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Sintered abrasives

Using the results of recent research on solgel-abrasives,
the project aims to improve the properties of alumina-based
sintered abrasives by adding certain additives in order to
change the microstructure of the sintered material.

In previous work, four different materials based on sintered alumina were developed with varying properties for different applications as abrasive grits. Recently, several patents were published or granted to other companies covering three of the above-mentioned products. Only one of them can be used by TS AG at the moment. This restricts the applications and reduces possible market penetration. It is therefore necessary to increase the performance and adapt the material to different applications. At the same time, attention must be paid to the patent situation and the obtainable price/performance ratio of the product in order to assure economic industrial production. To reach these goals, several methods will be used to modify the existing material and technology in cooperation with ETH-ZUERICH. Good feedback from actual grinding tests in different applications is necessary for the development. We will therefore closely cooperate with two customers, one for coated and one for bonded abrasives. They will carry out tests in a broad band of applications. A market study will establish the potential uses and quantities, assuming that the properties of the above- mentioned materials can be approximated by the new materials to be developed. For the definition phase, several composites based on alumina with matrix crystallite sizes between 1 and 5fm will be studied in the laboratory. We will establish the relationship between microstructure and grinding performance. The amount, composition and size of the second phase will be varied, several mechanical properties will be evaluated (hardness, fracture toughness, creep resistance) and grinding tests in different applications will be performed. At the same time, another important part of the project will consider the cost of the process. The most obvious steps to work on are the raw material, the drying step and the sintering temperature, all of them are expensive and provide the highest possibility to reduce costs. The variation in processing will cover conventional processing and solgel routes. The implementation of the successful process in a pilot plant depends strongly on the results of the laboratory phase. It should begin as early as possible, as some applications demand larger quantities of samples for testing than can be managed in the laboratory. By 1997, the concept and cost estimate for industrial production will be established.
Acronym: 
SINTABR
Project ID: 
1 332
Start date: 
01-01-1995
Project Duration: 
54months
Project costs: 
1 680 000.00€
Technological Area: 
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.