An abrasive grain includes a surface having at least a first face with a first outline, and at least one second face with a second outline. The first outline does not contain any vertices, but the second outline contains at least one vertex. The abrasive grain may include a ceramic material, especially polycrystalline α-Al.sub.2O.sub.3.

Shaped ceramic abrasive particles include a first surface having a perimeter having a perimeter comprising at least first and second edges. A first region of the perimeter includes the second edge and extends inwardly and terminates at two corners defining first and second acute interior angles. The perimeter has at most four corners that define acute interior angles. A second surface is disposed opposite, and not contacting, the first surface. A peripheral surface is disposed between and connects the first and second surfaces. The peripheral surface has a first predetermined shape. Methods of making the shaped ceramic abrasive particles, and abrasive articles including them are also disclosed.

Embodiments of the invention relate to non-cylindrical polycrystalline diamond compacts (“PDCs”), and methods of fabricating such non-cylindrical PDCs without substantially undercutting a cemented carbide substrate thereof from an overlying polycrystalline diamond (“PCD”) table thereof. According to various embodiments, a PDC includes a PCD table including an upper surface and a table non-cylindrical lateral periphery. The PDC includes a cemented carbide substrate bonded to the PCD table. In an embodiment, the cemented carbide substrate includes a substrate non-cylindrical lateral periphery that is not substantially undercut from the table non-cylindrical lateral periphery of the PCD table. In an embodiment, the PDC includes at least one alignment feature positioned on the cemented carbide substrate and/or the PCD table.

Embodiments of the invention relate to non-cylindrical polycrystalline diamond compacts (“PDCs”), and methods of fabricating such non-cylindrical PDCs without substantially undercutting a cemented carbide substrate thereof from an overlying polycrystalline diamond (“PCD”) table thereof. According to various embodiments, a PDC includes a PCD table including an upper surface and a table non-cylindrical lateral periphery. The PDC includes a cemented carbide substrate bonded to the PCD table. In an embodiment, the cemented carbide substrate includes a substrate non-cylindrical lateral periphery that is not substantially undercut from the table non-cylindrical lateral periphery of the PCD table. In an embodiment, the PDC includes at least one alignment feature positioned on the cemented carbide substrate and/or the PCD table.

A method of forming a shaped abrasive particle including extruding a mixture into a form, applying a dopant material to an exterior surface of the form, and forming a precursor shaped abrasive particle from the form.

Provided is an abrasive film not likely to cause an end face defect of an optical fiber connector due to variation in load conditions during polishing, while providing a great grinding force. The abrasive film comprises a substrate film and an abrasive layer overlaid thereon, the abrasive layer comprising abrasive particles and a binder therefor and a wear quantity of the abrasive layer being from 10 mg to 25 mg. A content of the abrasive particles in the abrasive layer is preferably no less than 85% by mass. The abrasive particles preferably comprise first abrasive particles (primary particle diameter: of no less than 10 nm and less than 50 nm), and second abrasive particles (primary particle diameter: no less than 50 nm and less than 250 nm). An average thickness of the abrasive layer is preferably from 4 μm to 15 μm. The abrasive particles are preferably silica particles.

Provided is an abrasive film not likely to cause an end face defect of an optical fiber connector due to variation in load conditions during polishing, while providing a great grinding force. The abrasive film comprises a substrate film and an abrasive layer overlaid thereon, the abrasive layer comprising abrasive particles and a binder therefor and a wear quantity of the abrasive layer being from 10 mg to 25 mg. A content of the abrasive particles in the abrasive layer is preferably no less than 85% by mass. The abrasive particles preferably comprise first abrasive particles (primary particle diameter: of no less than 10 nm and less than 50 nm), and second abrasive particles (primary particle diameter: no less than 50 nm and less than 250 nm). An average thickness of the abrasive layer is preferably from 4 μm to 15 μm. The abrasive particles are preferably silica particles.

Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate and a preformed polycrystalline diamond table including an interfacial surface bonded to the substrate and an opposing working surface. The preformed polycrystalline diamond table includes a proximal region extending from the interfacial surface to an intermediate location within the preformed polycrystalline diamond table that includes a metallic infiltrant infiltrated from the substrate, and a distal region extending from the working surface to the intermediate location that is substantially free of the metallic infiltrant. A boundary exists between the proximal and distal regions that has a nonplanar irregular profile characteristic of the metallic infiltrant having been infiltrated into the preformed polycrystalline diamond table.

Embodiments relate to polycrystalline diamond compacts (“PDCs”) including a polycrystalline diamond (“PCD”) table in which a metal-solvent catalyst is alloyed with at least one alloying element to improve thermal stability of the PCD table. In an embodiment, a PDC includes a substrate and a PCD table bonded to the substrate. The PCD table includes diamond grains defining interstitial regions. The PCD table includes an alloy comprising at least one Group VIII metal and at least one metallic alloying element that lowers a temperature at which melting of the at least one Group VIII metal begins. The alloy includes one or more solid solution phases comprising the at least one Group VIII metal and the at least one metallic alloying element and one or more intermediate compounds comprising the at least one Group VIII metal and the at least one metallic alloying element.

Methods of making abrasive articles involve adhering shaped abrasive particles to a reinforcing member according to a predetermined pattern and optionally orientation, and depositing a space-filling binder precursor on the reinforcing member and shaped abrasive particles to provide a filled abrasive preform, disposing another reinforcing member onto the filled abrasive preform, and curing the abrasive article precursor to form the abrasive articles. In some aspects, multiple abrasive preforms are stacked on each other. Bonded abrasive wheels preparable according to the methods are also disclosed.