EP2516351A1

EP2516351A1 - Powder comprising zirconia granules

Info

Publication number: EP2516351A1
Application number: EP10814667A
Authority: EP
Inventors: Nabil Nahas; Henri Bocciarelli
Original assignee: Saint Gobain Centre de Recherche et dEtudes Europeen SAS
Current assignee: Saint Gobain Centre de Recherche et dEtudes Europeen SAS
Priority date: 2009-12-24
Filing date: 2010-12-21
Publication date: 2012-10-31
Also published as: US20120326361A1; US9193630B2; CN102803181B; JP2013515666A; FR2954761A1; CN102803181A; FR2954761B1; JP5732473B2; WO2011077381A1

Abstract

The invention relates to a granulated powder intended, in particular, for the production of ceramic sintered parts, said powder having the following chemical weight composition, based on dry matter, namely: a zirconia stabiliser selected from the group containing Y₂O₃, Sc₂O₃, MgO, CaO, CeO₂, and mixtures thereof, the weight content of stabiliser, based on the total zirconia and stabiliser content, being between 2 % and 20 % and the MgO + CaO content being less than 5 % based on the total zirconia and stabiliser content; at least 1 % of a first binder having a glass transition temperature less than or equal to 25°C; 0 - 4 % of an additional binder having a glass transition temperature greater than 25°C; 5 - 50 % alumina; 0 - 4 % of a temporary additive different from the first binder and the additional binder, the total content of the first binder, the additional binder and the temporary additive being less than 9 %; less than 2 % impurities; and ZrO2 to make up 100%. According to the invention, the median diameter D₅₀ of the powder is between 80 and 130 μm, the percentile D_99.5 is less than 500 μm and the relative density of the granules is between 30% and 60%.

Description

Zirconia granules powder

Technical area

The invention relates to a zirconia-based granule powder, a process for producing such granules and a sintered part obtained from such granules. State of the art

In a sintered zirconia-based part, the mechanical strength decreases with the amount of defects within the part and increases with the density.

JP8217448 discloses a use of zirconia granules to increase sintering density and three-point flexural strength. These granules are obtained by atomizing a slip whose weight per liter is set between 0.80 and 1.2 g / cm ³ . This weight per liter is adjusted by vigorous stirring as well as by the use of foaming agents or foam inhibitors. The examples also disclose the addition in the slip of 3% of an acrylic resin as a percentage of the dry matter. These granules have a diameter of between 0.01 and 0.2 mm, and a median diameter of about 60 microns. They allow a good filling of the mold during the manufacture of the preform and have an ability to deform under the effect of the forming pressure, which limits the number of defects present in the preform after pressing.

However, the granules described in JP8217448 are not suitable for the manufacture of large parts, and in particular for the manufacture of parts having a volume greater than 100 cm ³ . Indeed, the large parts obtained from the granules described in JP8217448 may have, after sintering, cracks in their heart and surface defects, mainly flaking defects.

There is a permanent need for a powder making it possible to manufacture a sintered zirconia-based part having a volume greater than 100 cm ³ , in particular with all dimensions greater than 2 cm, good mechanical performance and a high density.

An object of the invention is to meet this need. Summary of the invention

The invention proposes a powder of granules intended in particular for the manufacture of ceramic sintered parts, said powder having the following specific chemical composition, on the basis of the dry matter: ZrC "2: 100% complement;

a stabilizer of the zirconia selected from the group consisting of Y2O3, SC2O3, MgO, CaO, CeC "2, and mixtures thereof, the mass content of stabilizer, based on the sum of the zirconia and stabilizer contents being between 2.0% and 20%, the mass content MgO + CaO being less than 5.0%>, based on the sum of the zirconia and stabilizer contents;

at least 1.0% of a first binder having a glass transition temperature (Tg) of less than or equal to 25 ° C;

0 to 4.0% of an additional binder having a glass transition temperature greater than 25 ° C;

0 to 5.0%) alumina;

0 to 4.0% of a temporary additive different from a first binder and an additional binder, the total content of said first binder, said additional binder and said temporary additive being less than 9.0%;

- less than 2.0%) impurities;

the median diameter D50 of the powder being between 80 and 130 μιη, the percentile being less than 500 μιη and the relative density of the granules being between 30%> and 60%>. Preferably, more than 80%, more than 90%, or even substantially 100% of the granules have a composition in accordance with the composition of the powder.

As will be seen in more detail in the remainder of the description, the inventors have discovered that the particular distribution of the granule sizes according to the invention makes it possible to obtain excellent mechanical performances, provided that the total content of the first binder is limited. additional binder and temporary additive less than 9.0%>. The inventors have indeed found that, contrary to the practice of increasing the binder content in proportion to the median diameter, it was advantageous in the median diameter range claimed to maintain the relatively low first binder content. In particular, they have discovered that this limitation of the content of the first binder limits the appearance of permanent internal defects, that is to say, not eliminated during the sintering of the preform obtained by pressing said granules.

The inventors have also found that, contrary to the practice of adding binders having high glass transition temperatures to improve the green strength, it was advantageous to select binders having a glass transition temperature of less than 25. ° C. They have indeed found that this type of binder facilitates the deformation of the granules during pressing without reducing unacceptably their strength in green. The use of a binder having a low glass transition temperature is contrary to a technical prejudice according to which it is considered that the green strength decreases with the glass transition temperature of the binder.

A powder according to the invention may also comprise one or more of the following optional and preferred characteristics:

The relative density of the granules is between 40% and 50%. The content of said stabilizer, on the basis of the sum of the zirconia and stabilizer contents, is less than 15%, preferably less than 12%, preferably less than 10%, preferably less than 8%, preferably less than 6.5% and / or more than 4%.

The granules incorporate particles of said stabilizer whose median diameter is less than 0.8 μιη, preferably less than 0.5 μιη.

At least a portion of said stabilizer is replaced by an equivalent amount of precursor of said stabilizer.

The granules incorporate zirconia particles whose median diameter (D ₅₀ ) is less than 1 μιη, preferably less than 0.8 μιη, or even less than 0.5 μιη. The granules contain Al ₂ O ₃ alumina, the alumina content preferably being greater than 0.1%, preferably greater than 0.2% and / or less than 2%, preferably less than 1%, preferably still less than 0.6%.

The first binder has a glass transition temperature greater than -30 ° C and / or less than 20 ° C, preferably less than 15 ° C.

The first binder is chosen from amorphous organic polymers, polyacrylic resins, polymers based on pure acrylates, co-polymers based on acrylates and styrene, and mixtures thereof. Preferably, the first binder is chosen from polyacrylic resins, polymers based on pure acrylates, copolymers based on acrylates and styrene, and mixtures thereof. More preferably, the first binder is selected from polyacrylic resins, co-polymers based on acrylates and styrene, and mixtures thereof.

Preferably, the zirconia and / or the first binder and / or the additional binder and / or the temporary additive, preferably the zirconia and the first binder and the additional binder and the temporary additive, are distributed homogeneously within granules of the powder.

The first binder and / or the additional binder are chosen from polymers that do not contain inorganic elements. The content of temporary additive is less than 1%. Preferably, the temporary additive is an organic additive, preferably selected from dispersants or surfactants, thickeners, anti-foaming agents, preservatives, lubricants, and mixtures thereof.

The impurity content is less than 1.0%, preferably less than 0.5%, or even less than 0.3%, and even less than 0.1%. Preferably, the impurities are oxides.

The median diameter (D ₅₀ ) of the powder is greater than 90 μιη and / or less than 120 μιη.

The percentile 10 (D ₁₀ ) is greater than 40 μιη, preferably greater than 50 μιη, more preferably greater than 60 μιη.

The 90 percentile (D ₉₀ ) is less than 300 μιη, preferably less than 250 μιη, more preferably less than 200 μιη.

The 99.5 percentile (p99, ₅₎ is less than 400 μιη, more preferably less than 300 μιη.

In an advantageous embodiment, the stabilizer is chosen from the group formed by Y 2 O 3, SC 2 O 3 and their mixtures and the content of said stabilizer, on the basis of the sum of the zirconia and stabilizer mass contents, is less than 6.5%. .

In an advantageous embodiment, the stabilizer is selected from the group consisting of MgO, CaO and mixtures thereof and the content of said stabilizer, based on the sum of the zirconia and stabilizer mass contents, is less than 4%.

In an advantageous embodiment, the stabilizer is CeC-2 and the content of said stabilizer, based on the sum of the zirconia and stabilizer mass contents, is greater than 10% and less than 15%.

In an advantageous embodiment, the stabilizer is chosen from the group formed by Y 2 O 3, CeC "2 and their mixtures, and preferably respects the relationship 10% <3.Y 2 O 3 + CeC" 2 <20%, in percentages on the basis of the sum of the zirconia and stabilizer mass contents.

In an advantageous embodiment, the stabilizer is Y2O3, that is to say that the granules comprise only Y2O3 as stabilizer. In particular, in this embodiment, the Y 2 O 3 content is preferably greater than 3%, preferably greater than 4%, preferably greater than 4.5%, and / or less than 6.5%, preferably less than 5%. , 5%, based on the sum of the zirconia and stabilizer mass contents. The granules may comprise stabilized zirconia, or a mixture of zirconia particles, stabilized or not, and particles of said stabilizer, or a mixture of particles in which zirconia, stabilized or otherwise, and said stabilizer are intimately mixed. In one embodiment, the granules comprise particles in which the zirconia, stabilized or otherwise, and the stabilizer are intimately mixed. Preferably, the granules comprise particles in which the zirconia is stabilized, i.e. the stabilizer is in solid solution in the zirconia particles. Preferably, the granules comprise particles in which the stabilized zirconia and alumina are intimately mixed.

In a first particular embodiment, the stabilizer is Y ₂ O ₃ , the stabilizer content is between 4.5% and 5.5%, based on the sum of the zirconia mass contents and the stabilizer content. in alumina is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of first binder is between 2.5% and 4%, and the content of impurities is less than 0. , 5%>, preferably less than 0.1%, in percentages by weight on the basis of the dry matter, and the residual moisture content is between 0.2 and P / o, preferably between 0.2 % and 0.6%, in weight percent based on the wet powder.

In a second particular embodiment, the stabilizer is Y ₂ O ₃ , the stabilizer content is between 4.5% and 5.5%, based on the sum of the zirconia mass contents and the stabilizer content. in alumina is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of first binder is between 2.5% and 4%, the additional binder content is between 0 , 5% and 2%, preferably between 0.5% and 1%, and the content of impurities is less than 0.5%, preferably less than 0.1%, in percentages by weight on the basis of the material dry, and the residual moisture content is between 0.2 and 1%, preferably between 0.2% and 0.6%, as a percentage by weight based on the wet powder.

In a third particular embodiment, the stabilizer is Y ₂ O ₃ , the stabilizer content is between 4.5% and 5.5%, based on the sum of the zirconia mass contents and the stabilizer content. in alumina is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of first binder is between 2.5% and 4%, the additional binder content is between 0 , 5% and 2%, preferably between 0.5% and 1%, the content of temporary additive is between 0.5% and 1%, and the impurity content is less than 0.5%, preferably lower 0.1%, in percentages by mass on the basis of the dry matter, and the residual moisture content is between 0.2 and 1%, preferably between 0.2% and 0.6%), as a percentage by weight based on the wet powder.

In a fourth particular embodiment, the stabilizer of the zirconia is CeO ₂ , the stabilizer content is between 10% and 15%, based on the sum of the zirconia mass contents and the stabilizer, the alumina content. is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of first binder is between 2.5 and 4%, and the content of impurities is less than 0.5% >, preferably less than 0.1%, in percentages by weight on the basis of the dry matter, and the residual moisture content is between 0.2% and P / 0, preferably between 0.2% and 0.6%, in percent by weight based on the wet powder.

In a fifth particular embodiment, the stabilizer of the zirconia is CeO ₂ , the stabilizer content is between 10% and 15%, based on the sum of the zirconia mass contents and the stabilizer, the alumina content is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of the first binder is between 2.5 and 4%, the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, and the impurity content is less than 0.5%, preferably less than 0.1%, in percentages by weight on the basis of the dry matter, and the residual moisture content is between 0.2% and P / O, preferably between 0.2% and 0.6%, as a percentage by weight based on the wet powder.

In a sixth particular embodiment, the stabilizer of the zirconia is CeO ₂ , the stabilizer content is between 10% and 15%, based on the sum of the zirconia mass contents and the stabilizer, the alumina content is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of the first binder is between 2.5 and 4%, the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, the content of temporary additive is between 0.5% and 1%, and the impurity content is less than 0.5%, preferably less than 0.1. %, in percentages by mass on the basis of the dry matter, and the residual moisture content is between 0.2% and 1%, preferably between 0.2% and 0.6%, in percentage by mass on the base of the wet powder.

In a seventh particular embodiment, the stabilizer of zirconia is a mixture of Y ₂ O ₃ and CeO ₂ , the content of Y ₂ O ₃ is between 1% and 2%, based on the sum of the contents. zirconia and stabilizer content, the content of Ce0 ₂ is between 11% and 13%, based on the sum of the zirconia and stabilizer mass contents, the alumina content is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of first binder is between 2.5% and 4%, and the content of impurities is less than 0.5%, preferably less than 0.1%, in percentages by weight on the basis of the dry matter, and the residual moisture content is between 0.2%> and 1%, preferably between 0.2%> and 0, 6%), in percent by weight based on the wet powder.

In an eighth particular embodiment, the zirconia stabilizer is a mixture of Y ₂ O ₃ and CeO ₂ , the content of Y ₂ O ₃ is between 1% and 2%, based on the sum of the contents. zirconia and stabilizer content, the content of Ce0 ₂ is between 11% and 13%, based on the sum of the zirconia and stabilizer mass contents, the alumina content is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of the first binder is between 2.5% and 4%, the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, and the impurity content is less than 0.5%, preferably less than 0.1%, in percentages by weight on the basis of the dry matter, and the residual moisture content is included between 0.2% and 1%, preferably between 0.2% and 0.6%), as a percentage by mass on the basis of the wet powder.

In a ninth particular embodiment, the zirconia stabilizer is a mixture of Y ₂ O ₃ and CeO ₂ , the content of Y ₂ O ₃ is between 1% and 2%, based on the sum of the contents. zirconia and stabilizer content, the content of Ce0 ₂ is between 11% and 13%, based on the sum of the zirconia and stabilizer mass contents, the alumina content is greater than 0.1% and less than 1%, preferably substantially equal to 0.25%, the content of the first binder is between 2.5% and 4%, the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, the content of temporary additive is between 0.5% and 1%), and the content of impurities is less than 0.5%, preferably less than 0.1%, in percentages in mass on the basis of the dry matter, and the residual moisture content is between 0.2% and 1%, preferably between 0.2% and 0.6%, as a percentage by weight on the basis of based on the wet powder.

Preferably, a powder according to the invention is manufactured by atomizing a slip, preferably according to a process comprising steps a) to d) described below.

Such a process advantageously makes it possible to manufacture granules having a relative density of less than 60%, or even less than 50%.

The invention also relates to a method for manufacturing a sintered part comprising the following steps:

A) mixture of raw materials to form a feedstock,

B) shaping said feedstock so as to obtain a preform,

C) optionally, machining said preform, D) sintering said preform so as to obtain said sintered part,

E) optionally, machining and / or grinding of said sintered part,

this method being remarkable in that the feedstock comprises a powder of granules according to the invention.

The invention also relates to a preform obtained by implementing a method comprising at least steps A) and B), or even C) of a manufacturing method according to the invention.

The invention also relates to a ceramic sintered part obtained by sintering a preform, optionally machined, according to the invention. In particular, all the dimensions of the sintered part may be greater than 2 cm. Definitions

By "binder" is meant a constituent which, in a suitable quantity, makes it possible, during a granulation operation, to form granules having, after drying, a cohesion allowing their handling, for example their transfer from a container to a container. another or pouring into a mold (especially in industrial conditions), without breaking. Preferably, this cohesion is at least that obtained with a polymeric binder.

The granulation operation is not limiting and comprises in particular the atomization or the implementation of a granulator. The invention is therefore not limited to granules made by atomization.

By "temporary additive" is meant a constituent that can be removed when it is subjected to a temperature greater than or equal to 1000 ° C, for example during a sintering operation at a temperature greater than or equal to 1000 ° C. .

- A precursor of a constituent is a compound capable, during sintering of a preform obtained from a powder according to the invention, to lead to this constituent. The replacement of a constituent by an "equivalent" quantity of a precursor of this constituent does not modify the amounts of said constituent in the sintered product obtained by sintering a powder according to the invention.

By "impurities" is meant the inevitable constituents introduced involuntarily and necessarily with the raw materials or resulting from reactions with these constituents. Impurities are not necessary constituents, but only tolerated.

By "granule" is meant an agglomerate of particles, said agglomerate having a sphericity index greater than 0.6, that is to say being in a substantially spherical form. By "sphericity index" of a granule, is meant the ratio between its smallest diameter and its largest diameter, the diameters being measured on clichés made for example by optical microscopy at a magnification of x 10.

"Unpacked density" of a powder of granules means the ratio of the mass of a known volume of said powder divided by said volume, the volume being filled by free falling of the powder, avoiding vibrations. . The unpacked density is determined according to standard NF EN 725-9 and is expressed in g / cm ³ .

By "absolute density" of a granule powder is conventionally meant the ratio equal to the mass of dry matter of said powder after grinding to such a fineness that it remains substantially no closed pore, divided by the volume of this mass after grinding. It can be measured by helium pycnometry.

By "real density" of a powder of granules is meant the average of the apparent densities of each granule of this powder.

The "bulk density" of a granule conventionally means the ratio equal to the mass of the granule divided by the volume occupied by said granule.

By "relative density" of a granule powder is meant the ratio of the actual density divided by the absolute density, expressed as a percentage. By "glass transition temperature" of a binder is conventionally meant the middle of the temperature range, called "transition domain", wherein said binder becomes progressively more viscous and goes from the liquid state to the state solid. The glass transition temperature can be determined by differential scanning calorimetry (DSC). A list of the glass transition temperatures of the main families of polymers is given in Polymer Handbook (4th Edition) 1999; 2005 John Wiley & Sons. The amplitude of a transition domain is typically about 5 to 10 ° C.

The percentiles or "percentiles" (Di ₀ ), 50 (D ₅₀ ) and 90 (D ₉₀ ) of a powder are the particle sizes corresponding to the percentages, by weight, of 10%, 50% and 90% respectively. on the cumulative particle size distribution curve of the particle sizes of the powder, the particle sizes being ranked in ascending order. For example, 10% by weight of the granules of a powder are smaller than Di ₀ and 90% of the granules by weight are larger than Di ₀ . Sizes and percentiles can be determined using a particle size distribution using a laser granulometer. The 50th percentile D50 is still conventionally called the "median diameter".

The term "organic constituent" conventionally means a constituent containing only the elements carbon, oxygen, nitrogen and hydrogen. In a source of zirconia particles, Hf0 ₂ is not chemically separable from Zr0 ₂ . "Zr0 ₂ " conventionally refers to the total content of these two oxides. According to the present invention, Hf0 ₂ is not voluntarily added to the feedstock. Hf0 ₂ therefore only designates the traces of hafnium oxide, this oxide always being naturally present in zirconia sources at levels generally less than 5%, or even less than 2%. For the sake of clarity, the zirconia and trace element content of hafnium oxide can be referred to either as "Zr0 ₂ + Hf0 ₂ " or "Zr0 ₂ ", or as "zirconia content".

By "comprising one", it is necessary to include "including at least one", unless otherwise indicated.

"A first binder" (or "additional binder") does not necessarily correspond to a single compound, but may be a mixture of several compounds each having a glass transition temperature of less than or equal to 25 ° C (or greater than 25 ° C). Similarly, a "stabilizer" or "temporary additive" may be mixtures of several compounds each constituting a stabilizer or a temporary additive, respectively.

Unless otherwise indicated, all percentages are based on the mass of the dry powder, except for percentages for stabilizers. The stabilizer content of an oxide is in fact conventionally defined, by default, in percentages by weight on the basis of the total content of said oxide and of said stabilizer.

The properties of the powder can be evaluated by the characterization methods used for the examples.

Brief description of the figures

Other characteristics and advantages of the invention will become apparent on reading the following description and on examining the appended drawing in which FIG. 1 represents a photograph of the granules of Example 6.

detailed description

A granule powder according to the invention can be manufactured by a method comprising a step of atomizing a slip. Such a method may especially comprise the following steps: a) production of a slip by suspending in a liquid, preferably in water, the various raw materials necessary to obtain, after step b), a powder of granules according to invention;

b) atomizing said slip to form granules;

c) optionally, sieving the granules obtained in step b);

d) optionally, drying the granules obtained in step b) or c).

In step a), the raw materials are mixed in a liquid, for example distilled water, so as to form a slip.

In the slip, the dry mass content may be between 35 and 70%. The dry matter content in the slip is adjusted so that the relative density of the granules obtained at the end of step b) is between 30%> and 60%>. An increase in this content is generally accompanied by an increase in the relative density of the granules obtained at the end of step b).

Preferably, zirconia is introduced into the feedstock so that the granule powder according to the invention has a zirconia content greater than 80%> or even greater than 90%.

The zirconia introduced can be stabilized with said stabilizer. The stabilizer can also be added independently of the zirconia. In one embodiment, the zirconia can be introduced in the form of particles in which zirconia, stabilized or otherwise, and the stabilizer are intimately mixed, optionally with alumina particles.

In a preferred embodiment, the zirconia is introduced in the form of stabilized zirconia particles, i.e. the stabilizer is in solid solution in the zirconia particles.

In another preferred embodiment, the zirconia is introduced in the form of particles in which the stabilized zirconia and alumina are intimately mixed.

The use of stabilized zirconia particles and / or particles in which stabilized zirconia and alumina are intimately mixed is particularly preferred for the particular embodiments described above.

Binders are constituents of the feedstock that make agglomeration possible during atomization.

Conventionally, the manufacture of granules uses binders of the APV ("PVA" in English) or PEG type, APV binders or PEGs having a molecular weight greater than 600 Da do not have a glass transition temperature (Tg) less than or equal to 25 ° C. The inventors have discovered that the presence of a binder having a glass transition temperature (Tg) less than or equal to 25 ° C, or "first binder", promotes the deformation of the granules during pressing and reduces the number of defects. It thus leads to an improvement in the mechanical properties of the sintered part obtained from the powder according to the invention.

A first binder content of less than 1%, however, does not lead to a quantifiable effect. Preferably, the first binder has a glass transition temperature greater than -30 ° C., preferably greater than -20 ° C., or even greater than -15 ° C. and / or less than 20 ° C., or even less than 15 ° C. .

The first binder may be chosen from polymers. A list of such polymers is disclosed in "Polymer Handbook (4 ^th Edition)", 1999; 2005 John Wiley & Sons. Preferably, the first binder is chosen from amorphous organic polymers and their mixtures. Preferably, the first binder is chosen from polymers based on acrylates (monomer - (CH ₂ = CHCOO -) -), pure or in the form of co-polymers (with styrene monomers for example) and their mixtures. The polymer can thus be an acrylic resin. Preferably, the first binder is chosen from polymers based on pure acrylates (monomer - (CH ₂ = CHCOO -) -), co-polymers based on acrylates (monomer - (CH ₂ = CHCOO -) - ) and styrene (monomer - (CsHs)) and mixtures thereof.

Preferably, the first binder is chosen from organic polymers having, after curing, a tensile strength greater than 1 N / mm ² , or even greater than 5 N / mm ² , measured according to DIN 535455.

Preferably still, the first binder is chosen from organic polymers having, after curing, an elongation at break greater than 100%, preferably greater than 200%, or even greater than 500%, measured according to DIN53455.

Preferably, the first binder is chosen from polymers containing no inorganic elements, in particular the elements of column 1, and in particular lithium (Li), sodium (Na) and potassium (K), as well as the elements of column 17, and especially fluorine (F), chlorine (Cl), bromine (Br), iodine (I). Advantageously, the content of impurities is reduced and the mechanical strength of the sintered parts made from the powders of granules according to the invention is increased.

Preferably, the content of the first binder is determined to be greater than 2%, preferably greater than 2.5% and / or less than 8%, preferably less than 6%, preferably less than 5%. %>, preferably less than 4%> in the manufactured powder. The additional binder is preferably chosen from polymers having a glass transition temperature greater than 25 ° C. and less than 100 ° C., preferably less than 80 ° C., preferably less than 50 ° C., or even lower than 40 ° C. , and their mixtures.

Preferably, the additional binder content is less than 3%, preferably less than 2%, more preferably less than 1% and / or greater than 0.5%.

Preferably, the additional binder is a polymer containing no inorganic elements, in particular the elements of columns 1 and 17. Advantageously, the content of impurities is reduced and the mechanical strength of the parts made from the granules according to the invention is increased.

Preferably, the additional binder is chosen from amorphous organic polymers and their mixtures. Preferably, the additional binder is chosen from compounds based on alcohols. Preferably, the additional binder is chosen from polyvinyl alcohols and polyalkylene glycols, preferably chosen from polyethylene glycols with a molecular weight greater than 600 Da.

A temporary additive may be added during the manufacture of the granules.

The temporary additive is preferably an organic additive, which, according to rules well known to those skilled in the art, can be added in particular to facilitate the manufacture of granules or their shaping.

The content of temporary additive is preferably greater than 0.5% and / or less than 1%, the total content of binder (s) and of temporary additive being preferably less than 8%, preferably less than 6%, preferably less than 5%, or even less than 4%, as a percentage by mass on the basis of the dry matter. Preferably, the organic additive is chosen from dispersants or surfactants, thickeners, anti-foaming agents, preservatives or biocides, lubricants, and mixtures thereof. By way of examples, the dispersants or surfactants may be polyacrylates or ionic or nonionic surfactants, of the family of DOLAPIX sold by Zschimmer-Schwarz or else DARVAN or methacrylic acids marketed by R. T. Vanderbilt Company. The thickeners may be acrylic acid emulsions marketed by Zschimmer-Schwarz or by BASF. The anti-foaming agents may be those of the range marketed by Zschimmer-Schwarz. Preservatives or biocides may be quaternary ammonium salts marketed by Zschimmer-Schwarz or BASF. Lubricants may be those of the range marketed by Zs Chimmer-S chwarz.

Preferably, the purity of the raw materials is determined so that the impurity content of a granule powder according to the invention is less than 1%, preferably less than 0,5%, or even less than 0,3%, or even less than 0,1%>. Hafnium oxide is not considered an impurity.

Preferably the impurities are oxides.

Preferably, the raw materials are chosen so that the granules contain no other constituent than zirconia, zirconia stabilizer, alumina, binders, temporary additive, residual moisture and impurities.

Preferably, the zirconia, alumina and stabilizer powders are introduced into the slip before the binder (s) and the optional temporary additive.

Each of the various raw materials of the granules, in particular the refractory oxide powders, preferably has a median diameter of less than 50 μιη, preferably less than 20 μιη, preferably less than 10 μιη, and / or a specific surface area of preference. less than 30 m ² / g, preferably less than 20 m ² / g.

At the end of step a), the dry matter of the prepared slurry preferably has a median diameter of less than 1 μιη, preferably less than 0.5 μιη, more preferably less than 0.3 μιη and a specific surface area greater than 5 m ² / g, preferably greater than 6 m ² / g and / or less than 30 m ² / g, preferably less than 20 m ² / g.

For this purpose, especially if the raw materials do not have a median diameter and / or a specific surface area, the slip is preferably dispersed or ground according to methods well known to those skilled in the art, for example by passing the slip in a mill, preferably an attritor mill. This step advantageously makes it possible to obtain a good homogeneity of the various compounds of the desired powder at the end of step a). In particular, this step leads to a substantially homogeneous distribution of the first binder within the granules of the powder.

If step a) contains a grinding operation, the additional binder and the optional temporary additive, as well as the first binder, are preferably introduced after this step.

In step b), the atomization leads to particles having a low relative density, of between 30 and 60%, unlike processes such as rolling granulation, or "rolling granulation". drop casting "," drip casting "in English, which classically lead to high relative densities.

Preferably the atomization is carried out so that the granules contain residual moisture, the moisture content is preferably less than 1%, preferably less than 0.6%, and / or greater than 0.2%, in percent by weight based on the wet powder. Advantageously, a residual moisture content greater than 0.2% contributes to the deformation of the granules under the effect of pressure. A residual moisture content greater than 1% may, however, lead to an increase in the number of surface defects of the preforms manufactured by pressing from a powder of granules according to the invention, for example following a bonding of said preforms to the walls of the molds used for pressing.

More than 80%, preferably more than 90% by number of the granules have a sphericity index greater than 0.6, preferably greater than 0.7, preferably greater than 0.8, preferably greater than 0.9. .

In step c), the optional sieving is preferably carried out using sieves of less than 500 μιη opening, or even less than 400 μιη. Advantageously, this step makes it possible to eliminate the larger granules, which may be useful for certain applications.

In step d), the optional drying is preferably carried out at a temperature between 80 ° C and 1 10 ° C, for a period preferably greater than 2 hours.

Preferably, the process does not contain step d). The inventors have found that a powder according to the invention may have the following properties:

The relative density of the granules is preferably greater than 40% and / or less than 50%.

The unpacked density of the powder is greater than 1.4 g / cm ³ , preferably greater than 1.5 g / cm ³ , preferably greater than 1.6 g / cm ³ and / or less than 1.8 g / cm ^3. g / cm ³ , preferably less than 1.7 g / cm ³ .

The flowability of the powder is greater than 1 g / s, preferably greater than 1.5 g / s, preferably greater than 2 g / s.

A granule powder according to the invention can be used to manufacture a sintered part according to steps A) to E).

Step A) may comprise steps a) and b), or even c) and / or d).

The starting charge may consist of a granule powder according to the invention.

Alternatively, the feedstock can comprise a powder of granules according to the invention and one or more other powders. Preferably, the granule powder according to the invention represents at least 60%, preferably at least 75%, preferably at least 90%, preferably at least 95% of the mass of the feedstock. In step B), the shaping is preferably carried out by pressing, plastic injection or extrusion, preferably by pressing. Preferably, the pressing is selected from cold pressing and cold isostatic pressing techniques.

In the case of shaping by pressing, the initial charge is poured into a mold, then subjected to a pressure preferably greater than 80 MPa and preferably less than 200 MPa, or even less than 150 MPa, so as to constitute a raw part, or "preform". The granules of the powder according to the invention deform efficiently under the effect of this pressure. The preform can then be demolded.

In optional step C), the preform can be machined, according to any technique known to those skilled in the art.

In step D), the preform is sintered, preferably in air, preferably at atmospheric pressure or under pressure (hot pressing) and / or hot isostatic pressing ("Hot Isostatic Pressing"). in English, or HIP)) and at a temperature between 1300 ° C and 1500 ° C, preferably greater than 1350 ° C and / or less than 1450 ° C, so as to constitute a sintered part.

Steps B) and D) can be carried out in a single step, for example by hot pressing.

In optional step E), the sintered part can be machined, according to any technique known to those skilled in the art. Examples

The following nonlimiting examples were manufactured according to a process comprising steps A) to E) above.

Step A) presents the following steps a), b) and c).

In step a), for each of the examples made, the zirconia powder whose main characteristics appear in Table 1 below is dispersed by microbrilling. The alumina of this zirconia powder is advantageously used as a sintering additive.

Na ₂ (ppm) 100

CaO (ppm) 30

Fe ₂ O ₃ (ppm) 10

MgO (ppm) <20

Ti0 ₂ (ppm) <20

Specific area (m ² / g) 7

Dio (μι ^η ) 0.2

D ₅₀ (μηι) 0.4

D ₉₀ (μ ^η ι) 1, 0

Table 1

This microbrilling is carried out in a wet ball mill (zirconia beads 3 mol% Y ₂ O ₃ , diameter 0.8 mm) or attritor mill. After the micromilling, the powder has a median diameter equal to 0.35 μιη. The solids content of the suspension is 50% by mass.

The binders, in the form of 50% by weight solutions, are then added to the suspension.

The slip thus obtained is stirred for 12 hours.

In step b), the slip is then atomized on a FSD Minor equipment marketed by the company GEA NIRO, with an inlet atomizer temperature of 280 ° C and an outlet temperature of 100 ° C atomizer . At the end of step b), a powder of granules is obtained.

In step c), the granule powder is screened with a 400 μιη sieve.

In step B), and for each of the powders of granules obtained at the end of step A), the following preforms were made:

pellets with a diameter of 32 mm and a mass of 8 grams were produced by uniaxial pressing at a pressure of 100 MPa for the measurement of the apparent density,

10 strips having a section 4 × 5 cm ² and a length of 10 cm were made by uniaxial pressing at a pressure of 100 MPa for the measurement of the yield,

strips 1 × 1 cm ² and 3 cm long were made by uniaxial pressing at a pressure of 100 MPa for measuring the 3-point bending. The preforms thus obtained did not undergo a step C).

In step D), said preforms have been sintered according to the following cycle:

- rise in temperature at 500 ° C to 100 ° C / h,

holding at 500 ° C. for 2 hours,

- rise in temperature up to 1450 ° C, at 100 ° C / h, - maintaining at 1450 ° C for 2 hours,

- lowering temperature by natural cooling.

In step E), the strips for the 3-point bending measurements were machined to the dimensions required to perform this measurement (25 × 10 × 3 mm ³ ). The properties of the examples were evaluated according to the following characterization methods:

The dry matter is measured after drying at 110 ° C for at least two hours. The flowability of a granule powder is measured by equipment of "Ford cut" type, according to standard NF EN 658-5. The measurement consists of evaluating the time required for 200 g of powder to flow through a funnel of internal diameter 10 mm. The flowability of the powder is then calculated by the ratio equal to the powder mass divided by the time required for its flow through the funnel.

The unpacked density of a granule powder is measured by equipment of "Ford cut" type, according to standard NF EN 725-9. The measurement consists of evaluating the mass of granule powder introduced after filling of a container of standard dimensions. The unpacked density is then calculated by giving the ratio of the mass of powder to the volume of the container.

The absolute density of a granule powder is measured by helium pycnometry on Micromeretics® AccuPyc 1330 equipment. The granule powder is calcined beforehand at 500 ° C. for 2 hours.

The actual density of a granule powder is measured by mercury porosimetry on a Hg porosimeter AutoPores IV 9500 equipment marketed by Micromeretics®. A mass of 1 gram of granule powder is introduced into the equipment. After placing under primary vacuum for 5 minutes, the mercury is introduced in steps of 3447 Pa (0.5 psi). The actual density is calculated by:

"Mass powder

Actual density =

Total Volume - Volume Hg 100 psi

the total volume being equal to the empty volume of the measuring chamber and the volume Hg 100 psi being the volume of mercury Hg introduced into the chamber in the presence of the powder at a pressure of 0.689 MPa (100 psi).

The apparent density of a sintered part is measured on samples of diameter 30 mm and thickness 3 mm, obtained after pressing at 100 MPa of the powder of granules according to the example under consideration, and sintered according to the following cycle: at 500 ° C at a rate of 100 ° C / hr, 2 hour stage at 500 ° C, raised to 1450 ° C at a rate of 100 ° C / h, 2 hours at 1450 ° C, down to 500 ° C at a rate of 200 ° C / h, then free cooling.

The modulus of rupture is measured on strips 25 × 10 × 3 mm ³ machined in pieces obtained by pressing at 100 MPa of the powder of granules according to the example considered, and sintered according to the following cycle: raised to 500 ° C. a speed of 100 ° C / h, 2 hour stage at 500 ° C, mounted at 1450 ° C at a speed of 100 ° C / h, 2 hours at 1450 ° C, down to 500 ° C at a speed of 200 ° C / h, then free cooling.

The particle size distributions are determined using a Partica LA-950 laser particle size analyzer marketed by HORIBA. The granule powder is directly introduced into the laser granulometer for measurement, without suspension.

The chemical analysis is determined by X-ray fluorescence spectroscopy for elements with a content greater than 0.1% by mass; if the content of an element is less than 0.1% by weight, it is determined by ICP (Induction Coupled Plasma) on a Vista AX model (marketed by Varian).

The sphericity index is measured on a Morphologi 3 G equipment marketed by Malvern Instruments. The granule powder is directly introduced into the measuring equipment. The sphericity index of a granule is determined by the ratio of the smallest diameter to the largest diameter, measured on a photograph of the granule made by optical microscopy at a magnification of x 10. To measure the percentage of granules having a specific sphericity, a statistical count is made on the granules observed over 500 to 1000 plates.

The modulus of rupture in 3-point bending is measured according to standard NF EN 658 -5, on a Lloyd press, with a distance between external supports of 15 mm, on bars of length equal to 25 mm, width equal to 10 mm and of thickness equal to 3 mm.

The nature and the content of temporary additive and binder (s), in particular polymers, are measured by infrared spectroscopy on a Spectrum 400 equipment marketed by Perkin Elmer. The intensity data are recorded over a range of 4000-1000 cm ^-1 with a pitch of 1 cm ^1. The polymers are identified by comparison with FTIR data (Fourier Transform Infrared Spectroscopy, or "Fourier

Transformed InfraRed Spectroscopy "reported for example in" Handbook of fourier transform Raman and infrared spectra of polymers ", AH Kuptsov, German Nikolaevich Zhizhin, vol. 45, 1998, Elsevier. The nature and the polymer content can also be confirmed by other well-known methods such as liquid chromatography (HPLC) equipped with separation column (s) adapted to the nature and number of compounds to be separated. Equipment such as the Surveyor Plus sold by Thermo Scientifïc, equipped with a Hypersil Gold column 1.9 μιη diameter can be used.

The total content of temporary constituents is determined by the difference between the mass of powder after calcination at 1000 ° C. and the mass of powder after drying at

110 ° C, reduced to the total mass after drying.

The production yield corresponds to the percentage of sintered pieces "compliant", that is to say having no cracks, including in their core, or surface defects, on the basis of the number of sintered parts manufactured.

Table 2

As shown in Figure 1, the granules 10 according to Example 6 are substantially O-rings. They thus have an orifice 12 passing through them through their center. The sphericity index of these granules is greater than 0.8.

The inventors consider that the filling ability of a mold can be evaluated by the unpacked density of the powder and its flowability. A high unpacked density and a high flowability value correspond to good mold filling ability.

Table 2 makes the following observations:

The granule powder of Example 1, using the same binders as the powder of Examples 6 and 7, has a lower bulk density and flowability value. Its ability to fill a mold is lower than those of the powders of Examples 2 to 7. The production yield of pieces of dimensions 10 x 5 x 4 cm ³ (volume 200 cm ³ ) is much lower than that obtained with the powders of granules of Examples 2, 6 and 7, which illustrates the interest of a median diameter D50 greater than 80 μιη.

The granule powders of Examples 2 and 3, using binders which do not have a glass transition temperature below 25 ° C., do not make it possible, after pressing and sintering, to obtain a sintered part having a high density and a modulus of high 3-point bending fracture.

Unlike the granule powder of Example 4, having a total binder content of 8%, the granule powder of Example 5, having a total binder content of greater than 9%, does not allow, after pressing and sintering, to obtain a sintered piece having a high density and a modulus of rupture in high 3-point bending.

The granule powder of Example 8 according to the invention contains 2.5% of an acrylic resin having a glass transition temperature of -10 ° C.

The granule powder of Example 9 according to the invention contains 2.5% of an acrylic resin having a glass transition temperature of 20 ° C.

The granule powders of Examples 6 and 7 according to the invention allow the manufacture with high yields of sintered parts of large volume and / or having remarkable mechanical properties. Of course, the invention is not limited to the embodiments provided as examples. In particular, the bulk density of a sintered part according to the invention is not limiting.

In addition, other processes than atomization can be implemented to manufacture a powder of granules according to the invention, for example a process involving a lyophilization step, or a process involving a fluidized bed granulation step , or a granulation step using a paddle mixer.

Claims

1. Powder of granules intended in particular for the manufacture of ceramic sintered parts, said powder having the following chemical composition on the basis of the dry matter:

- ZrC "2: 100% complement;

a stabilizer of the zirconia chosen from the group formed by Y 2 O 3, SC 2 O 3, MgO, CaO, CeC "2, and mixtures thereof, the mass content of stabilizer, based on the sum of the zirconia and stabilizer contents, being comprised between 2.0% and 20%, the MgO + CaO mass content being less than 5.0%> on the basis of zirconia and stabilizer contents;

at least 1.0% of a first binder having a glass transition temperature of less than or equal to 25 ° C .;

0 to 5.0%) of alumina;

- less than 2.0%> impurities;

the median diameter D ₅₀ of the powder being between 80 and 130 μιη, the percentile D ₉ 9 _{i 5} being less than 500 μιη and the relative density of the granules being between 30% and 60%.

2. Powder according to the preceding claim, wherein

the stabilizer is chosen from the group formed by Y 2 O 3, SC 2 O 3 and their mixtures and the content of said stabilizer is less than 6.5%, based on the sum of the zirconia and stabilizer mass contents; or

the stabilizer is chosen from the group formed by MgO, CaO and mixtures thereof and the content of said stabilizer is less than 4%, on the basis of the sum of the zirconia and stabilizer mass contents, or

the stabilizer is CeO ₂ and the content of said stabilizer is greater than 10% and less than 15%, based on the sum of the zirconia and stabilizer mass contents.

3. Powder according to any preceding claim, wherein the stabilizer is selected from the group consisting of Y ₂ O ₃ , Ce0 ₂ and mixtures thereof, and respects the relationship 10% <3.Y ₂ O ₃ + Ce0 ₂ <20%, the mass contents being expressed on the basis of the sum of zirconia and stabilizer mass contents.

The powder according to any one of the preceding claims, wherein Y ₂ O ₃ is the sole stabilizer and the Y ₂ O _{3 content} is greater than 3% and less than 6.5%, based on the sum of mass contents of zirconia and stabilizer.

Powder according to any one of the preceding claims, wherein

the stabilizer is Y ₂ O ₃ ,

the stabilizer content is between 4.5% and 5.5%, based on the sum of the zirconia and stabilizer mass contents,

the alumina content is greater than 0.1% and less than 1%, in percentage by mass on the basis of the dry matter,

the content of the first binder is between 2.5% and 4%, in percentage by mass on the basis of the dry matter, and

the impurity content is less than 0.5%, in percentage by mass on the basis of the dry matter,

the residual moisture content is between 0.2 and 1%, in percentage by mass on the basis of the wet powder.

6. Powder according to the preceding claim, wherein the additional binder content is between 0.5% and 1%, in percentage by weight on the basis of the dry matter.

7. Powder according to the preceding claim, wherein the content of temporary additive is between 0.5% and 1%.

Powder according to any one of claims 1 to 3, wherein

the stabilizer of the zirconia is CeO ₂ ,

the stabilizer content is between 10 and 15%, based on the sum of the zirconia and stabilizer mass contents,

the content of the first binder is between 2.5 and 4%, in percentage by mass on the basis of the dry matter, and the impurity content is less than 0.5%, in percentage by mass on the basis of the dry matter, and

9. The powder according to any one of claims 1 to 3, wherein

the stabilizer of zirconia is a mixture of Y ₂ O ₃ and CeO ₂ ,

the Y ₂ O _{3 content} is between 1% and 2%, in percentage on the basis of the sum of the zirconia and stabilizer mass contents,

the content of Ce0 ₂ is between 11% and 13%, in percentage on the basis of the sum of the zirconia and stabilizer mass contents,

the content of the first binder is between 2.5% and 4%, in percentage by mass on the basis of the dry matter,

the content of impurities is less than 0.5%, preferably 0.1%, and

- The residual moisture content is between 0.2 and 1%, preferably between 0.2 and 0.6% by weight percentage based on the wet powder.

10. Powder according to any one of the preceding claims, wherein the granules comprise particles in which the zirconia is stabilized.

11. Powder according to any one of the preceding claims, wherein the granules incorporate zirconia particles whose median diameter D50 is less than 1 μιη.

Powder according to any one of the preceding claims, in which the granules contain Al ₂ O ₃ alumina, the alumina content being greater than 0.2% and less than 0.6%), in percentage by mass on the basis of the dry matter.

Powder according to any one of the preceding claims, wherein the first binder has a glass transition temperature above -30 ° C.

The powder of any preceding claim, wherein the first binder has a glass transition temperature of less than 15 ° C.

15. The powder as claimed in any one of the preceding claims, in which the first binder is chosen from amorphous organic polymers, polyacrylic resins, polymers based on pure acrylates, co-polymers based on acrylates and styrene, and mixtures thereof.

16. The powder as claimed in any one of the preceding claims, in which the first binder is chosen from polyacrylic resins, polymers based on pure acrylates, co-polymers based on acrylates and styrene, and mixtures thereof. .

17. Powder according to any one of the preceding claims, wherein the first binder is selected from polyacrylic resins, co-polymers based on acrylates and styrene, and mixtures thereof.

18. Powder according to any one of the preceding claims, wherein the first binder and / or the additional binder are chosen from polymers containing no inorganic elements.

19. Powder according to any one of the preceding claims, wherein said temporary additive is an organic additive, the content of said organic additive being less than 1%, the total content of binder (s) and organic additive being less than 5%. said organic additive being selected from dispersants or surfactants, thickeners, antifoamers, preservatives, lubricants, and mixtures thereof.

20. The powder according to any one of the preceding claims, wherein at least a portion of said stabilizer is replaced by an equivalent amount of precursor of said stabilizer.

Powder according to any of the preceding claims, wherein

the median diameter D ₅₀ is greater than 90 μιη and less than 120 μιη; and or

the 10 D ₁₀ percentile is greater than 40 μιη; and or

the 90 D ₉₀ percentile is less than 300 μιη; and or

- The percentile 99.5 D ₉ 9 _{i 5} is less than 400 μιη.

22. Powder according to any one of the preceding claims, wherein the residual moisture content is between 0.2 and 1%, in percentage by weight based on the wet powder.

23. A powder according to any one of the preceding claims, wherein more than 80% of the granules have said chemical composition.

24. Powder according to any one of the preceding claims, wherein the zirconia, alumina, the first binder, the additional binder and the temporary additive are distributed homogeneously within the granules of the powder.

25. A method of manufacturing a sintered part comprising the following steps:

A) raw material mixture for forming a feedstock comprising a powder of granules according to any of the preceding claims, said granule powder representing at least 60% of the mass of the feedstock,

B) forming a preform from said feedstock,

C) optionally machining said preform,

D) sintering said preform so as to obtain said sintered part,

E) optionally, machining and / or grinding of said sintered part.