Fabrication of Metal-Based Functionally Graded Grinding Wheel by a Centrifugal Mixed-Powder Method

Metal-bonded diamond grinding wheel was fabricated by a centrifugal mixed-powder method. The centrifugal mixed-powder method is a novel and effective casting process to obtain functionally graded material (FGM). At the beginning, we performed fundamental experiments using Al-Si alloy system for the purpose of knowing the migration behavior of mixed-powder under centrifugal force. Al-Si hypereutectic alloyed-powder or mixed-powder of Al and Si particles was placed into the mold, and then Al molten metal was cast under a centrifugal force. Cross sectional microstructure observation and quantitative analysis of Si content were conducted using an electron probe microanalyzer. Amount of Si decreased with receding from a mixed-powder region. Si concentration gradient in the sample fabricated Al-Si powder was smaller than the one fabricated using mixed-powder of Al and Si particles. Subsequently, φ 20 mm Cu/diamond grinding wheel was fabricated by the casting method. Graded diamond distribution was successfully obtained.