Method of making amorphous materials and ceramics
Methods of making amorphous material and ceramic materials. Embodiments of the invention can be used to make abrasive particles. The abrasive particles can be incorporated into a variety of abrasive articles, including bonded abrasives, coated abrasives, nonwoven abrasives, and abrasive brushes.
1. A method for making amorphous material comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the amorphous material, the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al 2 O 3 ; and
cooling the melt to provide the amorphous material.
2. A method for making amorphous material comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the amorphous material, the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al oxide
to provide a melt, wherein at least a portion of Al in the melt is oxidized; and
cooling the melt to provide the amorphous material.
3. The method according to claim 2 wherein the amorphous material is glass.
4. The method according to claim 3 wherein the glass comprises 60 to 70 percent by weight Al 2 O 3 , based on the total weight of the glass.
5. The method according to claim 3 wherein the complex metal oxide comprising M oxide is a complex Al 2 O 3 .metal oxide.
6. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
7. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
8. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
9. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and glass, respectively, collectively comprise the Al 2 O 3 , REO, and at least one of ZrO 2 , or HfO 2 , and less than 20 percent by weight SiO 2 , and less than 20 percent by weight B 2 O 3 , based on the total weight of the melt and the glass, respectively.
10. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and glass, respectively, collectively comprise the Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , and less than 20 percent by weight SiO 2 and less than 20 percent by weight B 2 O 3 , based on the total weight of the melt and the glass, respectively.
11. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and the glass, respectively, collectively comprise the Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , and less than 40 percent by weight collectively SiO 2 , B 2 O 3 , and P 2 O 5 , based on the total weight of the melt and the glass, respectively.
12. The method according to claim 3 wherein each of the melt and the glass comprises Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and the glass, respectively, collectively comprise the Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , and less than 40 percent by weight collectively SiO 2 , B 2 O 3 , and P 2 O 5 , based on the total weight of the melt and the glass, respectively.
13. A method for making ceramic comprising glass, the glass comprising at least 35 percent by weight Al 2 O 3 , based on the weight of the glass, the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al 2 O 3 ; and
cooling the melt to provide the ceramic, wherein at least a portion of the melt provides the glass.
14. A method for making ceramic comprising glass, the glass comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass, the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al
to provide a melt, wherein at least a portion of Al in the melt is oxidized; and
cooling the melt to provide the ceramic, wherein at least a portion of the melt provides the glass.
15. A method for making an article comprising glass comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide,
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
cooling the melt to provide glass particles, the glass having a T g ;
heating the glass particles above the T g such that the glass particles coalesce to form a shape; and
cooling the shape to provide the article.
16. A method for making an article comprising glass, the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al
to provide a melt, wherein at least a portion of Al in the melt is oxidized;
cooling the melt to provide glass particles, the glass having a T g ;
heating the glass particles above the T g such that the glass particles coalesce to form a shape; and
cooling the shape to provide the article.
17. A method for making an article comprising glass comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide,
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
cooling the melt to provide glass beads, the glass having a T g ;
crushing the glass beads to provide glass particles;
heating the glass particles above the T g such that the glass particles coalesce to form a shape; and
cooling the shape to provide the article.
18. A method for making an article comprising glass, the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al
to provide a melt, wherein at least a portion of Al in the melt is oxidized;
cooling the melt to provide glass beads, the glass having a T g ;
crushing the glass beads to provide glass particles;
heating the glass particles above the T g such that the glass particles coalesce to form a shape; and
cooling the shape to provide the article.
19. A method for making glass-ceramic comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass-ceramic the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide,
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
cooling the melt to provide amorphous material; and
heat-treating the amorphous material to convert at least a portion of the amorphous material to the glass-ceramic.
20. A method for making glass-ceramic comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass-ceramic the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al oxide
to provide a melt, wherein at least a portion of Al in the melt is oxidized;
cooling the melt to provide amorphous material; and
heat-treating the amorphous material to at least a portion of the amorphous material to the glass-ceramic.
21. The method according to claim 20 wherein the amorphous material is glass.
22. The method according to claim 21 wherein the glass comprises 60 to 70 percent by weight Al 2 O 3 , based on the total weight of the glass.
23. The method according to claim 21 wherein the complex metal oxide comprising M oxide is a complex Al 2 O 3 .metal oxide.
24. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
25. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
26. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
27. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and glass, respectively, collectively comprise the Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , and less than 20 percent by weight SiO 2 and less than 20 percent by weight B 2 O 3 , based on the total weight of the melt and the glass, respectively.
28. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and glass, respectively, collectively comprise the Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , and less than 20 percent by weight SiO 2 and less than 20 percent by weight B 2 O 3 , based on the total weight of the melt and the glass, respectively.
29. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and the glass, respectively, collectively comprise the Al 2 O 3 , REO, and at least one of ZrO 2 or HfO 2 , and less than 40 percent by weight collectively SiO 2 , B 2 O 3 , and P 2 O 5 , based on the total weight of the melt and the glass, respectively.
30. The method according to claim 21 wherein each of the melt and the glass comprises Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 60 percent by weight of the melt and the glass, respectively, collectively comprise the Al 2 O 3 , Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , and less than 40 percent by weight collectively SiO 2 , B 2 O 3 , and P 2 O 5 , based on the total weight of the melt and the glass, respectively.
31. A method for making a glass-ceramic article comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide,
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
cooling the melt to provide glass;
crushing glass to provide glass particles, the glass having a T g ;
heating the glass particles above the T g such that the glass particles coalesce to form a shape;
cooling the shape to provide a glass article; and
heat-treating the glass article to provide a glass-ceramic article.
32. A method for making a glass-ceramic article, the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al
to provide a melt, wherein at least a portion of Al in the melt is oxidized;
cooling the melt to provide glass;
crushing glass to provide glass particles, the glass having a T g ;
heating the glass particles above the T g such that the glass particles coalesce to form a shape;
cooling the shape to provide a glass article; and
heat-treating the glass article to provide a glass-ceramic article.
33. A method for making abrasive particles comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide,
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
cooling the melt to provide amorphous material;
crushing the amorphous material to provide amorphous particles; and
heat-treating the particles such that at least a portion of the amorphous material is converted to glass-ceramic to provide abrasive particles comprising glass-ceramic, the glass-ceramic comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass-ceramic.
34. A method for making abrasive particles, the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof: and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al oxide
to provide a melt, wherein at least a portion of Al in the melt is oxidized;
cooling the melt to provide amorphous material;
crushing the amorphous material to provide amorphous particles; and
heat-treating the particles such that at least a portion of the amorphous material is converted to glass-ceramic to provide abrasive particles comprising glass-ceramic, the glass ceramic comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass-ceramic.
35. A method for making abrasive particles comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide,
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
converting the melt into particles comprising amorphous material, wherein the converting includes cooling the melt to provide the amorphous material; and
heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramic to provide abrasive particles comprising glass-ceramic, the glass-ceramic comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass-ceramic.
36. A method for making abrasive particles comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising Al or an alloy thereof; and
(b) at least one of:
(i) an Al oxide and a source of metal oxide other than the Al oxide; or
(ii) a complex metal oxide comprising Al oxide
to provide a melt, wherein at least a portion of Al in the melt is oxidized;
converting the melt into particles comprising amorphous material, wherein the converting includes cooling the melt to provide the amorphous material; and
heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramics and provide abrasive particles comprising glass-ceramic, the glass-ceramic comprising at least 35 percent by weight Al 2 O 3 , based on the total weight of the glass-ceramic.
37. The method according to claim 15 , wherein the glass comprises at least 35 percent by weight of the Al 2 O 3 , based on the total weight of the glass.
38. The method according to claim 15 , wherein the melting includes flame melting.
39. The method according to claim 16 , wherein the glass comprises at least 35 percent by weight of the Al 2 O 3 , based on the total weight of the glass.
40. The method according to claim 16 , wherein the melting includes flame melting.
41. The method according to claim 17 , wherein the glass comprises at least 35 percent by weight of the Al 2 O 3 , based on the total weight of the glass.
42. The method according to claim 17 , wherein the melting includes flame melting.
43. The method according to claim 18 , wherein the glass comprises at least 35 percent by weight of the Al 2 O 3 , based on the total weight of the glass.
44. The method according to claim 18 , wherein the melting includes flame melting.
45. The method according to claim 31 , wherein the glass-ceramic article comprises at least 35 percent by weight of the Al 2 O 3 , based on the total weight of the glass.
46. The method according to claim 31 , wherein the melting includes flame melting.
47. The method according to claim 32 , wherein the glass-ceramic article comprises at least 35 percent by weight of the Al 2 O 3 , based on the total weight of the glass.
48. The method according to claim 32 , wherein the melting includes flame melting.
49. A method of making amorphous material comprising Al 2 O 3 , the method comprising:
flame melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al 2 O 3 ; and
cooling the melt to provide the amorphous material.
50. The method according to claim 49 wherein M is at least Al.
51. The method according to claim 50 wherein the amorphous material is glass.
52. The method according to claim 51 , wherein each of the melt and the glass comprises Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
53. A method of making ceramic comprising glass comprising Al 2 O 3 , the method comprising:
flame melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises Al 2 O 3 ; and
cooling the melt to provide the ceramic, wherein at least a portion of the melt provides the glass.
54. The method according to claim 53 wherein M is at least Al.
55. A method of making glass-ceramic comprising glass comprising Al 2 O 3 , the method comprising:
melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises M oxide comprises Al 2 O 3 ; and
cooling the melt to provide amorphous material; and
heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramic.
56. The method according to claim 55 wherein M is at least Al.
57. The method according to claim 56 wherein the amorphous material is glass.
58. The method according to claim 57 wherein each of the melt and the glass comprises Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO or HfO 2 , wherein at least 80 percent by weight of the melt and the glass, respectively, collectively comprises the Al 2 O 3 , REO, Y 2 O 3 , and at least one of ZrO 2 or HfO 2 , based on the total weight of the melt and the glass, respectively.
59. A method for making particles comprising Al 2 O 3 ,the method comprising:
flame melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprises M oxide comprises Al 2 O 3 ;
cooling the melt to provide amorphous material;
crushing the amorphous material to provide amorphous particles; and
heat-treating the particles such that at a portion of the amorphous material is converted to glass-ceramic to provide abrasive particles comprising glass-ceramic.
60. The method according to claim 59 , wherein M is at least Al.
61. A method for making abrasive particles comprising Al 2 O 3 , the method comprising:
flame melting
(a) particulate, metallic material comprising at least one of a metal, M, that has a negative enthalpy of oxide formation or an alloy thereof; and
(b) at least one of:
(i) a M oxide and a source of metal oxide other than the M oxide; or
(ii) a complex metal oxide comprising M oxide
to provide a melt, wherein at least a portion of the metal, M, in the melt is oxidized, and wherein at least one of the M oxide, the metal oxide other than the M oxide, or the complex metal oxide comprising M oxide comprises Al 2 O 3 ;
converting the melt into particles comprising amorphous material, wherein the converting includes cooling the melt to provide the amorphous material; and
heat-treating the amorphous material to convert at least a portion of the amorphous material to glass-ceramic and provide abrasive particles comprising the glass-ceramic.
62. The method according to claim 61 , wherein M is at least Al.