A method for producing armored rod and wire saws

Claim 1

THE METHOD OF PROGRESSIVELY APPLYING AN ABRASIVE ARMORING COATING TO A LONG LENGTH OF A BASE METAL, WIRE SUBSTRATE, WHICH COMPRISES: CONTINOUSLY FEEDING SAID WIRE IN A DOWNWARD DIRECTION THROUGH A CONTINOUSLY STIRRED SLURRY COMPRISING A HOMOGENEOUS ADMIXTURE OF A FLUX ADHESIVE AND BRAZING METAL POWDERS AND THENCE THROUGH A DIE WITH A CONVERGING ORIFICE OF MINIMUM DIAMETER EXCEEDING THAT OF THE WIRE SUBSTRATE SUCH AS TO APPLY THERETO A SELECTED COATING THICKNESS OF SAID SLURRY, PASSING THE SO COATED SUBSTRATE THENCE DOWNWARDLY THROUGH A DOWNWARDLY MOVING AND VIBRATORILY FED MASS OF ABRASIVE PARTICLES DIRECTED TO CONVERGE ABOUT SAID SUBSTRATE THUS TO APPLY THERETO AN OVERCOATING OF SAID ABRASIVE PARTICLES, THENCE PROGRESSIVELY DRYING SAID COATING AND INDUCTIVELY HEATING THE COATED SUBSTRATE TO TEMPERATURE SUFFICIENTLY HIGH TO FUSE SAID BRAZING METAL POWDERS IN SAID COATING AND TO PARTIALLY IMMERSE SAID ABRASIVE PARTICLES THEREIN, THENCE PROGRESSIVELY COOLING THE SO HEATED, COATED SUBSTRATE TO TEMPERATURE SUFFICIENTLY LOW TO SOLIDIFY SAID BRAZING METAL IN THE COATING AND PERMANENTLY BOND THE SAME TO SAID SUBSTRATE AND TO PARTIALLY EMBED AND ANCHOR SAID ABRASIVE PARTICLES THEREIN, SAID BRAZING METAL HAVING A MELTING POINT BELOW SAID BASE METAL AND SAID ABRASIVE PARTICLES, AND SAID FLUX ADHESIVE BEING SELECTED FROM THE GROUP CONSISTING OF ORGANIC ADHESIVES AND SOLUBLE BORON CONTAINING FLUXING AGENTS IN VOLATILE SOLVENT.

Claim 2

THE METHOD OF PROGRESSIVELY APPLYING AN ABRASIVE ARMORING COATING TO A LONG LENGTH OF A BASE METAL, WIRE SUBSTRATE, WHICH COMPRISES: CONTINOUSLY FEEDING SAID WIRE IN A DOWNWARD DIRECTION THROUGH A CONTINOUSLY STIRRED SLURRY COMPRISING A HOMOGENEOUS ADMIXTURE OF A FLUX ADHESIVE AND BRAZING METAL POWDERS AND THENCE THROUGH A DIE WITH A CONVERGING ORIFICE OF MINIMUM DIAMETER EXCEEDING THAT OF THE WIRE SUBSTRATE SUCH AS TO APPLY THERETO A SELECTED COATING THICKNESS OF SAID SLURRY, PASSING THE SO COATED SUBSTRATE THENCE DOWNWARDLY THROUGH A DOWNWARDLY MOVING AND VIBRATORILY FED MASS OF ABRASIVE PARTICLES DIRECTED TO CONVERGE ABOUT SAID SUBSTRATE THUS TO APPLY THERETO AN OVERCOATING OF SAID ABRASIVE PARTICLES, THENCE PROGRESSIVELY DRYING SAID COATING AND INDUCTIVELY HEATING THE COATED SUBSTRATE TO TEMPERATURE SUFFICIENTLY HIGH TO FUSE SAID BRAZING METAL POWDERS IN SAID COATING AND TO PARTIALLY IMMERSE SAID ABRASIVE PARTICLES THEREIN, THENCE PROGRESSIVELY COOLING THE SO HEATED, COATED SUBSTRATE TO TEMPERATURE SUFFICIENTLY LOW TO SOLIDIFY SAID BRAZING METAL IN THE COATING AND PERMANENTLY BOND THE SAME TO SAID SUBSTRATE AND TO PARTIALLY EMBED AND ANCHOR SAID ABRASIVE PARTICLES THEREIN, SAID BRAZING METAL HAVING A MELTING POINT BELOW SAID BASE METAL AND SAID ABRASIVE PARTICLES, AND SAID FLUX ADHESIVE BEING SELECTED FROM THE GROUP CONSISTING OF ORGANIC ADHESIVES AND SOLUBLE BORON CONTAINING FLUXING AGENTS IN VOLATILE SOLVENT.

Claim 5

The method of applying an abrasive armoring coating to a length of a base metal, wire substrate, which comprises: passing said wire in a downward direction through a continuously stirred slurry comprising a homogeneous admixture of a flux adhesive and brazing metal powders and thence through a die with a converging orifice of minimum diameter exceeding that of the wire substrate such as to apply thereto a selected coating thickness of said slurry, rotating the so coated substrate within a downward falling stream of abrasive particles to deposit an overcoating of said abrasive particles to deposit an overcoating of said abrasive particles thereon, thence heating and cooling the so coated substrate to fuse and solidify said brazing coating and partially embed said abrasive particles therein with said coating permanently bonded to the substrate and to said particles partially embedded and anchored therein, said brazing metal having a melting point below said base metal and said abrasive particles, and said flux aDhesive being selected from the group consisting of organic adhesives and soluble boron containing fluxing agents in volatile solvent.

Claim 6

The method of applying an abrasive armoring coating to a length of a base metal, wire substrate, which comprises: passing said wire in a downward direction through a continuously stirred slurry comprising a homogeneous admixture of a flux adhesive and brazing metal powders and thence through a die with a converging orifice of minimum diameter exceeding that of the wire substrate such as to apply thereto a selected coating thickness of said slurry, rotating the so coated substrate within a downward falling stream of abrasive particles to deposit an overcoating of said abrasive particles to deposit an overcoating of said abrasive particles thereon, thence heating and cooling the so coated substrate to fuse and solidify said brazing coating and partially embed said abrasive particles therein with said coating permanently bonded to the substrate and to said particles partially embedded and anchored therein, said brazing metal having a melting point below said base metal and said abrasive particles, and said flux aDhesive being selected from the group consisting of organic adhesives and soluble boron containing fluxing agents in volatile solvent.

Claim 8

The method of applying an abrasive armoring coating to a length of a base metal, wire substrate, which comprises: vertically locating in a support a hand tool with a chuck at its lower end, feeding said wire in a downward direction through a continuously stirred slurry comprising a homogeneous admixture of a flux adhesive and brazing metal powders and thence through a die with a converging orifice of minimum diameter exceeding that of the wire substrate such as to apply thereto a selected coating thickness of said slurry, continuing to feed the so coated substrate downwardly until its lower end is received in said chuck, removing said tool from said support with one end of said coated substrate secured in said chuck and subsequently engaging the free end of said coated substrate with said tool, placing said coated substrate while held by said tool with the aid of the latter within a downward falling stream of abrasive particles and thereupon rotating said coated substrate to deposit an overcoating of said abrasive particles thereon, thence removing the coated substrate from said tool and sequentially heating and cooling the same to fuse and thence solidify said brazing coating and partially embed said abrasive particles therein with said coating permanently bonded to the substrate and said particles partially embedded and anchored therein, said brazing metal having a melting point below said base metal and said abrasive particles, and said flux adhesive being selected from the group consisting of organic adhesives and soluble boron containing fluxing agents in volatile solvent.

Claim 9

The method of applying an abrasive armoring coating to a length of a base metal, wire substrate, which comprises: vertically locating in a support a hand tool with a chuck at its lower end, feeding said wire in a downward direction through a continuously stirred slurry comprising a homogeneous admixture of a flux adhesive and brazing metal powders and thence through a die with a converging orifice of minimum diameter exceeding that of the wire substrate such as to apply thereto a selected coating thickness of said slurry, continuing to feed the so coated substrate downwardly until its lower end is received in said chuck, removing said tool from said support with one end of said coated substrate secured in said chuck and subsequently engaging the free end of said coated substrate with said tool, placing said coated substrate while held by said tool with the aid of the latter within a downward falling stream of abrasive particles and thereupon rotating said coated substrate to deposit an overcoating of said abrasive particles thereon, thence removing the coated substrate from said tool and sequentially heating and cooling the same to fuse and thence solidify said brazing coating and partially embed said abrasive particles therein with said coating permanently bonded to the substrate and said particles partially embedded and anchored therein, said brazing metal having a melting point below said base metal and said abrasive particles, and said flux adhesive being selected from the group consisting of organic adhesives and soluble boron containing fluxing agents in volatile solvent.

Claim 11

The method of progressively applying an abrasive armoring coating to a long length of a base metal, wire substrate, which comprises: continuously feeding said wire in a substantially vertically downward direction through a continuously stirred slurry comprising a homogeneous admixture of a flux adhesive and brazing metal powders selected from the group consisting of nickel-base and cobalt-base alloys, and thence through a die with a converging orifice of minimum diameter exceeding that of the wire substrate such as to apply thereto a selected coating thickness of said slurry, passing the so coated substrate thence downwardly through a downwardly moving and vibratorily fed mass of refractory metal carbide abrasive particles directed to converge about said substrate thus to apply thereto an overcoating of said abrasive particles, thence gaseously blowing from the so coated substrate, loosely adhering abrasive particles, thence progressively drying said coating and inductively heating the coated substrate to temperature of about 1,850*- 2,150*F and sufficiently high to fuse said brazing coating and partially immerse said abrasive particles therein, thence progressively cooling the so heated coated substrate to temperature sufficiently low to solidify said brazing metal in the coating and permanently bond the same to said substrate and to partially embed and anchor said abrasive particles therein, said brazing metal having a melting point below said base metal and said abrasive particles, and said flux adhesive being selected from the group consisting of organic adhesives and soluble boron containing fluxing agents in volatile solvent.

Claim 12

The method of progressively applying an abrasive armoring coating to a long length of a base metal, wire substrate, which comprises: continuously feeding said wire in a substantially vertically downward direction through a continuously stirred slurry comprising a homogeneous admixture of a flux adhesive and brazing metal powders selected from the group consisting of nickel-base and cobalt-base alloys, and thence through a die with a converging orifice of minimum diameter exceeding that of the wire substrate such as to apply thereto a selected coating thickness of said slurry, passing the so coated substrate thence downwardly through a downwardly moving and vibratorily fed mass of refractory metal carbide abrasive particles directed to converge about said substrate thus to apply thereto an overcoating of said abrasive particles, thence gaseously blowing from the so coated substrate, loosely adhering abrasive particles, thence progressively drying said coating and inductively heating the coated substrate to temperature of about 1,850*- 2,150*F and sufficiently high to fuse said brazing coating and partially immerse said abrasive particles therein, thence progressively cooling the so heated coated substrate to temperature sufficiently low to solidify said brazing metal in the coating and permanently bond the same to said substrate and to partially embed and anchor said abrasive particles therein, said brazing metal having a melting point below said base metal and said abrasive particles, and said flux adhesive being selected from the group consisting of organic adhesives and soluble boron containing fluxing agents in volatile solvent.