A cubic boron nitride sintered material comprises 30% by volume or more and 80% by volume or less of cubic boron nitride grains and 20% by volume or more and 70% by volume or less of a binder phase, the cubic boron nitride grains having a dislocation density of 3×10.sup.17/m.sup.2 or more and 1×10.sup.20/m.sup.2 or less.

The cubic boron nitride sintered material comprises 30% by volume or more and 80% by volume or less of cubic boron nitride grains and 20% by volume or more and 70% by volume or less of a binder phase, the cubic boron nitride grains having a dislocation density of 1×10.sup.15/m.sup.2 or more and 1×10.sup.17/m.sup.2 or less.

The present application is a new improvement in the fine-grained cubic boron nitride sintered compact which may be employed to manufacture a cutting tool. The compact contains at least 80 vol % cBN with a metallic binder system and is sintered under HPHT conditions. The improvement incorporates alloys of aluminum in the metallic binder system.

A system may include an energy delivery device and a computing device. The computing device may be configured to: control the energy delivery device to deliver energy to an abrasive coating, wherein the abrasive coating comprises a metal matrix and abrasive particles at least partially encapsulated by the metal matrix; and control the energy delivery device to scan the energy across a surface of the abrasive coating and form a series of softened or melted portions of the metal matrix.

A cubic boron nitride sintered material includes 40% by volume or more and 96% by volume or less of cubic boron nitride grains and 4% by volume or more and 60% by volume or less of a binder phase, and the cubic boron nitride grains have a dislocation density of less than 1×10.sup.5/m.sup.2.

Provided is a cubic boron nitride sintered body including more than or equal to 85 volume percent and less than 100 volume percent of cubic boron nitride particles, and a remainder of a binder, wherein the binder contains WC, Co, and an Al compound, the binder contains W.sub.2Co.sub.21B.sub.6, and, when I.sub.A represents an X-ray diffraction intensity of a (111) plane of the cubic boron nitride particles, I.sub.B represents an X-ray diffraction intensity of a (100) plane of the WC, and I.sub.C represents an X-ray diffraction intensity of a (420) plane of the W.sub.2Co.sub.21B.sub.6, a ratio I.sub.C/I.sub.A of the I.sub.C to the I.sub.A is more than 0 and less than 0.10, and a ratio I.sub.C/I.sub.B of the I.sub.C to the I.sub.B is more than 0 and less than 0.40.

Systems and methods include a computer-implemented method for manufacturing a binder for spraying onto tools. A binder is manufactured for binding compacts onto a tool substrate. The binder is designed to provide a coating strength on the tool substrate. The binder includes: a metal selected from iron (Fe), cobalt (Co), and nickel (Ni); an alloy including the metal selected from Fe, Co, and Ni; or a refractory alloy selected from tungsten, tantalum (Ta), molybdenum (Mo), and niobium (Nb). An ultra-high-pressure, high-temperature operation is performed on pure wurtzite boron nitride (w-BN) powder to synthesize w-BN and cubic boron nitride (c-BN) compact. A binder-compact mixture is produced by turbulently mixing the binder with the compact in a mixer within a vacuum. The binder-compact mixture is thermally sprayed onto a tool substrate to coat the tool.

A drilling tip according to the disclosure has a tip body which is provided with a tip portion tapered toward a tip side of the tip body; and a hard layer which is formed on a surface of the tip portion of the tip body, an outermost layer of the hard layer is a cBN sintered material having 70 to 95 vol % of cBN grains, and when a cross-sectional structure of the outermost layer is observed, a binder phase having a width of 1 nm or greater and 30 nm or less and containing Al, B, and N, and in which a ratio of an O content to an Al content is 0.1 or less exists between neighboring cBN grains.

Conventional sintering processes convert a portion of cBN to hBN which is softer than cBN which negatively affects functional properties of an alumina composite. The invention is directed to method for making an alumina-cubic boron nitride (Al.sub.2O.sub.3-cBN) composite that contains substantially no hexagonal boron nitride (hBN) by non-conventional spark plasma sintering of cBN with nano-sized alumina particles. The invention is also directed to Al.sub.2O.sub.3-cBN/Ni composites, which contain substantially no hBN, and which exhibit superior physical and mechanical properties compared to alumina composites containing higher amounts of hBN.

A structured multi-phase composite which include a metal phase, and a low stiffness, high thermal conductivity phase or encapsulated phase change material, that are arranged to create a composite having high thermal conductivity, having reduced/controlled stiffness, and a low CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured multi-phase composite is useful for use in structures such as, but not limited to, high speed engine ducts, exhaust-impinged structures, heat exchangers, electrical boxes, heat sinks, and heat spreaders.