IP Library › Granted Patent US 10,723,657
Granted Patent B2
US 10,723,657 · App. 15/749,034 · Granted Jul 28, 2020

Sintered alumina-based and zirconia-based product

Inventor: Thomas Perie (Avignon, FR)
Assignee: SAINT-GOBAIN CENTRE DE RECHERCHES ET D'ETUDES EUROPEEN
C04B35/4885A44C27/003A61C13/083A61K6/818A61K6/822G04B37/225C04B2235/3208C04B2235/3213C04B2235/3215C04B2235/3224C04B2235/3225C04B2235/3227C04B2235/3229C04B2235/3246C04B2235/3262C04B2235/3272C04B2235/3281C04B2235/3284C04B2235/5445C04B2235/6562C04B2235/72C04B2235/77C04B2235/783C04B2235/785C04B2235/786C04B2235/788C04B2235/96F05D2230/22
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Quick Facts
Patent No.
US 10,723,657
App. No.
15/749,034
Granted
Jul 28, 2020
Kind
B2
Abstract

Sintered product having a chemical analysis such that, in percentage by mass based on the oxides: ZrO 2 partially stabilized with CeO 2 and Y 2 O 3 is balance to 100%; Al 2 O 3 is >10% and <19%; additive chosen from CaO, manganese oxides, ZnO, praseodymium oxides, SrO, copper oxides, Nd 2 O 3 , BaO, iron oxides, and mixtures thereof is 0.2-6%; impurities are <2%; and CeO 2 and Y 2 O 3 being present in amounts such that, as a molar percentage on the basis of the sum of ZrO 2 , CeO 2 and Y 2 O 3 , CeO 2 is ≥2.5 mol % and <5.5 mol %, and Y 2 O 3 is 0.5-2 mol %.

Claims (38)

1. A sintered product having a chemical analysis such that, as percentages by weight on a basis of oxides present in the sintered product,

ZrO 2 partially stabilized with CeO 2 and Y 2 O 3 : balance to 100%,

Al 2 O 3 : >10% and <19%

additive selected from the group consisting of CaO, manganese oxides, ZnO, praseodymium oxides, SrO, copper oxides, Nd 2 O 3 , BaO, iron oxides, and mixtures thereof: 0.2-6%,

impurities: <2%,

CeO 2 and Y 2 O 3 being present in amounts such that, as a molar percentage on a basis of a sum of ZrO 2 , CeO 2 and Y 2 O 3 ,

CeO 2 : ≥2.5 mol % and <5.5 mol %

Y 2 O 3 : 0.5-2 mol %.

2. The sintered product as claimed in claim 1 , wherein a molar content of CeO 2 is less than 5% and greater than 3%.

3. The sintered product as claimed in claim 2 , wherein a molar content of CeO 2 is less than 4%.

4. The sintered product as claimed in claim 1 , wherein a molar content of Y 2 O 3 is less than 1.7% and greater than 1%.

5. The sintered product as claimed in claim 1 , wherein a content of alumina Al 2 O 3 is greater than 11% and less than 16%, as a percentage by weight on the basis of the oxides.

6. The sintered product as claimed in claim 1 , wherein a content of the additive is greater than 0.5% and less than 4%, as a percentage by weight on the basis of the oxides.

7. The sintered product as claimed in claim 1 , wherein the additive is a mixture of CaO and of one or more manganese oxides.

8. The sintered product as claimed in claim 7 , wherein a content of CaO is greater than 0.2% and less than 1%, and wherein the content of manganese oxide(s) expressed in the form MnO is greater than 0.2% and less than 1%.

9. The sintered product as claimed in claim 1 , having a microstructure comprising grains, having a particle size distribution such that a mean size of the grains having a shape factor of less than 2.5 is less than 2 μm, and having aluminous elongated nodules, a mean length of the aluminous elongated nodules being less than 20 μm, an aluminous elongated nodule being a structure having a shape factor greater than or equal to 2.5 and formed of an aluminous grain or of several adjacent aluminous grains, an aluminous grain being a grain formed, for more than 40% of its weight, of Al 2 O 3 and of the additive, the “shape factor of a grain or of a nodule” referring to a ratio between a largest dimension of the grain or of the nodule and a largest dimension measured perpendicularly to a direction of said largest dimension of the grain or of the nodule, said dimensions being measured in a viewing plane of a polished section of the sintered product.

10. The sintered product as claimed in claim 9 , said product having aluminous elongated nodules covering a surface, and wherein a ratio of the surface covered by the aluminous elongated nodules to the surface covered by the aluminous elongated nodules and by the grains having a shape factor of less than 2.5 and comprising more than 40% by weight of alumina, expressed as percentages, is greater than 5% and less than 95%.

11. The sintered product as claimed in claim 9 , wherein a mean length of the aluminous elongated nodules is greater than 1 μm.

12. The sintered product as claimed in claim 1 , manufactured with a process comprising the following steps:

a) preparing a feedstock comprising a particulate mixture having a median size of less than 1.0 μm,

b) shaping the feedstock so as to obtain a preform, and

c) sintering the preform at a sintering temperature above 1300° C. so as to obtain said sintered product,

said particulate mixture comprising ZrO 2 particles, Al 2 O 3 particles, CeO 2 particles, Y 2 O 3 particles and particles of an additive chosen from CaO, and/or particles of one or more manganese oxides and/or SrO particles and/or BaO particles and/or particles of precursors of these oxides, and/or particles of several of these oxides and/or precursors of these oxides.

13. The sintered product as claimed in claim 12 , said particulate mixture comprising ZrO 2 particles, Al 2 O 3 particles, CeO 2 particles, Y 2 O 3 particles, CaO particles and particles of one or more manganese oxides, and/or particles of precursors of these oxides, and/or particles of several of these oxides and/or precursors of these oxides.

14. The sintered product as claimed in claim 12 , said particulate mixture having a median size of which is less than 1 μm.

15. A device selected from the group consisting of:

a mechanical wearing part,

a dental article,

an optical fiber connector, and

a decorative article selected from the group consisting of a jewel, a watch, a bracelet, a necklace, a ring, a brooch, a tie pin, a handbag, a telephone, a piece of furniture, a household utensil, a handle, a button, a veneer, a visible part of a consumer goods item, a part of a spectacle frame, a piece of crockery and a frame,

comprising a sintered product as claimed in claim 1 .

16. A device selected from the group consisting of:

a mechanical wearing part,

a dental article,

an optical fiber connector, and

a decorative article selected from the group consisting of a jewel, a watch, a bracelet, a necklace, a ring, a brooch, a tie pin, a handbag, a telephone, a piece of furniture, a household utensil, a handle, a button, a veneer, a visible part of a consumer goods item, a part of a spectacle frame, a piece of crockery and a frame,

comprising a sintered product manufactured from a particulate mixture comprising ZrO 2 particles, Al 2 O 3 particles, CeO 2 particles, Y 2 O 3 particles and particles of an additive chosen from CaO, and/or particles of one or more manganese oxides and/or SrO particles and/or BaO particles and/or particles of precursors of these oxides, and/or particles of several of these oxides and/or precursors of these oxides, the particulate mixture having a chemical composition suitable for the manufacture of the of a sintered product according to claim 1 .

17. The sintered product as claimed in claim 13 , wherein the particles of one or more manganese oxides are selected from the group consisting of MnO particles, Mn 3 O 4 particles, and mixtures thereof.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 11, 2018
From: PERIE, THOMAS
To: SAINT-GOBAIN CENTRE DE RECHERCHES ET D'ETUDES EUROPEEN
Reel/Frame 046039/0009 →
Priority Claims (1)
FR 15 57315 · Jul 30, 2015 · national
Continuity (1)
Related Publication 20180230058A1 · Aug 16, 2018
Cited By (2)
US 12,481,512 US 12,697,286