Method of manufacturing diamond abrasive tools

Claim 1

A METHOD OF BONDING A ONOLAYER OF DIAMOND CRYSTALS TO A METAL SUBSTRATE WITHOUT THE USE OF MOLDS AND MOLDING PRESSURE COMPRISING THE STEPS OF APPLYING DIAMOND CRYSTALS AND PARTICLES OF A SELF-WETTING BRAZE ALLOY TO A METAL SUBSTRATE SURFACE BY USE OF ATEMPORARY BINDER TO FORM AN ASSEMBLY, HEATING SAID ASSEMBLY IN A REDUCING ATMOSPHERE OR VACUUM TO A TEMPERATURE LESS THAN ABOUT 1300*C TO MELT THE BRAZE ALLOY, AND COOLING SAID ASSEMBLY TO SOLIDIFY SAID BRAZE ALLOY TO BOND THE DIAMOND TO THE SUBSTRATE, WHEREIN SAID BRAZE ALLOY INCLUDES AT LEAST APPROXIMATELY 50 PERCENT NICKEL AND GREATER THAN APPROXIMATELY 5 PERCENT CHROMIUM AND UP TO A TOTAL OF APPROXIMATELY 10 PERCENT OF ONE OR MORE ELEMENTS TAKEN FROM THE GROUP CONSISTING OF BORON, SILICON AND PHOSPHOROUS AND IS CHARACTERIZED BY ITS ABILITY TO READILY WET THE SURFACE OF THE DIAMOND CRYSTALS TO ACHIEVE A VERY SECURE BOND OF THE DIAMOND TO THE METAL SUBSTRATE.

Claim 2

A METHOD OF BONDING A ONOLAYER OF DIAMOND CRYSTALS TO A METAL SUBSTRATE WITHOUT THE USE OF MOLDS AND MOLDING PRESSURE COMPRISING THE STEPS OF APPLYING DIAMOND CRYSTALS AND PARTICLES OF A SELF-WETTING BRAZE ALLOY TO A METAL SUBSTRATE SURFACE BY USE OF ATEMPORARY BINDER TO FORM AN ASSEMBLY, HEATING SAID ASSEMBLY IN A REDUCING ATMOSPHERE OR VACUUM TO A TEMPERATURE LESS THAN ABOUT 1300*C TO MELT THE BRAZE ALLOY, AND COOLING SAID ASSEMBLY TO SOLIDIFY SAID BRAZE ALLOY TO BOND THE DIAMOND TO THE SUBSTRATE, WHEREIN SAID BRAZE ALLOY INCLUDES AT LEAST APPROXIMATELY 50 PERCENT NICKEL AND GREATER THAN APPROXIMATELY 5 PERCENT CHROMIUM AND UP TO A TOTAL OF APPROXIMATELY 10 PERCENT OF ONE OR MORE ELEMENTS TAKEN FROM THE GROUP CONSISTING OF BORON, SILICON AND PHOSPHOROUS AND IS CHARACTERIZED BY ITS ABILITY TO READILY WET THE SURFACE OF THE DIAMOND CRYSTALS TO ACHIEVE A VERY SECURE BOND OF THE DIAMOND TO THE METAL SUBSTRATE.

Claim 3

A method of bonding diamond crystals to a metal substrate to form a monolayer type working abrasive tool surface without the use of molds and molding pressure comprising the steps of applying diamond crystals and particles of a braze alloy to the surface of a self-wetting metal substrate by the use of a temporary binder material; heating said diamond, braze alloy and metal substrate assembly in a reducing atmosphere or vacuum to a temperature less than 1,300* C to melt the braze alloy and cooling said assembly to solidify the braze alloy, wherein said braze alloy includes approximately 60 to 92 percent of one or more metals taken from a group consisting of nickel and cobalt and includes more than approximately 5 percent chromium, and is characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal susbtrate.

Claim 4

A method of bonding diamond crystals to a metal substrate to form a monolayer type working abrasive tool surface without the use of molds and molding pressure comprising the steps of applying diamond crystals and particles of a braze alloy to the surface of a self-wetting metal substrate by the use of a temporary binder material; heating said diamond, braze alloy and metal substrate assembly in a reducing atmosphere or vacuum to a temperature less than 1,300* C to melt the braze alloy and cooling said assembly to solidify the braze alloy, wherein said braze alloy includes approximately 60 to 92 percent of one or more metals taken from a group consisting of nickel and cobalt and includes more than approximately 5 percent chromium, and is characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal susbtrate.

Claim 7

A method of bonding diamond crystals to a metal substrate to form a monolayer abrasive tool surface without the use of molds and molding pressure comprising the steps of applying diamond crystals and particles of a braze alloy to the surface of a metal substrate by the use of a temporary binder material; heating said diamond, braze alloy and metal substrate assembly in a reducing atmosphere or vacuum to a temperature sufficient to melt the braze alloy; and cooling said assembly to solidify the braze alloy, wherein said braze alloy includes approximately 60 to 92 percent of one or more metals taken from a group consisting of nickel and cobalt and includes at least approximately 2 to 30 percent chromium and is characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal substrate.

Claim 8

A method of bonding diamond crystals to a metal substrate to form a monolayer abrasive tool surface without the use of molds and molding pressure comprising the steps of applying diamond crystals and particles of a braze alloy to the surface of a metal substrate by the use of a temporary binder material; heating said diamond, braze alloy and metal substrate assembly in a reducing atmosphere or vacuum to a temperature sufficient to melt the braze alloy; and cooling said assembly to solidify the braze alloy, wherein said braze alloy includes approximately 60 to 92 percent of one or more metals taken from a group consisting of nickel and cobalt and includes at least approximately 2 to 30 percent chromium and is characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal substrate.

Claim 9

A method of bonding diamond crystals to a metal substrate to form a monolayer abrasive tool surface without the use of molds and molding pressure comprising the steps of applying diamond crystals and particles of a self-wetting braze alloy to the surface of a metal substrate by the use of a temporary binder material; heating said diamond, braze alloy and metal substrate assembly in a reducing atmosphere or vacuum to a temperature sufficient to melt the braze alloy; and cooling said assembly to solidify the braze alloy, wherein said braze alloy includes a composition having at least 17 to 92 percent nickel, less than approximately 52 percent cobalt and 2 to 26 percent chromium and less than approximately 12 percent of one or more of the following group consisting of boron, silicon and phosphorous; said alloy being characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal substrate.

Claim 10

A method of bonding diamond crystals to a metal substrate to form a monolayer abrasive tool surface without the use of molds and molding pressure comprising the steps of applying diamond crystals and particles of a self-wetting braze alloy to the surface of a metal substrate by the use of a temporary binder material; heating said diamond, braze alloy and metal substrate assembly in a reducing atmosphere or vacuum to a temperature sufficient to melt the braze alloy; and cooling said assembly to solidify the braze alloy, wherein said braze alloy includes a composition having at least 17 to 92 percent nickel, less than approximately 52 percent cobalt and 2 to 26 percent chromium and less than approximately 12 percent of one or more of the following group consisting of boron, silicon and phosphorous; said alloy being characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal substrate.

Claim 13

A method of bonding diamond crystals to a metal substrate to form a monolayer tool working tool surface without the use of molds and pressure comprising the steps of applying untreated diamond crystals and particles of a self-wetting braze alloy to a metal substrate surface by use of a temporary binder to form an assembly; heating said diamond alloy, and substrate assembly in a reducing atmosphere or vacuum to a temperature sufficient to melt the braze alloy; and cooling said assembly to solidify said braze alloy to bond the diamond to the substrate; wherein said braze alloy includes 60 to 80 percent nickel and 5 to 15 percent chromium and is characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal substrate.

Claim 14

A method of bonding diamond crystals to a metal substrate to form a monolayer tool working tool surface without the use of molds and pressure comprising the steps of applying untreated diamond crystals and particles of a self-wetting braze alloy to a metal substrate surface by use of a temporary binder to form an assembly; heating said diamond alloy, and substrate assembly in a reducing atmosphere or vacuum to a temperature sufficient to melt the braze alloy; and cooling said assembly to solidify said braze alloy to bond the diamond to the substrate; wherein said braze alloy includes 60 to 80 percent nickel and 5 to 15 percent chromium and is characterized by its ability to readily wet the surface of the diamond crystals to achieve a very secure bond of the diamond to the metal substrate.

Claim 16

A method of bodning a monolayer of diamond crystals to a metal substrate without the use of molds and pressure comprising the steps of applying particles of a braze alloy characterized by its ability to readily wet the surface of diamond crystals to a metal substrate surface by use of a temporary binder; heating said braze alloy and substrate assembly in a reducing atmosphere or a vacuum to melt the braze alloy on the substrate surface; cooling said braze alloy, applying diamond crystals to the surface of said braze alloy by using a temporary binder; heating said diamond, braze alloy and substrate assembly in a reducing atmosphere or a vacuum to again melt the alloy and cooling said assembly to obtain a secure attachment of the diamond on the metal substrate, said braze alloy including at least 60 to 80 percent nickel and 5 to 15 percent chromium.

Claim 17

A method of bodning a monolayer of diamond crystals to a metal substrate without the use of molds and pressure comprising the steps of applying particles of a braze alloy characterized by its ability to readily wet the surface of diamond crystals to a metal substrate surface by use of a temporary binder; heating said braze alloy and substrate assembly in a reducing atmosphere or a vacuum to melt the braze alloy on the substrate surface; cooling said braze alloy, applying diamond crystals to the surface of said braze alloy by using a temporary binder; heating said diamond, braze alloy and substrate assembly in a reducing atmosphere or a vacuum to again melt the alloy and cooling said assembly to obtain a secure attachment of the diamond on the metal substrate, said braze alloy including at least 60 to 80 percent nickel and 5 to 15 percent chromium.