PARTIALLY STABILIZED ZIRCONIA MATERIALS
A ceramic material formed from a mixture including between about 50 wt % and about 85 wt % of a first zirconia-based material comprising between about 2 mol % and about 6 mol % yttria and between about 5 wt % and about 50 wt % of a second zirconia-based material comprising not greater than about 1 mol % yttria. The mixture can further include between about 1 wt % and about 10 wt % of an alumina material.
1 . A ceramic material formed from:
a mixture comprising:
between about 50 wt % and about 85 wt % of a first zirconia-based material comprising between about 2 mol % and about 6 mol % yttria;
between about 5 wt % and about 49 wt % of a second zirconia-based material comprising not greater than about 1 mol % yttria; and
between about 1 wt % and about 10 wt % of an alumina material.
2 . The ceramic material of claim 1 , wherein the mixture comprises between about 70 wt % and about 80 wt % of the first zirconia-based material.
3 . (canceled)
4 . The ceramic material of claim 1 , wherein the mixture comprises between about 10 wt % and about 25 wt % of the second zirconia-based material.
5 . (canceled)
6 . The ceramic material of claim 1 , wherein the mixture comprises between about 1 wt % and about 5 wt % of the alumina material.
7 . (canceled)
8 . The ceramic material of claim 1 , wherein the first zirconia-based material comprises between about 2 mol % and about 4 mol % yttria.
9 . (canceled)
10 . The ceramic material of claim 1 , wherein the second zirconia-based material comprises not greater than about 0.5 mol % yttria.
11 . The ceramic material of claim 10 , wherein the second zirconia-based material is essentially free of yttria.
12 . (canceled)
13 . The ceramic material of claim 1 , wherein the second zirconia-based material comprises an average particle size of less than about 1 micron.
14 - 21 . (canceled)
22 . A ceramic material comprising:
a partially stabilized zirconia ceramic body comprising:
a toughness (K1c) of not less than about 5.5 MPam 1/2 as measured according to an indentation fracture method using a 10 Kg load; and
a hydrothermal degradation factor of not greater than about 1% linear expansion after exposure to 69 psi of water at a temperature of 150° C. for 120 hours.
23 . The ceramic material of claim 22 , wherein the partially stabilized zirconia body is essentially intact after exposure to 69 psi of water at a temperature of 150° C. for 120 hours.
24 . (canceled)
25 . The ceramic material of claim 22 , wherein the partially stabilized zirconia body comprises a hydrothermal degradation factor of not greater than about 2% linear expansion after exposure to 225 psi of water at a temperature of 200° C. for 48 hours.
26 - 27 . (canceled)
28 . The ceramic material of claim 22 , wherein the toughness (K1c) is not less than about 6 MPam 1/2 as measured according to an indentation fracture method using a 10 Kg load.
29 . The ceramic material of claim 28 , wherein the toughness (K1c) is not less than about 7 MPam 1/2 as measured according to an indentation fracture method using a 10 Kg load.
30 . The ceramic material of claim 29 , wherein the toughness (K1c) is not less than about 7.5 MPam 1/2 as measured according to an indentation fracture method using a 10 Kg load.
31 . The ceramic material of claim 30 , wherein the toughness (K1c) is within a range between about 7.75 MPam 1/2 and about 12 MPam 1/2 as measured according to an indentation fracture method using a 10 Kg load.
32 - 33 . (canceled)
34 . The ceramic material of claim 22 , wherein the partially stabilized zirconia body comprises a hardness as measured using the Vickers indentation under a 10 Kg load in accordance with ASTM C1327 of at least about 10 GPa.
35 - 36 . (canceled)
37 . The ceramic material of claim 22 , wherein the partially stabilized zirconia body comprises a flexure strength of at least about 800 MPa as measured according to ASTM C1161.
38 - 41 . (canceled)
42 . The ceramic material of claim 22 , wherein the ceramic body is essentially free of magnesia.
43 - 47 . (canceled)
48 . The ceramic comprising:
a ceramic body comprising a yttria-stabilized zirconia material having a flexure strength of at least about 800 MPa as measured according to ASTM C1161 and a toughness (K1c) of not less than about 5.5 MPam 1/2 as measured according to an indentation fracture method using a 10 Kg load.
49 - 50 . (canceled)
51 . The ceramic material of claim 48 , wherein the ceramic body comprises a flexure strength of at least about 1000 MPa.
52 - 63 . (canceled)