KR910002175B1 - Magnesia partially-stabilized zirconia - Google Patents

Abstract

The present invention relates to a partially stabilized high content monoclinic zirconia body composed of a molded, non-calcined mixture of zirconia powder and magnesia powder containing silica.

Description

Partially stabilized high content monoclinic zirconia body and its manufacturing method

The present invention relates to fire resistant products made from zirconia partially stabilized by magnesia, and in particular to products made from zirconia containing a relatively large amount of silica. These zirconia products have high strength and toughness at normal and elevated temperatures, and have excellent thermal shock resistance even at temperatures above those in which ceramic refractory products are commonly used.

Unstable zirconia is not suitable for products that are exposed to temperature fluctuations within the range in which deformation occurs because the volume changes rapidly while the zirconia is transformed into a monogonal / square. Accordingly, stabilizers have been added and reacted with zirconia to at least partially stabilize the zirconia in cubic crystal form throughout the temperature range. Zirconia is stabilized "in whole" or "partially" depending on whether a stabilizer is present in an amount sufficient to form a cubic solid solution with all or part of the zirconia. Partial stabilization is sufficient to eliminate heat changes in volume in zirconia. Magnesia, one of the best stabilizers, is effective in partially stabilizing zirconia such that zirconia has desirable thermal shock resistance at levels as low as about 2.5-4.0 weight percent. ·

One important use of partially stabilized zirconia is to use it as an extrusion die for high speed, high temperature extrusion of both ferrous and nonferrous metals. In this application, the extrusion temperature and the extrusion pressure can reach up to 1250 ° C. and 1500 MPa, respectively. Since the die material is subjected to large stresses, the material must be physically strong to avoid cracking by thermal and mechanical stresses.

Particularly strong, thermally stable magnesia, partially stabilized zirconia (MgO-PSZ) is described in US Pat. No. 4,279,655 (Garvie et al., July 21, 1981). The zirconia described in this document is stabilized by about 2.8-4.0% by weight magnesia and stabilized in the cubic state throughout the stages of heating, cooling, heat aging and the like. A microstructure is formed that features a matrix of grains of zirconia, where each grain contains separate precipitates of monoclinic zirconia and square zirconia. These microstructures confer thermal shock resistance, strength and toughness against a wide range of temperature changes.

However, the zirconium dioxide powder used in the production of stabilized zirconia must be highly pure, containing up to 0.03% by weight of silica in order for the process of the present invention to impart the desired properties to the final zirconia body. This requirement is unreasonable for practical use because the concentration of silica in most commercially available zirconium dioxide powders is outside the stated maximums. For example, ZIRCOA A (singular) zirconia powder (available from Corning Glass Works, Corning, NY, USA) was prepared as taught in US Pat. No. 2,578,748, which is generally about 0.05-0.5 weight. It contains% silica. In addition to Calcia, other oxides may be present in small amounts, as shown in Table 1 below. Easily available zirconia powders do not meet the purity requirements of US Pat. No. 4,279,655.

TABLE 1

* Contains HfO ₂ as a natural impurity.

The published British Patent Application No. 2,149,773A describes MgO-PSZ containing 0.8-1.5% silica. However, this publication does not state that fired zirconia products are not produced in the manner of the specific cooling and heat-aging order described above and consequently have the advantageous microstructures described above. Nevertheless, the published PCT application WO 83/04247, according to the method of this patent, preferably obtains a partially stabilized microstructure by adding certain additives to zirconia powders that do not meet the purity requirements of US Pat. No. 4,279,655. It can be processed so that it can be done. 0.05-1.0% by weight of certain "additives" (metal oxides, preferably strontia, baria, or rare earth oxides, which produce insoluble zirconates that do not mix with magnesia) are added to the batch prior to the firing process. In addition, it is described that up to 1.0% by weight of silica in the final product is acceptable. However, if an additive is present, a long aging time is generally required, and excessive cost and decrease in high temperature strength due to aging are disadvantages of the present method and the composition.

It is therefore an object of the present invention to provide a zirconia ceramic partially stabilized by magnesia, wherein the zirconia ceramic has strength, toughness and thermal shock resistance imparted by the microstructure comprising the precipitate, preferably Can be prepared from readily available batch ZrO ₂ powders that do not require further purification of the batch or addition of specific additives by removing the silica.

Zirconia bodies partially stabilized with magnesia and methods for preparing these zirconia bodies are provided by the present invention. This method produces a green body of a molded, uncalcined mixture of zirconia powder and magnesia powder containing about 0.05-0.5% by weight silica. This partially stabilized zirconia body consists essentially of crystalline zirconia, silica and magnesia, wherein silica is present at about 0.05-0.5% by weight relative to the weight of the zirconia and magnesia is present at about 2.5-4.0% by weight do ; The zirconia body has a substantially crystalline microstructure, which contains (1) zirconia and a large amount of magnesia, and magnesia is a cubic stabilized cubic form contained in cubic, square and monogonal zirconia in the zirconia body. Zirconia grains, and (2) separate precipitates of square zirconia in this cubic grain (this is an oval with a long diameter of about 0.1-0.4 microns in length), and (3) separate precipitates of monoclinic zirconia in this cubic grain (this is long diameter Ellipsoidal, approximately 0.1-0.4 microns long), and (4) composed of single yarn zirconia present at the cubic grain interface. The partially stabilized zirconia of the zirconia body (a) has a monolithic zirconia content of about 10-20% by volume and a thermal expansion coefficient of about (65-105) × 10 ^-7 / ° C over a temperature range of 25-1000 ° C. Has a microstructure with a fracture modulus of at least 400 MPa when measured at 25 ° C. after a known thermal shock test; Or (b) a single zirconia content of about 20-60% by volume, thermal expansion coefficient of about (10-65) × 10 ^-7 / ° C over a temperature range of 25-1000 ° C, measured at 25 ° C after a known thermal shock test. When characterized in that having a microstructure having a fracture modulus of at least 250MPa.

The zirconia body of the present invention has a crystalline microstructure which takes one of two types of zirconia described below: low-temperature sweetness having excellent physical properties such as toughness and fracture modulus at a temperature of about 400 ° C. from room temperature (about 25 ° C.). Death penalty zirconia (about 10-20% by volume); And high content of single yarn zirconia (about 20-60% by volume) which exhibits good physical properties at temperatures below about 1000 ° C. Both types of zirconia have excellent thermal shock resistance. ·

The method for preparing the zirconia body includes certain heating and cooling steps, including a heat-aging step, which develops the desired microstructure. In the production of products, various crystalline forms can be obtained by modifying the firing and cooling steps, including the heat-aging step. Therefore, the zirconia bodies thus prepared are widely used because they have the advantages of high strength, high toughness, high fire resistance, high thermal shock resistance, high density and low thermal conductivity, which are shown by partially stabilized zirconia. Among the zirconia bodies according to the present invention, zirconia bodies having a high content of single yarn zirconia are particularly useful as extrusion die nibs in high temperature metal working processes. Dinib made from these zirconia can withstand the strong thermo-mechanical stresses associated with high speed extrusion and can also provide good surface finish for the extruded product.

The present invention is based on the new finding that partially stabilized zirconia bodies with good physical properties and thermal shock resistance can be prepared from zirconia powder that does not need to be purified to a low silica content (0.03% by weight or less). The zirconia bodies produced by the present invention are partially stabilized by magnesia, can be separated by monoclinic zirconia at the cubic grain interface, and contain cubic stabilized zirconia containing separate precipitates of tetragonal and monoclinic zirconia. It features a microstructure made of grain.

The zirconia bodies of the present invention with crystalline microstructure and good physical properties are qualitatively similar to those described in US Pat. No. 4,279,655 to Garvie et al. Surprisingly, however, such microstructures and physical properties are obtained in the present invention despite the higher silica levels than those taught by Garvie et al. It has also been found that it is not necessary to scaveng silica by adding an additive as described in PCT application WO 83/04247 (published Dec. 8, 1983). Such additives are described as metal oxides that produce insoluble zirconates, which do not mix with MgO and produce glass with silica.

The zirconia material of the present invention does not contain such metal oxides, and is not particularly in the range of the amount described in the literature (0.05-1.0% by weight), but thermal aging at 1100 ° C. (this aging is thermal shock in a single material In spite of resistance and good strength / toughness), and contains a silica level known in the art to prevent obtaining excellent thermal shock resistance. See US Pat. No. 4,279,655, lines 58-68 of column 11, and table 2 of column 12.

In spite of the high silica content, the unexpected ability to exhibit thermal shock resistance as well as good physical properties allows the use of inexpensive zirconia powders, which are widely used, which eliminates the need to purify these zirconia to lower silica contents. Accordingly, many commercially available zirconia powders containing at least about 0.05% silica by weight can be used directly to prepare the zirconia bodies of the present invention. For example, zirconia-A zirconia powder (made according to the process of US Pat. No. 2,578,748 and marketed by Corning Glass Works) typically contains about 0.05-0.25% by weight of silica, although it is common to be as high as 0.5%. have. This is shown in Table 1 above.

In addition to silica, the zirconia powders produced by the process of US Pat. No. 2,578,748 may comprise up to about 0.25% by weight of other oxides, such as calcia, magnesia, titania, alumina, iron oxide, each present in small amounts. Any or all of the above-described oxides may not be present. Preferred zirconia starting materials used in the present invention may be prepared according to the method described in US Pat. No. 2,578,748, although zirconia powders made from other raw materials may be used.

The zirconia bodies according to the invention consist mainly of crystalline zirconia, ie zirconia partially stabilized by magnesia, and further contain silica. The magnesia content is about 2.5-4.0% by weight, preferably about 3.0-4.0% by weight, more preferably about 3.0-3.5% by weight. Silica is present in an amount of at least 0.05% by weight to about 1.0% by weight, but an amount of at most 0.5% by weight, preferably at most 0.25% by weight is preferred.

Zirconia bodies include cubic zirconia grains stabilized by magnesia; Sedimentation of tetragonal zirconia in this cubic grain; Isolated precipitates of single yarn-like zirconia in this cubic grain; It is characterized by a crystalline microstructure mainly composed of single yarn zirconia at the interface of cubic grains. Cubic zirconia grains generally have a diameter of about 20-100 microns. Precipitates in the grains are generally elliptical or lenticular with a major axis of about 0.1-0.4 microns, preferably 0.1-0.3 microns in length. Grain consisting of a cubic stabilized material with precipitates dispersed therein constitutes the bulk of the microstructure, accounting for at least about 75% by volume of the microstructure, and the microstructure also has a grain boundary. It has a phase and porosity and occupies most of the volume in the zirconia body.

In general, almost all stabilized zirconia in cubic form is in the form of cubic grains, and nearly all square zirconia is in the form of sediments in these grains, and single-shaped zirconia is present in the sediment in the cubic grains, or in the grain boundary layer. do. However, it is present in sediments in large quantities of cubic grains. Large amounts of magnesia are present in the cubic grains and are introduced into solid solution with cubic stabilized zirconia. Small amounts of magnesia are in grain boundaries dispersed in single-bed zirconia. Silica is almost all in the grain boundary layer and forms a silicate phase with magnesia.

Surprisingly, it has been found that the physical properties of zirconia bodies do not vary significantly in the range of up to about 0.5% by weight of silica, even without additives that compensate for silica. This is in contrast to those taught in Examples (3) and (4) below and taught in US Pat. No. 4,279,655 and published PCT application WO 83/04247. Stabilizing oxides such as the "additives" disclosed in the PCT application are rarely used in the present invention. This means that even if these oxides are present as impurities in the batch, these oxides are present in amounts up to 0.05% by weight, which is lower than the concentrations exhibiting the efficacy taught in the PCT application. In this respect, the term "substantially constructed" as used herein is limited only to its original meaning-that is, small amounts of components other than the components described herein do not react with the components described above, This means that they can exist in categories that do not alter their characteristics. For example, oxides such as calcia, titania, or alumina may be present, but this means that oxides that act as additives of the PCT application by producing insoluble zirconates and silicates are excluded or substantially absent.

The fired zirconia body of the present invention takes one of two composition forms based on the final calculated single yarn zirconia content, that is, one of the "low content monolithic" form and the "high content monolithic" form. Take The final form can be adjusted according to the firing schedule used in the production of zirconia bodies, which are characterized by having somewhat different physical properties to suit somewhat different end uses.

Methods for measuring monoclinic crystalline zirconia phase in final zirconia bodies are described in Garvie, R.C. and Finish prepared using 6-micron diamond paste by the method described in "Phase Analysis in Zirconia Systems," by Nicholson, PS,-Journal of the American Ceramic Society, 55 (6) 303-305 (1972). Can be determined on the treated surface.

Low content monoclinic zirconia is characterized by having a monoclinic zirconia of about 10-20% by volume and having excellent physical properties and excellent thermal shock resistance against temperatures from room temperature to about 400-500 ° C. or less. In particular, the low content monoclinic zirconia body is about 9 MPa.m. ⁵ or more, generally about 9-12 MPa.m. ^It has a room temperature toughness of ⁵ (Mega-Pascal × Square Meter) and at 800 ° C., about 3-6 MPa.m. ^{5 has} toughness. At room temperature the fracture modulus (MOR) is at least about 500 MPa and at 800 ° C. the MOR is at least about 250 MPa and is generally in the range of 300-350 MPa. The density after firing is about 5.3-5.9 gm / cc. The thermal expansion coefficient of this type of zirconia in the range 25-1000 ° C. is about (65-105) × 10 ⁻⁷ / ° C. After exposure to thermal shock, the low content monoclinic zirconia of the present invention maintains a MOR of at least about 400 MPa at room temperature and generally maintains about 75% of a "pre-shock" MOR.

In general, thermal shock resistance refers to a measure of a material's ability to withstand a wide range of rapid temperature changes without causing substantial strength loss or cracking. As used herein, "exposure" of zirconia material to "thermal shock" is defined as follows: The fired rod of the material is post-processed to 3 x 3 x 65 mm on a grinder equipped with 320-grit diamond wheels. do. The sample rod was kept at room temperature and then immersed in a molten tin bath maintained at 900 ° C. for 15 seconds, then removed from the bath for 2 minutes to contact the reinforced air stream at room temperature and alternately re-immersed in the bath. Conduct.

The process is carried out three immersion processes, and finally the rod is cooled to room temperature. The fracture modulus of the sample rod is determined at 25 ° C. both before and after the dipping cycle.

The use of the low content monoclinic zirconia body of the present invention is used as a valve guide and a cylinder liner of a pump part in contact with an engine, a die hot liquid for extrusion of powder or hot aluminum metal and a non-ferrous liquid metal.

The high content single yarn zirconia body of the present invention generally contains about 20-60% by volume single yarn zirconia, and has excellent high temperature physical properties and thermal shock resistance, which are suitable even when used at a temperature of about 1000-1200 ° C or less. do. In particular, the high content monoclinic zirconia body is about 5 MPa.m. Room temperature toughness of ⁵ or more and 4 MPa.m. ^It has a toughness of ⁵ or more. At room temperature and 800 ° C., MOR is at least about 300 MPa, generally in the range of about 350-450 MPa. Room temperature MORs of 20 MPa or more are maintained after exposure to thermal shock and generally 75% of the "pre-shock" MOR is maintained. The density after firing is about 5.3-5.9 gm / cc.

The coefficient of thermal expansion of monoclinic zirconia is about (10-65) x 10 ^-7 / ° C over the range 25-1000 ° C.

Single yarn zirconia is used for extrusion dies of brass or copper or extrusion dies for iron or titanium metals, engine parts and pump parts in contact with liquid metals. Single yarn zirconia is used in particular as a die for extrusion of copper-beryllium alloys and ferrous metals, for example stainless steel.

The method for preparing the zirconia body of the present invention includes a firing schedule including a heat aging step, which plays an important role in determining the crystalline microstructure ultimately obtained by the zirconia body. Firing is described in US Pat. No. 4,279,655, issued July 21, 1981 to Garvie et al. Extensively, the process of the present invention comprises (a) wet pulverization by mixing zirconia and magnesia powder to form into a desired form to produce a "green" sieve; (b) suing the green body at a sintering temperature of 1525-1800 ° C .; (c) cooling the calcined green body to a primary cooling temperature of about 1300-1450 ° C. under primary cooling rate; (d) further cooling the green body to a secondary cooling temperature range of about 1000-1200 ° C. under the secondary cooling rate, and then optionally ripening the green body at this secondary cooling temperature; (e) cooling the green body to room temperature; Optionally (f) heating the green body within a temperature range of about 1000-1200 ° C. and ripening the green body at this temperature such that the total aging time of steps (d) and (f) is 10-150 hours; (g) cooling the green body to room temperature.

The production of green bodies is accomplished by methods commonly used in the ceramic art. Zirconia and magnesia powders are mixed in proportions providing a magnesia content of about 2.5-4.0 weight percent. Magnesia can be added in the form of precursor compounds that are thermally decomposed to magnesia, examples of which are oxalates of magnesium, acetates, nitrates, fluorides, sulfates, carbonates, hydroxides and the like. The amount of magnesia precursor used is such that it can produce magnesia content within this range. After mixing, the powders are wet pulverized with water or inorganic liquid to have an average particle size of about 0.5-2.0 microns, preferably about 0.7-1.7 microns and most preferably about 1.0 micron. The wet milling step is carried out by sodium polyacrylates such as Darvan 7, or Darvan C, ammonium polyacrylate, (RT Vanderbit Co.), or Strodex PK-30 (potassium salt of organic polyphosphoric ester acid anhydride, Dexter Chemical Corp.). In the presence of. Darvan C is the preferred solution. After grinding, about 2-5% by weight of organic binder is added and the mixture is spray dried or evaporated to dryness. When the concentration of Strodex PK-90, an alkali- and phosphoric acid-containing peptizer in the pulverized mixture, is present in about 0.5% by weight solids, it is possible to eliminate or substantially reduce the cracking of the final zirconia body. It turned out. The resulting powder is pressed into the desired shape.

The sintering temperature for firing the green body depends on the magnesia content of the zirconia body. Preferably, the sintering temperature is the temperature at which the material forms almost single-phase homogeneous cubic crystals. The temperature can be determined from the magnesia / zirconia phase diagram but in general the temperature is in the range of 1525-1800 ° C. for the magnesia level described herein and the lower the magnesia level, the higher the temperature. For the most preferred magnesia level, 3.0-3.5% by weight, a temperature of about 1550-1750 ° C. may be used and a temperature of about 1625-1675 ° C. is most suitable for a magnesia level of about 3.3% by weight. The sintering temperature is preferably reached by heating the green body at a rate of about 50 ° C./hour, but this rate is not critical. The green body may optionally be maintained at this temperature for about 20 hours. The size of cubic zirconia grains depends on the hold time at the best temperature. The longer the hold time, the larger the grain size. In general, the smaller the particle size, the better the strength of the calcined body, and for this reason it is maintained for about 5 hours, preferably about 2 hours or less, at the best temperature.

It is desirable to slowly heat the green body to 400 ° C. to “burn out” the binder when the organic binder is present. This heating schedule heats the green body at about 250 ° C. for 4 hours, keeps the green body at that temperature for about 2 hours, heats the green body at about 400 ° C. for 6 hours, and heats the green body at about 400 ° C. It is composed of keeping for 4 hours at.

After this step, the green body is fired to the best sintering temperature as described above.

After the sintering step, the green body is cooled from the best temperature to a primary cooling temperature of about 1300-1450 ° C., preferably about 1400 ° C. Cooling takes place at a rate of about 150-600 ° C./hour, preferably about 200-450 ° C./hour. ; Optionally, this cooling schedule is maintained for about three hours under the primary cooling temperature.

In step (d) of the present invention, the green body is cooled to a secondary cooling temperature of about 1000-1200 ° C. This cooling step is carried out at a rate of about 20-200 ° C./time. A rate of about 50-100 ° C./hour, about 75 ° C./hour is preferred when the MgO content is about 3.3% by weight. Generally, the cooling ratio within the above range depends on the amount of MgO in the green body. Green bodies with low MgO content require faster cooling and vice versa. At the secondary cooling temperature, a holding time of about 150 hours can optionally be introduced. Heat-matured zirconia in this temperature range is needed to increase the single yarn content in the structure. Thus, this ripening step can be introduced at step (d) or optionally at any reheating step (f) as described below.

The cooling steps (c) and (d), especially the step (d) in which the green body is cooled from the primary cooling temperature to the secondary cooling temperature, are important for developing a suitable crystalline microstructure. Under slower cooling rates than those described above, the particle size of the square precipitate becomes larger and may deviate from the preferred upper limit of about 0.4 microns. Square precipitates exceeding this size spontaneously deform into single yarns during the cooling process, losing the "transformation toughening" properties of zirconia bodies. Similarly, cooling faster than the rates described above results in low toughness because it produces a square precipitate of the desired size or less.

The green body is further cooled to room temperature according to step (e) of the present invention. Although a cooling rate of about 300 ° C./hour or less is preferred to minimize cracking, a cooling rate of about 400 ° C./hour or less may be used in this step. Cooling this green body under "speed of the furnace" (200 ° C / hour) follows the following process.

Thermal aging of zirconia at temperatures of 1000-1200 ° C. is necessary to provide the desired level of monoclinic zirconia in the zirconia, and the zirconia is generally aged with heat for 10-150 hours. Thus, if no aging process of step (d) is used or if aging after 10 hours is used, the zirconia body is reheated in step (f) to a temperature of 1000-1200 ° C. and aged at this temperature for several hours. . After this step, the zirconia body is cooled back to room temperature in the ratio of the furnace.

It is important that the zirconia body undergo a total of 10-150 hours of heat aging below 1000-1200 ° C., whether the heat aging is carried out during the cooling step (d) or in another reheating step (f). The number of heat aging times required to provide a "low" or "high" single yarn form of the zirconia body of the present invention depends in part on the rate at which the cooling steps (c) and (d) are performed. In general, when the cooling steps (c) and (d) are carried out at the desired ratios of about 200-450 ° C./hour and 75 ° C./hour, respectively, the “low content” single yarn zirconia is after a heat aging time of about 10-20 hours. “High content” single forms appear after about 20-80 hours.

It can be seen that the heat aging in the temperature range of 1000-1200 ° C. does not need to maintain the zirconia body at a certain temperature within this temperature range for the aging time. This temperature can be reduced or varied within this range through slow cooling at 1000-1200 ° C. while the zirconia body is maintained at 1000-1200 ° C. for 10-150 hours.

The heat aging step of the zirconia material of the present invention makes it useful as a die used in high temperature forming processes of metals and alloys where strength and thermal shock resistance are important. For example, in the processing of copper alloys, cylinder preheated billets (5 inch diameter 30 inch length) are extruded through a zirconia die at 750 ° C. and formed into 1/2 inch diameter rods (rods). This failure mode of the die is due to the cracking occurring near the die inlet, which creates a "fin" on the extruded material which eventually renders the die useless. Dies made from the high content single yarn zirconia of the present invention (at least about 20 hours of heat-aging) are not ruptured and can withstand about 180 extrusions. Low content monoclinic materials can only withstand 50-100 extrusions.

Zirconia materials having the compositions described herein are useful for many applications even if they are not heat aged. For example, if heat aging has not been introduced during the cooling step (d), the zirconia body removed from the furnace after reaching room temperature according to step (e) is less than about 10% by volume, usually less than about 5% by volume. Contains the death penalty zirconia. The unmatured form has good low temperature properties and in general this zirconia body is suitable for use in end uses that are not exposed to rapid temperature fluctuations. In particular, this low content monofilament form is about 8 MPa.m. ⁵ , about 3 MPa.m. ^{It has} a toughness of ⁵ . Fracture modulus has at least about 500 MPa at room temperature, but below this level at 800 ° C., generally at about 250-400 MPa. These zirconia bodies have a coefficient of thermal expansion of at least 5.5 gm / cc after firing and a coefficient of thermal expansion of at least 95 × 10 ⁻⁷ / ° C. in a temperature range of 25-1000 ° C. The zirconia body which has not been aged is a prosthetic device; Wear resistant linings and tiles; Sizing powder metal fittings; Scraping blades in the mining industry; Valves, seals, valve guides; It is used as a nozzle and low temperature extrusion die or injection die.

Unless otherwise specified, the physical properties of calcined zirconia are measured as follows;

Thermal expansion is measured on the bar of the product using an expansion meter. Using alumina as standard, a heating rate of 3 ° C. per minute is used over the range from room temperature to about 1000 ° C.

Fracture modulus is measured on a 4-point curve using 50 mm span (support span) and 13 mm span (load span). The MOR at room temperature is measured on a bar sample of 3 x 3 x 65 bar clay polished plastic material by a 320 grit diamond wheel on a surface grinder. MOR at 800 ° C. is done on a bar sample of fired material similarly finished with a bar size of 8 × 1.5 × 65 mm.

Toughness is measured on a four-point curve using a 40mm span (support span) and a 5mm span (loaded span). The sample is a Sevron-loaded firing bar with a size of 5 × 6 × 60 mm. The crosshead speed to facilitate stable rupture is 0.50 mm per minute.

Density is measured by adding water at room temperature.

The following examples are only intended to illustrate the present invention, but the present invention is not limited thereto. In the examples, the zirconia used is a zirconia-A single yarn powder containing a prescribed amount of SiO ₂ .

Example 1

A batch of the following composition was made.

The batch was wet milled with water in the presence of 1.0% by weight of DARVAN C peptizer based on solids weight. Grinding continued until solids had an average particle size of about 1.0 micron in the ground batch. About 3% by weight of organic binder mixture (CARBOWAX 400 and CARBOWAX 400, Union Carbide Corp.) based on solids weight was added to the batch. After sufficient mixing to disperse the binder, the batch was spray dried and compressed into a test bar (8 × 10 × 80 mm).

The compressed bar was calcined to a temperature of 1625 ° C. in the following order: 4 hours at room temperature to 250 ° C .: 2 hours at 250 ° C .: 6 hours at 150-100 ° C .: 4 hours at 400 ° C .: 50 ° C. / 400-1625 ° C. under time. The bar was kept at 1625 ° C. for 2 hours and then cooled to 1400 ° C. under 450 ° C./hour, to 1100 ° C. under 75 ° C./hour, and then to room temperature at a 200 ° C./hour ratio. The bar was reheated and then aged at 1100 ° C. for 10 or 24 hours and again cooled to room temperature under “rate of furnace” (about 200 ° C./hour). The physical properties of the test bar due to heat aging are shown in the following table.

TABLE 2

* Measured on bars finished with 8 × 1.5 × 65 mm

** Value evaluated.

Larger MOR values for room temperature applications are provided by 10-hour heat aging; Longer aging times provide better high temperature physical properties.

Example 2

A batch mixture of the following composition was prepared:

Peptide Strodex PK-90 0.33 based on solids weight

The batch was milled with water in the presence of weight percent. Grinding was continued for solids until the average particle size was about 1.1 microns. About 4% by weight of organic binder, based on solids weight, was added to the batch. After sufficient mixing to disperse the binder, the batch was spray dried and compressed into a test bar (8 × 10 × 80 mm).

After the separate firing by exhausting the binder, the compressed bar was fired until the maximum temperature reached 1725 ° C. according to the following firing sequence: 400 ° C. at room temperature (RT) at 400 ° C./hour magnification; Heating from 400 ° C. to 1725 ° C. at a rate of 50 ° C./hour; Hold at 1725 ° C. for 2 hours. The cooling sequence is as follows; Cooling from 1725 ° C. to 1400 ° C. at a rate of 575 ° C./hour; Cooling from 1400 ° C. to 1000 ° C. at a rate of 130 ° C./hour. The samples are then classified into three types (A, B and C) for processing: furnaces (approximately 200 ° C./hour), cooling samples A and C from 1000 ° C. to room temperature and only C 1100 ° C. The furnace is reheated and aged at that temperature for 22 hours and cooled to room temperature under no-ratio. A does not reheat (do not mature). B is heated to 1100 ° C. at 1000 ° C., then aged at 1100 ° C. for 25 hours and cooled to room temperature under no-ratio.

The physical properties of the test bar due to the action of heat-maturation are listed in the table below. As can be seen in Sample A, it is not resistant to thermal shock and is not broken immediately upon impregnation in the tin bath. Samples B and C thermally aged by different processes have good thermal shock resistance.

Example 3

The following experiments were conducted to determine the effect of various silica concentrations on the properties of MgO-part stabilized zirconia. Three batches from Samples A to C were made of Zircoa-A powder with silica expressed in the following weights:

Each sample batch was of course wet milled in the presence of 0.33% by weight Strodex PK-90 with respect to the batch weight as peptizer. Grinding was continued on the solid until the average particle size was about 1.3 microns. About 4% by weight of organic binder, based on solids weight, was added to each batch. After sufficient mixing to disperse the binder, each batch was spray dried and compressed into a test bar (8 × 10 × 80 mm).

The compressed bar was fired until the maximum temperature reached 1675 ° C. in the following firing sequence. Heating from room temperature (RT) to 250 ° C. over 4 hours; Hold at 250 ° C. for 2 hours; 250 degreeC-400 degreeC heating over 6 hours; Hold at 400 ° C. for 6 hours; Heating from 400 ° C. to 1675 ° C. at 50 ° C./hour; Hold at 1675 ° C. for 2 hours. The cooling sequence is as follows. Cooling from 1675 ° C. to 1400 ° C. at a rate of 450 ° C./hour; Cooling from 1400 ° C. to 1100 ° C. at a rate of 75 ° C./hour; Cool to room temperature at 1100 ° C. at a rate of about 200 ° C./hour furnace. The calcined rod is then reheated and aged at 1100 ° C. for 20 hours.

The physical properties of the test bar according to the silica content are listed below. Various silica contents within the indicated ranges do not affect the properties and it can be seen that samples B and C of stable zirconia have acceptable strength and toughness even though they contain silica at more than 0.03% by weight.

* Measured on bars manufactured from 8 × 1.5 × 65MM

Example 4

A batch of the following composition was made.

The batch was processed by the method described in Example 1 except that the temperature was held at 1675 ° C. for 2 hours. After cooling to room temperature according to the method of Example 1, the test bar was reheated to 1100 ° C. and aged for 10 hours before cooling to room temperature. The density of the heated sample was 5.72 gm / cc and the coefficient of thermal expansion was 60 × 10 ⁻⁷ / ° C. over a temperature range of 25-1000 ° C. The average modulus for rupture of the sample maintained after the thermal shock test was 315 MPa.

Claims (11)

In a partially stabilized high content monoclinic zirconia composed of a molded, non-calcined mixture of zirconia powder containing silica and magnesia powder, the zirconia contains (1) zirconia and a large amount of magnesia, wherein magnesia is the zirconia Cubic-type stabilized zirconia grains contained in cubic, square and monogonal zirconia in the body, (2) Separated precipitates consisting of square zirconia in the cubic grains (3) Monolithic zirconia in the cubic grains Crystalline microstructure consisting of isolated sediment formed and (4) monoclinic zirconia present at the interface within the cubic grains, wherein the square and monoclinic precipitates each have an elliptical shape with a major axis of 0.1 to 0.4 microns, and the zirconia body Partially stabilized Zirconia material volume is the short threaded zirconia content of 20 to 60 cents, and blooming, a thermal expansion coefficient is in the range of ^{25-1000 ℃ (10-65) × 10 -7} / ℃, after exposure to thermal shock measured at 25 ℃ Partially stabilized high content monolithic zirconia with a microstructure having a fracture modulus of at least 250 MPa. The zirconia body according to claim 1, wherein the magnesia content is 3.0-4.0 wt%. The zirconia body according to claim 1, wherein the silica content of the zirconia body is 0.05-0.25% by weight and the magnesia content is 3.0-3.5%. (a) mixing magnesia powder and zirconia powder to prepare an uncalcined mixture containing 0.05-0.5% by weight of silica, and molding the mixture to produce a green body; (b) heating the green body to a sintering temperature of 1525-1800 ° C., and maintaining the green body at this temperature for about 20 hours; (c) cooling the green body to a primary cooling temperature of 1300-1450 ° C. at a rate of 150-600 ° C./hour; (d) cooling the green body to a secondary cooling temperature of 1000-1200 ° C. at a rate of 20-200 ° C./hour; (e) cooling the green body to room temperature at a rate of about 400 ° C./hour; (f) reheating the green body to a aging temperature in the range of 1000-1200 ° C. and aging the green body for 20-40 hours at ionicity; (g) A method for producing a high content monolithic zirconia body partially stabilized with magnesia consisting of cooling the green body to room temperature. The method according to claim 4, wherein the magnesia content of the zirconia body is 2.5-4.0% by weight, and the step (a) is performed by wet grinding the powders until their average particle size is 0.5-2.0 micron and Compacting in form. According to claim 4, (1) the magnesia content of the zirconia body is 2.5-4.0% by weight, (2) the cooling step (c) is carried out at a rate of 200-450 ℃ / hour, (3) the cooling step ( d) carried out at a rate of 50-100 ° C./hour. The method of claim 6, wherein the primary cooling temperature is 1400 ° C. and the secondary cooling temperature is 1100 ° C. 8. (a) mixing magnesia powder and zirconia powder to prepare an uncalcined mixture containing 0.05-0.5% by weight of silica, and molding the mixture to produce a green body; (b) heating the green body to a sintering temperature of 1525-1800 ° C. and maintaining the green body at the temperature for about 20 hours; (c) cooling the green body to a primary cooling temperature of 1300-1450 ° C. at a rate of 150-600 ° C./hour; (d) cooling the additive green body to a secondary cooling temperature of 1000-1200 ° C. at a rate of 20-200 ° C./hour and aging the green body at this temperature for 20-80 hours; (e) A method for producing a high content monoclinic zirconia body partially stabilized with magnesia, comprising cooling the green body to room temperature at a rate of about 400 ° C./hour. The method of claim 8, wherein the magnesia content of the zirconia body is 2.5-4.0% by weight, the step (a) is the wet grinding of the powder having an average particle size of 0.5-2.0 microns and the powder in a constant form The method comprising the step of pressing. According to claim 8, (1) the magnesia content of the zirconia body is 2.5-4.0% by weight, (2) the cooling step (c) is carried out at a rate of 200-450 ℃ / hour, (3) the cooling step ( d) is carried out at a rate of 50-100 ° C./hour, the zirconia body is aged at the secondary cooling temperature for 20-80 hours, and (4) cooling step (e) is performed at a rate of 200-300 ° C./hour. Method carried out. The method of claim 10, wherein the primary cooling temperature is 1400 ° C. and the secondary cooling temperature is 1100 ° C. 12. SUMMARY OF THE INVENTION The present invention relates to a partially stabilized high content monoclinic zirconia body composed of a molded, non-calcined mixture of silica containing zirconia powder and magnesia powder.