uscom

A method is provided for manufacturing a segmented diamond blade (1). The method includes the steps of placing a core (2) into a mold and pouring a metal mixture into a mold cavity surrounding the core (2). The metal mixture is cold pressed to the core (2) to form a blade having a continuous outer rim (14). Thereafter, the core (2) and outer rim (14) are suspended in a free-sintering furnace which is heated to an initial diffusion bonding temperature. The core (2) and outer rim (14) are heated for an initial bonding time period.

Thereafter, the furnace is heated to a final diffusion bonding temperature and the core (2) and the outer rim (14) are maintained at this temperature for a final diffusion bonding time period. After the blade (1) cools, it is placed in a cutting tool and segmented.

WHAT IS CLAIMED IS:

1. A method for producing a cutting blade having a core and a segmented outer rim comprising the steps of:

introducing a bond powder mixture onto said core to form a continuous uninterrupted outer rim, said bond powder mixture including metal particles and hardened cutting particles; after said introducing step, bonding said core to said continuous uninterrupted outer rim by heating said continuous uninterrupted outer rim and said core to a preselected temperature; and after said bonding step, forming notches through said continuous uninterrupted outer rim to remove portions of said outer rim and portions of said core to form a segmented outer rim.

2. A method for producing a cutting blade according to claim 1, further comprising the step of: forming a bond powder comprising first and second metals which bond to form a bronze or brass compound, a third metal which functions as a wetting agent, and a fourth metal which bonds to said bronze compound and said wetting agent.

3. A method for producing a cutting blade according to claim 1, further comprising the step of: forming a bond powder comprising at least three types of metal that will bond with one another and with said core.

4. A method for producing a cutting blade according to claim 1, further comprising the step of: forming a bond powder comprising at least two types of metal that will bond with one another and with said core, and at least one type of hardened particles for cutting.

5. A method for producing a cutting blade according to claim 1, further comprising the step of: forming a bond powder comprising at least one type of metal that will bond with one another and with said core, and diamond particles for cutting.

6. A method for producing a cutting blade according to claim 1, wherein said bonding step further includes the steps of: heating said core and outer rim to an initial bonding temperature for an initial bonding time period, and thereafter, heating said core and outer rim to a final bonding temperature for a final bonding time period.

7. A method for producing a cutting blade according to claim 1, wherein said bond powder comprises at least first and second metals and said bonding step further includes the step of: bonding said first and second metals to one another by heating said core and outer rim to an initial bonding temperature which is above a melting point of said first metal and below a melting point of said second metal during an initial bonding time period.

8. A method for producing a cutting blade according to claim 1, wherein said bond powder comprises at least first and second metals bonded to one another to form a bonded alloy and a third metal, said bonding step further includes the step of: bonding said bonded alloy and said third metal with one another by heating said core and outer rim to a final bonding temperature, which is above a melting point of said bonded alloy and below a melting point of said third metal, during a final bonding time period.

9. A method for producing a cutting blade according to claim 7, wherein said bond powder comprises at least a third metal and wherein said bonding step further comprises the step of: bonding said third metal and a bonded alloy formed by said first and second metals by heating said core and outer rim to a final bonding temperature, which is above said initial bonding temperature, during an initial bonding time period.

10. A method for producing a cutting blade according to claim 9, wherein said final bonding temperature is below a melting point of said third metal.

11. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: centering said core within a mold and pouring said bond powder mixture into a void surrounding said core; and cold pressing said bond powder mixture to obtain approximately 65% compression thereof with respect to a maximum compression.

12. A method for producing a cutting blade according to claim 1, wherein said bonding step is free-sintering while densification and bond shrinkage occur.

13. A method for producing a cutting blade according to claim 1, wherein said bond powder includes at least two metals and wherein said core and outer rim are heated during said bonding step to a temperature between melting points of said two metals.

14. A method for producing a cutting blade according to claim 1, wherein said bonding step includes the steps of:

initially heating said core and outer rim to a temperature between 1400°F and 1600°F to effect initial bonding; and finally heating said core and outer rim to a temperature between 1600°F and 2000°F to effect final bonding.

15. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: hot pressing said bond powder mixture to obtain partial compression thereof.

16. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: performing rapid solidification of said bond powder mixture to obtain partial compression thereof and adhesion to said core.

17. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: sintering of said bond powder mixture to obtain partial compression thereof and adhesion to said core.

18. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: microwave sintering of said bond powder mixture to obtain partial compression thereof and adhesion to said core.

19. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: hot isostatically pressing said bond powder mixture to obtain adhesion to said core.

20. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: coining said bond powder mixture to obtain adhesion to said core.

21. A method for producing a cutting blade according to claim 1, wherein said introducing step further comprises the step of: forging said bond powder mixture to obtain adhesion to said core.

22. A cutting blade having a circular core with an outer periphery having gullets formed thereabout and with a continuous outer rim thereon, said continuous outer rim having notches therein proximate said gullets, said blade being formed by a method comprising the steps of:

introducing a bond powder mixture onto said core to form a continuous uninterrupted outer rim, said bond powder mixture including metal particles and hardened cutting particles: after said introducing step, bonding said core to said continuous uninterrupted outer rim by heating said continuous uninterrupted outer rim and said core to a preselected temperature; and after said bonding step, forming notches through said continuous uninterrupted outer rim to remove portions of said outer rim and portions of said core to form a segmented outer rim.

23. A cutting blade formed by the method of claim 22, further comprising the step of: forming a bond powder comprising first and second metals which bond to form a bronze compound, a third metal which functions as a wetting agent, and a fourth metal which bonds to said bronze compound and said wetting agent.

24. A cutting blade formed by the method of claim 22, further comprising the step of: forming a bond powder comprising at least three types of metal that will bond with one another and with said core.

25. A cutting blade formed by the method of claim 22 comprising the step of: forming a bond powder comprising at least two types of metal that will bond with one another and with said core, and at least one type of hardened particles for cutting.

26. A cutting blade formed by the method of claim 22, further comprising the step of: forming a bond powder comprising at least one type of metal that will bond with one another and with said core, and diamond particles for cutting.

27. A cutting blade formed by the method of claim 22 wherein said bonding step further includes the steps of:

heating said core and outer rim to an initial bonding temperature for an initial bonding time period, and thereafter, heating said core and outer rim to a final bonding temperature for a final bonding time period.

28. A cutting blade formed by the method of claim 22, wherein said bond powder comprises at least first and second metals and said bonding step further includes the step of: bonding said first and second metals to one another by heating said core and outer rim to an initial bonding temperature which is above a melting point of said first metal and below a melting point of said second metal during an initial bonding time period.

29. A cutting blade formed by the method of claim 22, wherein said bond powder comprises at least first and second metals bonded to one another to form an alloy and a third metal, said bonding step further includes the step of: bonding said bonded compound and said third metal with one another by heating said core and outer rim to a final bonding temperature, which is above a melting point of said alloy and below a melting point of said third metal, during a final bonding time period.

30. A cutting blade formed by the method of claim 22, wherein said bond powder comprises at least a third metal and wherein said bonding step further comprises the step of: bonding said third metal and a bonded compound formed by said first and second metals by heating said core and outer rim to a final bonding temperature, which is above said initial bonding temperature, during an initial bonding time period.

31. A cutting blade formed by the method of claim 30, wherein said final bonding temperature is below a melting point of said third metal.

32. A cutting blade formed by the method of claim 22, wherein said introducing step further comprises the step of: centering said core within a mold and pouring said bond powder mixture into a void surrounding said core; and cold pressing said bond powder mixture to obtain approximately 65% compression thereof with respect to a maximum compression.

33. A cutting blade formed by the method of claim 22, wherein said bonding step is free-sintering while densification and bond shrinkage occur.

34. A cutting blade formed by the method of claim 22, wherein said bond powder includes at least two metals and wherein said core and outer rim are heated during said bonding step to a temperature between melting points of said two metals.

35. A cutting blade formed by the method of claim 22, wherein said bonding step includes the steps of: initially heating said core and outer rim to a temperature between 1400°F and 1600°F to effect initial bonding; and finally heating said core and outer rim to a temperature between 1600°F and 2000°F to effect final bonding.

36. A method for producing a cutting blade according to claim 22, wherein said introducing step further comprises the step of: hot isostatically pressing said bond powder mixture to obtain adhesion to said core. 

37. A method for producing a cutting blade according to claim 22, wherein said introducing step further comprises the step of: coining said bond powder mixture to obtain adhesion to said core.

38. A method for producing a cutting blade according to claim 22, wherein said introducing step further comprises the step of: forging said bond powder mixture to obtain adhesion to said core.

39. A method for producing a cutting blade according to claim 1, wherein said harden cutting particles include diamond particles.

40. A cutting blade according to claim 15, wherein said hardened cutting particles include diamond particles.

41. A cutting blade formed by the method of claim 22, wherein said hardened cutting particles include diamond particles.

42. A method for producing a cutting blade having a core and a segmented outer rim comprising the steps of:

introducing a bond powder mixture onto said core to form a continuous outer rim; bonding said core to said continuous outer rim by heating said continuous outer rim and said core to a preselected temperature, wherein said bonding step includes the steps of, heating said core and outer rim to an initial bonding temperature for an initial bonding time period; and thereafter, heating said core and outer rim to a final bonding temperature for a final bonding time period; and forming notches through said continuous outer rim to remove portions of said outer rim and portions of said core to form a segmented outer rim.

43. A method for producing a cutting blade having a core and a segmented outer rim comprising the steps of:

introducing a bond powder mixture onto said core to form a continuous outer rim; bonding said core to said continuous outer rim by heating said continuous outer rim and said core to a preselected temperature; and forming notches through said continuous outer rim to remove portions of said outer rim and portions of said core to form a segmented outer rim, wherein said bond powder includes at least two metals and wherein said core and outer rim are heated during said bonding step to a temperature between melting points of said two metals.

44. A cutting blade comprising: a circular core having an outer periphery with a continuous outer rim press molded thereon, said outer rim being formed from a bond powder mixture including at least two types of metal particles and at least one type of hardened cutting particles, said at least two types of metal particles being bonded to one another, said continuous outer rim having an innermost region proximate said outer periphery of said core in which said at least two types of metal particles are bonded to said outer periphery of said core, said continuous outer rim having a plurality of radially aligned notches cut therethrough to segment said continuous outer rim, wherein said two types of metal particles are bonded to one another by heating said outer rim to an initial bonding temperature which is between melting points of said two types of metal particles.

45. A cutting blade comprising: a circular core having an outer periphery with a continuous outer rim press molded thereon, said outer rim being formed from a bond powder mixture including at least one type of metal particles and at least one type of hardened cutting particles, said at least one type of metal particles being bonded to one another, said continuous outer rim having an innermost region proximate said outer periphery of said core in which said at least one type of metal particles are bonded to said outer periphery of said core, said continuous outer rim having a plurality of radially aligned notches cut therethrough to segment said continuous outer rim, wherein bonded metal particles in the outer rim form a substantially non-porous homogeneous alloy compound which, when cut, substantially evenly melts along a cut kerf to form the said notches.

46. A cutting blade having a circular core with an outer periphery having gullets formed thereabout and with a continuous outer rim thereon, said continuous outer rim having notches therein proximate said gullets, said blade being formed by a method comprising the steps of:

introducing a bond powder mixture onto said core to form a continuous outer rim; bonding said core to said continuous outer rim by heating said continuous outer rim and said core to a preselected temperature; and cutting notches through said continuous outer rim to remove portions of said outer rim and portions of said core to form a segmented outer rim, wherein said bond powder includes at least two metals and wherein said core and outer rim are heated during said bonding step to a temperature between melting points of said two metals.