A method of forming a shaped abrasive particle including forming a precursor shaped abrasive particle having a body including at least one predetermined stress concentration point and at least one predetermined stress concentration vector and processing the precursor shaped abrasive particle and fracturing the precursor shaped abrasive particle substantially along the predetermined stress concentration vector to form a fractured shaped abrasive particle.

The present disclosure relates to the formation of polycrystalline diamond materials with fine diamond grains and nano-sized particles of a grain growth inhibitor. In one embodiment, a method of fabricating a polycrystalline diamond material is provided. The method includes providing a mixture of diamond particles with an average particle size of about 1 micron or less, distributing a plurality of nano-sized titanium-containing particles with the diamond mixture, to act as a grain growth inhibitor, and sintering the mixture of diamond particles and titanium-containing particles at high pressure and high temperature to create a polycrystalline structure of sintered diamond grains. The sintered diamond grains have an average size of about 1 micron or less.

In an embodiment, a polycrystalline diamond compact includes a substrate and a preformed polycrystalline diamond table having an upper surface, an interfacial surface, and at least one side surface extending therebetween. The interfacial surface of the polycrystalline diamond table is bonded to the substrate. The polycrystalline diamond table includes bonded diamond grains defining interstitial regions. The polycrystalline diamond table includes a first region extending inwardly from at least a portion of the upper surface and at least a portion of the at least one side surface. The first region spaced from the interfacial surface. The polycrystalline diamond table includes at least a second region extending inwardly from the interfacial surface to the upper surface. The first region includes at least a first infiltrant disposed interstitially between the bonded diamond grains thereof. The second region includes at least a second infiltrant disposed interstitially between the bonded diamond grains thereof.

A method of making shaped ceramic abrasive particles includes cutting a layer of ceramic precursor material using a laser beam and forming shaped ceramic precursor particles. Further thermal processing provides shaped ceramic abrasive particles. Shaped ceramic abrasive particles producible by the methods and abrasive articles containing them are also disclosed.

A method of making shaped ceramic abrasive particles includes cutting a layer of ceramic precursor material using a laser beam and forming shaped ceramic precursor particles. Further thermal processing provides shaped ceramic abrasive particles. Shaped ceramic abrasive particles producible by the methods and abrasive articles containing them are also disclosed.

Embodiments of the invention relate to thermally-stable polycrystalline diamond compacts (PDCs), and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate and a pre-sintered polycrystalline diamond (PCD) table bonded to the substrate. The pre-sintered PCD table includes bonded diamond grains defining a plurality of interstitial regions. The pre-sintered PCD table further including a first region remote from the substrate including a nonmetallic catalyst and a metallic catalyst each of which is disposed interstitially between the bonded diamond grains thereof, and a second region bonded to the substrate including a metallic-catalyst infiltrant disposed interstitially between the bonded diamond grains thereof. A nonplanar boundary is located between the first region and the second region.

Sialon materials contain HFO.sub.2 in a maximum of 1 mass-% as a sintering additive, methods of producing them and methods of using them an /-SiAlON material with 5 mass % to 50 mass %, /(/) RE--SiAlON wherein RE stands for at least one cation selected from the group consisting of Y, Sc, Lu, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Mg or Ca, and 95 mass % to 50 mass %, /(/) -SiAlON and of an Hf-containing amorphous or partially crystalline grain-boundary phase with a proportion with respect to the overall material is below 10 vol %, wherein the Hf content of the sintered material is 0.2 mass % to 1.0 mass %, and of a dispersion phase comprising globular particles with a mean particle size of from 0.2 m to 15 m, containing at least one hard material selected from the group consisting of SiC, TiN, TiC, Ti(C,N), carbides of further elements of groups IVb, Vb and VIb of the periodic system, nitrides of further elements of groups IVb, VB and VIb of the periodic system, scandium carbide and scandium oxycarbide, which are contained in the sintered compact in a proportion from 5 vol % to 30 vol %.

A cubic nitride compact containing a polycrystalline mass of cubic boron nitride particles, present in an amount of at least 70 percent by volume, and a binder phase, which is metallic in character. In addition, a compact in which the binder phase is preferably superalloy in character.

Provided are abrasive articles in which the make layer, abrasive particle layer, and size layer are coated onto a backing according to a coating pattern characterized by a plurality of discrete islands. The coating pattern has features in which all three components are generally in registration with each other, while providing a pervasive uncoated area extending across the backing. Advantageously, this configuration provides a coated abrasive that displays superior curl-resistance compared with previously disclosed abrasive articles. Moreover, this configuration resists loading, resists de-lamination, has enhanced flexibility, and decreases the quantity of raw materials required to achieve the same level of performance as conventional abrasive articles.

Embodiments of the invention relate to polycrystalline diamond compacts (PDCs) comprising a polycrystalline diamond (PCD) table including a thermally-stable region having at least one low-carbon-solubility material disposed interstitially between bonded diamond grains thereof, and methods of fabricating such PDCs. In an embodiment, a PDC includes a substrate, and a PCD table bonded to the substrate. The PCD table includes a plurality of diamond grains exhibiting diamond-to-diamond bonding therebetween and defining a plurality of interstitial regions. The PCD table further includes at least one low-carbon-solubility material disposed in at least a portion of the plurality of interstitial regions. The at least one low-carbon-solubility material exhibits a melting temperature of about 1300 C. or less and a bulk modulus at 20 C. of less than about 150 GPa.