at least one embodiment, pressing, such as cold pressing, can be carried out at a temperature that can facilitate improved formation of an abrasive article. For instance, pressing can be performed at a temperature of at most <NUM>, at most <NUM>, at most <NUM>, or at most <NUM>. In another instance, the temperature can be at least <NUM>. It is to be appreciated pressing can be performed at a temperature in a range including any of the minimum and maximum values disclosed herein. For instance, pressing can be performed at a temperature in a range including at least <NUM> and at most <NUM>, such as in a range including at least <NUM> and at most <NUM>. According to at least one embodiment, pressing can be performed in an ambient atmosphere, a reducing atmosphere, or an inert atmosphere. In a particular embodiment, pressing can be performed at room temperature (e.g., <NUM> to <NUM> ) and in ambient atmosphere.

According to an embodiment, a precursor abrasive component can include a green body having a metal bond matrix and abrasive particles contained within the metal bond matrix. The metal bond matrix can include any bond material composition disclosed herein. In a particular embodiment, the metal bond matrix can include a bond material composition including Cu, Sn, Ni, carbonyl iron, or a combination thereof.

According to a particular embodiment, the metal bond matrix can include a bond material composition that may be represented by the formula (WC)wWxFeyCrzX(<NUM>-w-x-y-z), wherein <NUM>≤w≤<NUM>, <NUM>≤x≤<NUM>, <NUM>≤y≤<NUM>, <NUM>≤z≤<NUM>, w+x+y+z≤<NUM>, and X can include other metals such as cobalt and nickel. According to another particular embodiment, the metal bond matrix can include a bond material composition represented by the formula (WC)wWxFeyCrzAgvX(<NUM>-v-w-x-y-z), wherein <NUM>≤w≤<NUM>, <NUM>≤x≤<NUM>, <NUM>≤y≤<NUM>, <NUM>≤z≤<NUM>, <NUM>≤v≤<NUM>, v+w+x+y+z≤<NUM>, and X can include other metals such as cobalt and nickel.

According to another embodiment, the precursor abrasive component can include a green body having a certain porosity that can facilitate improved formation of an abrasive article. In an example, the precursor body can have a porosity of at least <NUM>% for a total volume of the body, such as at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, or at least <NUM> vol%. In another example, the precursor body can include a porosity of at most <NUM> vol% for a total volume of the body, such as at most <NUM> vol%, at most <NUM> vol%, at most <NUM> vol%, at most <NUM> vol%, at most <NUM> vol%, or at most <NUM> vol%. It is to be understood that the porosity of the precursor body can be in a range including any of the minimum and maximum percentages disclosed herein. For instance, the porosity can be between <NUM> vol% and <NUM> vol%. According to another embodiment, a precursor abrasive component can include a body including a network of interconnected pores.

Referring to <FIG>, the process can continue to step <NUM>, infiltrating at least a portion of the at least one precursor abrasive component body. According to an embodiment, infiltrating can include applying an infiltrant material to at least a portion of the body, a portion of the core, or a portion of both. <FIG> includes an illustration of a portion of an abrasive article preform <NUM>. A precursor abrasive segment <NUM> is attached to a core <NUM>. The precursor abrasive segment <NUM> includes a body <NUM>, and the body <NUM> includes a top surface <NUM>, side surfaces <NUM> and <NUM>, an outer peripheral surface <NUM>, and an inner peripheral surface <NUM>. The infiltrant material can be applied to any surfaces of the body, as long as the infiltrant material is in contact with the body. For instance, the infiltrant material can be applied to the top surface <NUM> for ease of application.

In an embodiment, the infiltrant material can include a metal, a metal alloy, or a combination thereof. Particularly, the infiltrant material can consist essentially of a metal, metal alloy, or a combination thereof. Exemplary metal can include a transition metal element, an alloy including a transition metal element, or a combination thereof. In a particular embodiment, the infiltrant material can include Zn, Sn, Cu, Ag, Ni, Cr, Mn, Fe, Al, or any combination thereof. For instance, the infiltrant material can include copper, and in certain applications, the infiltrant material can be pure copper. In another example, the infiltrant material can include Ag, Ni, Cr, or a combination thereof. In a further example, an infiltrant material can include a brazing alloy, such as NiCr, or an alloy including at least one of Cu, Ag, Sn, and Ti.

In an exemplary embodiment, the infiltrant material can include a copper-tin bronze, a copper-tin-zinc alloy, or any combination thereof. Particularly, the copper-tin bronze may include a tin content not greater than <NUM> wt. %, such as not greater than <NUM> wt. In some instance, the copper-bronze may not include tin. Further, the tin content in the copper-tin bronze may be at least <NUM> wt. %, such as at least <NUM> wt. Similarly, the copper-tin-zinc alloy may include a tin content not greater than <NUM> wt%, such as not greater than <NUM> wt%. Alternatively or additionally, the tin content in the copper-tin-zinc alloy may be at least <NUM> wt. %, such as at least <NUM> wt. The copper-tin-zinc alloy may include a zinc content not greater than <NUM> wt%, such as not greater than <NUM> wt. The zinc content in the copper-tin-zinc alloy can be at least <NUM> wt. %, such as at least <NUM> wt.

According to a further embodiment, the infiltrant material may include an alloy including at most <NUM> wt. % of tin for the total weight of the alloy, such as at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. In another embodiment, the infiltrant material may not include tin. For instance, the infiltrant material can include an alloy including <NUM> wt. % to <NUM> wt. In another embodiment, the infiltrant material can include an alloy including zinc in a content of at most <NUM> wt. % of the total weight of the alloy. In still another embodiment, the infiltrant material may not contain zinc. In a further embodiment, the infiltrant material can include an alloy including <NUM> wt. % to <NUM> wt.

According to a further embodiment, the infiltrant material can have a melting point of at least <NUM> , such as at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>. In another embodiment, the melting point of the infiltrant material may be not greater than <NUM>, such as not greater than <NUM>, not greater than <NUM>, not greater than <NUM>, not greater than <NUM>. In a further embodiment, the infiltrant material can have a melting point between <NUM> and <NUM>.

In an embodiment, the infiltrant material can include powder. In another embodiment, the infiltrant material can be massive alloy. For instance, the infiltrant material can be a sheet of metal. In still another embodiment, the infiltrant material can be formed by cold pressing a powder of desired metal components. The powder can include particles of individual components or pre-alloyed particles. The particles can have a size of not greater than about <NUM> microns. Alternatively, the infiltrant material may be formed by other metallurgical techniques known in the art.

According to an embodiment, a heat can be applied to at least a portion of the body of the precursor component to facilitate infiltrating. In some embodiments, the abrasive article preform can be heated. Heating can be carried out in a furnace, such as a batch furnace or a tunnel furnace. Heating can be performed after the infiltrant material is applied and maintained until infiltration is completed. According to an embodiment, heating can be performed for at least <NUM> minutes to at most <NUM> hours.

Heat can be applied at a temperature that can facilitate infiltrating. For instance, heating can be performed at a temperature at least the melting point of the infiltrant material but below the melting point of the metal bond matrix and the core. For example, heating can be performed at a temperature of at least <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, or at least <NUM>. In another instance, heating can be performed at a temperature at most of <NUM>, such as at most of <NUM>, at most of <NUM>, at most of <NUM>, or at most of <NUM>. It is to be understood that heating can be performed at a temperature including any of the minimum and maximum values noted herein. For example, heat can be applied at a temperature in a range including at least <NUM> and at most <NUM>, such as in a range including at least <NUM> and at most of <NUM>, in a range including at least <NUM> and at most of <NUM>, in a range including at least <NUM> and at most of <NUM>, in a range including at least <NUM> and at most of <NUM>, or in a range including at least <NUM> and at most of <NUM>.

According to another embodiment, heating can be performed in a reducing atmosphere, an inert atmosphere, or an ambient atmosphere. Typically, reducing atmosphere can contain an amount of hydrogen to react with oxygen.

According to an embodiment, as the infiltrant material melts, the liquid infiltrant material can be drawn into pores of the precursor abrasive component, such as through capillary action. The infiltrant material can infiltrate and substantially fill the pores, forming an abrasive component. According to an embodiment, the abrasive component can have a densified body. The body can have a porosity of at most <NUM> vol%, such as at most <NUM> vol%, or at most <NUM> vol% for a total volume of the body. According to another embodiment, the porosity of the abrasive component body can be greater than <NUM>, such as at least <NUM> vol% or at least <NUM> vol% for a total volume of the body. In a further embodiment, the abrasive component body may have a porosity of <NUM> vol%.

According to an embodiment, the abrasive component can include a body including abrasive particles embedded in the metal bond matrix. The metal bond matrix can have a network of interconnected pores or pores that are partially or substantially fully filled with the infiltrant material. A bonding region can be between the core and the abrasive component and include the infiltrant material.

According to an embodiment, the abrasive component can include a body including a certain content of the metal bond matrix that can facilitate improved formation of an abrasive article. For instance, the content of the metal bond matrix can be at least <NUM> vol% for a total volume of the body, such as, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, or at least <NUM> vol%. In another instance, the abrasive component body can include the content of the metal bond matrix of at most <NUM> vol% for a total volume of the body, such as at most <NUM> vol%, at most <NUM> vol%, or at least <NUM> vol%. It is to be understood that an abrasive component can include a body including the metal bond matrix in a content including the minimum and maximum percentages included herein. For instance, the metal bond matrix can be present in the body of an abrasive component in a range including at least <NUM> vol% and at most <NUM> vol% for a total volume of the body.

According to another embodiment, the body can include a content of the metal bond matrix of at least <NUM> wt. % for a total weight of the abrasive component, such as at least <NUM> wt. %, at least <NUM> wt. %, or at least <NUM> wt. In another embodiment, the abrasive component body can include a content of the metal bond matrix of at most <NUM> wt. % for a total weight of the abrasive segment, such as at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. It is to be understood that an abrasive component can include a body including the metal bond matrix in a content including the minimum and maximum percentages included herein. For instance, the metal bond matrix can be present in the body of an abrasive segment in a range including at least <NUM> wt. % and at most <NUM> wt. % for a total weight of the body.

According to an embodiment, the body of an abrasive component can include a certain content of abrasive particles that can facilitate formation of an abrasive article with improved property and/or performance. For instance, abrasive particles can be present in an amount of at least <NUM> vol% for a total volume of the body, such as at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, at least <NUM> vol%, or at least <NUM> vol%. In another example, abrasive particles can be present in an amount of at most <NUM> vol%, such as at most <NUM> vol%, at most <NUM> vol%, at most <NUM> vol%, at most <NUM> vol%, or at most <NUM> vol%. Abrasive particles can be present in the body of an abrasive component in a content including any of the minimum and maximum percentages disclosed herein. For instance, abrasive particles can be in a content between <NUM> vol% to <NUM> vol%. Additionally, the content of abrasive particles may depend on the application. For example, an abrasive component of a grinding or polishing tool can include between <NUM> and <NUM> vol% abrasive particles for the total volume of the component body. Alternatively, an abrasive component of a cutting tool can include between <NUM> vol% and <NUM> vol% abrasive particles for the total volume of the component body. Further, an abrasive component for core drilling can include between about <NUM> vol% and <NUM> vol% abrasive particles for the total volume of the component body.

According to another embodiment, the body of an abrasive component can include a content of the abrasive particles of at least <NUM> wt. % for a total weight of the abrasive component, such as at least <NUM> wt. %, at least <NUM> wt. %, or at least <NUM> wt. In another embodiment, the abrasive component body can include a content of the abrasive particles of at most <NUM> wt. % for a total weight of the body, such as at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. In a further embodiment, the abrasive component body can include a content of the abrasive particles in a range of at least <NUM> wt. % and at most <NUM> wt. % for a total weight of the component body.

According to another embodiment, the body of an abrasive component can include a certain content of the infiltrant material that can facilitate formation of an abrasive article with improved property and/or performance. For instance, the body can include at least <NUM> vol% of the infiltrant material for the total volume of the body, such as at least <NUM> vol%, at least <NUM> vol%, or at least <NUM> vol% of the infiltrant material. In another instance, the body can include at most <NUM> vol% of the infiltrant material for the total volume of the body, such as at most <NUM> vol%, at most <NUM> vol%, at most <NUM> vol%, or at most <NUM> vol% of the infiltrant material. It is to be understood that the body can include the infiltrant material in a content including any of the minimum and maximum percentages disclosed herein. For example, the body of an abrasive component can include the infiltrant material in a content from at least <NUM> vol% to at most <NUM> vol%, such as from at least <NUM> vol% to at most <NUM> vol%.

According to another embodiment, the body can include a content of the infiltrant material of at least <NUM> wt% for a total weight of the body, such as at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, at least <NUM> wt. %, or at least <NUM> wt. In another embodiment, the body can include a content of the infiltrant material of at most <NUM> wt. % for a total weight of the abrasive component, such as at most <NUM> wt. %, at most <NUM> wt. %, at most <NUM> wt. %, at most <NUM> wt. %, at most <NUM> wt. %, or at most <NUM> wt. In a further embodiment, the body can include the infiltrant material in a content of at least <NUM> wt. % and at most <NUM> wt. % of a total weight of the abrasive component body.

<FIG> includes a flow chart illustrating an alternative process for forming an exemplary abrasive article. The process can include the same steps of <NUM> and <NUM> disclosed herein. At step <NUM>, forming at least one precursor abrasive component on a core can be performed while forming at least one infiltrant portion including an infiltrant material.

According to an embodiment, to allow simultaneous formation of the precursor abrasive component and infiltrant portion, the infiltrant material can be applied to the mixture prior to a pressure is applied to the mixture as noted above. The infiltrant material can be in direct contact with the mixture. When formation of a plurality of precursor abrasive component is desired, a plurality of infiltrant portions may be formed simultaneously. Particularly, each precursor abrasive component s can be in contact with an infiltrant portion. After applying the infiltrant material to the mixture, the process can proceed with applying a pressure as noted above.

At step <NUM>, after formation of the at least one precursor abrasive component and infiltrant portion, a heat can be applied to facilitate infiltrating the precursor abrasive component body. According to an embodiment, a heat can be applied to the at least one precursor abrasive component and the at least one infiltrant portion. Heating can be performed as noted above. After infiltration is completed, at least one abrasive segment on the core can be formed.

According to embodiments herein, the bonding region can form an identifiable interfacial layer that has a distinct phase from both the core and the abrasive component. The bonding region can include the infiltrant material. Particularly, the bonding region can have the same composition as the infiltrant material. <FIG> includes illustration of a portion of an abrasive article <NUM>. The abrasive article <NUM> includes a core <NUM>, bonding regions <NUM> and abrasive segments <NUM>. <FIG> includes illustration of a portion of an abrasive article <NUM>. The abrasive article <NUM> includes a core <NUM>, bonding regions <NUM> and a continuous rim <NUM>.

The abrasive article formed in accordance with embodiments herein can include abrasive tools having at least one abrasive component bonded to the core. Depending on the application, the abrasive article can be a tool including a plurality of abrasive segments bonded to the core. The abrasive article can also be a tool including a continuous rim bonded to the core. The abrasive article can be a cutting tool for cutting construction materials, such as a saw for cutting concrete. Alternatively, the abrasive tool can be a grinding tool such as for grinding concrete or fired clay or removing asphalt. <FIG> include photographs of exemplary abrasive articles formed in accordance with embodiments herein. The articles are in the order of the figures, cut-off blade, a continuous blade, cup wheel, and a turbo blade.

Claim 1:
A process, comprising:
forming at least one precursor abrasive component (<NUM>; <NUM>) on a core (<NUM>; <NUM>; <NUM>), the precursor abrasive component (<NUM>; <NUM>) including a body (<NUM>; <NUM>) having a metal bond matrix and abrasive particles contained within the metal bond matrix; and
infiltrating at least a portion of the body (<NUM>; <NUM>) after forming,
characterized in that,
forming the precursor abrasive component (<NUM>; <NUM>) on the core (<NUM>; <NUM>; <NUM>) comprises simultaneous formation of the body (<NUM>; <NUM>) and joining of the precursor abrasive component (<NUM>; <NUM>) to the core (<NUM>; <NUM>).