WO2011077380A2 - Poudre de granules de zircone et d'alumine - Google Patents

Poudre de granules de zircone et d'alumine Download PDF

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Publication number
WO2011077380A2
WO2011077380A2 PCT/IB2010/055992 IB2010055992W WO2011077380A2 WO 2011077380 A2 WO2011077380 A2 WO 2011077380A2 IB 2010055992 W IB2010055992 W IB 2010055992W WO 2011077380 A2 WO2011077380 A2 WO 2011077380A2
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content
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binder
powder
stabilizer
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PCT/IB2010/055992
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English (en)
French (fr)
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WO2011077380A3 (fr
Inventor
Nabil Nahas
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Saint Gobain Centre de Recherche et dEtudes Europeen SAS
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Saint Gobain Centre de Recherche et dEtudes Europeen SAS
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Priority to EP10814705.9A priority Critical patent/EP2516353B1/fr
Priority to CN201080059254.0A priority patent/CN102686537B/zh
Priority to US13/517,129 priority patent/US20120328879A1/en
Priority to JP2012545515A priority patent/JP2013515665A/ja
Publication of WO2011077380A2 publication Critical patent/WO2011077380A2/fr
Publication of WO2011077380A3 publication Critical patent/WO2011077380A3/fr
Anticipated expiration legal-status Critical
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Definitions

  • the invention relates to a powder of granules based on zirconia and alumina, a process for producing such granules and a sintered part obtained from such granules.
  • 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:
  • a stabilizer of the zirconia selected from the group consisting of Y2O3, SC2O3, MgO, CaO, Ce0 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 MgO + CaO content being less than 5.0%, based on the sum of the zirconia and stabilizer contents (i.e. on the basis of the sum of Zr0 2 Y 2 O 3 , SC 2 O 3 , MgO, CaO and CeO 2 );
  • Tg glass transition temperature
  • alumina sintering additive 0 to 2.0% of an alumina sintering additive; 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%;
  • an additional oxide selected from manganese oxide, ZnO, La 2 C3, SrO, BaO and mixtures thereof;
  • the median diameter D50 of the powder being between 80 and 130 ⁇ , the 0.99% percentile being less than 500 ⁇ and the relative density of the granules being between 30% and 60%.
  • more than 80%, more than 90% or even substantially 100% of the granules have a composition in accordance with the composition of the powder.
  • 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.
  • 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.
  • binders having high glass transition temperatures to improve the green strength
  • the relative density of the granules is between 40% and 50%.
  • the content of said stabilizer is less than 15%, preferably less than 12%, preferably less than 10%, preferably less than 8%, preferably less than 6.5% and / or greater than 4%, based on the sum of Zr0 2 , Y2O3, SC2O3, MgO, CaO and Ce0 2 .
  • the granules incorporate particles of said stabilizer whose median diameter is less than 0.8 ⁇ , preferably less than 0.5 ⁇ .
  • 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 (D50) is less than 1 ⁇ , preferably less than 0.8 ⁇ , or even less than 0.5 ⁇ .
  • the alumina content is preferably greater than 10%, preferably greater than 15% and / or 40%, preferably less than 30%, more preferably less than 25%.
  • the granules contain alumina.
  • alumina Preferably more than 50% by weight of the alumina is alpha alumina.
  • the alumina is substantially all alpha alumina.
  • the granules incorporate alumina particles whose median diameter (D 50 ) is less than 5 ⁇ , preferably less than 1 ⁇ , preferably less than 0.8 ⁇ , or even less than 0.5 ⁇ .
  • 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.
  • 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.
  • the zirconia and / or the alumina and / or the first binder and / or the additional binder and / or the temporary additive are distributed homogeneously within the granules of the powder.
  • the first binder and / or the additional binder are chosen from polymers that do not contain inorganic elements.
  • the powder comprises a sintering additive of alumina selected from titanium oxide, lanthanum oxide and mixtures thereof.
  • the sintering additive of alumina is lanthanum oxide.
  • the sintering additive content of the alumina is greater than 0.2% and / or less than 1%, preferably less than 0.8%.
  • the content of temporary additive is less than 1%.
  • 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%, or even less than 0.1%.
  • the impurities are oxides.
  • the median diameter (D50) of the powder is greater than 90 ⁇ and / or less than 120 ⁇ .
  • the percentile 10 (D] 0 ) is greater than 40 ⁇ , preferably greater than 50 ⁇ , more preferably greater than 60 ⁇ .
  • the 90 percentile (D 90 ) is less than 300 ⁇ , preferably less than 250 ⁇ , more preferably less than 200 ⁇ .
  • the 99.5 percentile (099.5) is less than 400 ⁇ , more preferably less than 300 ⁇ .
  • the stabilizer is selected from the group consisting of Y 2 O 3 , SC 2 O 3 and mixtures thereof and the content of said stabilizer is less than 6.5%, based on the sum of ⁇ 1 ⁇ 2, Y2O3 and SC2O3.
  • the stabilizer is selected from the group consisting of MgO, CaO and mixtures thereof and the content of said stabilizer is less than 4%, based on the sum of Zr0 2 , MgO and CaO.
  • the stabilizer is CeO 2 and the content of said stabilizer is greater than 10% and less than 1%, based on the sum of Zr0 2 , Y 2 O 3 and CeO 2.
  • the stabilizer is chosen from the group formed by Y 2 O 3 , CeO 2 and their mixtures, and preferably respects the relationship 10% ⁇ 3.Y 2 O 3 + Ce0 2 ⁇ 20%, on the basis of the sum of ZrO 2, Y 2 O 3 and CeO 2.
  • the stabilizer is Y 2 O 3, that is to say that the granules comprise only Y 2 O 3 as a stabilizer.
  • the content of Y 2 O 3 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 ZrC> 2 and Y 2 0 3 .
  • 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.
  • the granules comprise particles in which the zirconia, stabilized or otherwise, and the stabilizer are intimately mixed.
  • the granules comprise particles in which the zirconia is stabilized, i.e. the stabilizer is in solid solution in the zirconia particles.
  • the granules comprise particles in which the stabilized zirconia and alumina are intimately mixed.
  • the stabilizer is Y 2 O 3
  • the stabilizer content is between 4.5% and 5.5% by weight percentage based on the sum of ⁇ 1 ⁇ 2 and Y2O 3
  • the alumina content. is greater than 15% and less than 25%, preferably substantially equal to 20% by mass percentage on the basis of the dry matter
  • the content of the first binder is between 2.5% and 4% by weight percentage on the base of the dry matter
  • the lanthanum oxide content is greater than 0.2% and less than 0.8%, preferably substantially equal to 0.5% by weight percentage on the basis of the dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1% by weight percentage on the basis of the dry matter
  • 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.
  • the stabilizer is Y 2 O 3
  • the stabilizer content is between 4.5% and 5.5% by weight percentage based on the sum of ⁇ 1 ⁇ 2 and Y2O 3
  • the alumina content. is greater than 15% and less than 25%, preferably substantially equal to 20% by mass percentage on the basis of the dry matter
  • the content of the first binder is between 2.5% and 4% by weight percentage on the base of the dry matter
  • the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, in percentage by mass on the basis of the dry matter
  • the oxide content of lanthanum is greater than 0.2% and less than 0.8%, preferably substantially equal to 0.5% by weight percentage on the basis of the dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1% by weight, based on dry matter
  • the moisture content the residual is between 0.2 and 1%, preferably between 0.2% and 0.6%, as a percentage by weight on the basis of the wet powder.
  • the stabilizer is Y 2 O 3
  • the stabilizer content is between 4.5% and 5.5% by weight percentage based on the sum of ⁇ 1 ⁇ 2 and Y2O3
  • the alumina content is greater than 15% and less than 25%, preferably substantially equal to 20% by mass percentage on the basis of the dry matter
  • the content of the first binder is between 2.5% and 4% by weight percentage on the basis of based on the dry matter
  • the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, in percentage by weight on the basis of dry matter
  • the content of temporary additive is between 0.5% and 1%, in percentage by mass on the basis of the dry matter
  • the content of lanthanum oxide is greater than 0.2% and less than 0.8%, preferably substantially equal to 0.5% in weight percentage on the basis of the dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1% by weight percentage on the basis of the dry matter
  • the residual moisture content is between 0.2 and 1%, preferably between 0.2% and 0.6%, in
  • the stabilizer is Y 2 O 3
  • the stabilizer content is between 4.5% and 5.5% by weight percentage based on the sum of ⁇ 1 ⁇ 2 and Y2O 3
  • the alumina content. is greater than 15% and less than 25%, preferably substantially equal to 20% by mass percentage on the basis of the dry matter
  • the content of the first binder is between 2.5% and 4% by weight percentage on the basis of the dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1% by weight percentage on the basis of the dry matter
  • 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.
  • the stabilizer is Y 2 O 3
  • the stabilizer content is between 4.5% and 5.5% by weight percentage based on the sum of ⁇ 1 ⁇ 2 and Y2O 3
  • the alumina content. is greater than 15% and less than 25%, preferably substantially equal to 20% by mass percentage on the basis of the dry matter
  • the content of the first binder is between 2.5% and 4% by weight percentage on the base of the dry matter
  • the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, in percentage by weight on the basis of the dry matter
  • the content of impurities is less than 0.5%, preferably less than 0.1% by weight percentage on the basis of the dry matter
  • 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.
  • the stabilizer is Y 2 O 3
  • the stabilizer content is between 4.5% and 5.5% by weight percentage based on the sum of ⁇ 1 ⁇ 2 and Y 2 O 3
  • the alumina content is greater than 15% and less than 25%, preferably substantially equal to 20% by mass percentage on the basis of the dry matter
  • the content of the first binder is between 2.5% and 4% by weight percentage on the basis of the dry matter
  • the additional binder content is between 0.5% and 2%, preferably between 0.5% and 1%, in percentage by weight on the basis of the dry matter
  • the content of temporary additive is between 0.5% and 1%, in percentage by weight on the basis of the dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1. % by weight percentage on the basis of the dry matter
  • the residual moisture content is between 0.2 and 1%, preferably between 0.2% and 0.6%, as a percentage by mass on the basis of wet powder.
  • the stabilizer of zirconia is CeO 2
  • the stabilizer content is between 10% and 15% in percentages by weight based on the sum of Zr0 2 and CeO 2
  • the alumina content. is greater than 15% and less than 25%, preferably substantially equal to 20% by weight percent based on the dry matter content of the first binder is between 2.5 and 4% by weight percent on the based on the dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1% by weight percent based on the dry matter
  • the residual moisture content is between 0, 2% and 1%, preferably between 0.2% and 0.6%, in percentages by weight based on the wet powder.
  • the stabilizer of the zirconia is a mixture of Y 2 O 3 and CeC> 2, the Y 2 O 3 content is between 1% and 2% by weight percentage based on the sum of ZrC > 2, Y2O 3 and Ce0 2 , the content of CeC> 2 is between 11% and 13% by weight percentage on the basis of the sum of ZrC> 2, Y2O3 and CeC> 2, the alumina content is greater at 15% and less than 25%, preferably substantially equal to 20% by weight percentage on the basis of the dry matter, the content of the first binder is between 2.5% and 4% by weight percentage based on of the dry matter, the impurity content is less than 0.5%, preferably less than 0.1% by weight percentage 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.
  • the stabilizer of the zirconia is a mixture of Y 2 O 3 and CeC> 2
  • the Y 2 O 3 content is between 1% and 2% by weight percentage on the basis of the sum of ZrC> 2, Y2O 3 and CeC> 2
  • the content of CeC> 2 is between 11% and 13% in weight percentage on the basis of the sum of ZrC> 2, Y2O 3 and CeC> 2
  • the content alumina is greater than 15% and less than 25%, preferably substantially equal to 20% based on the dry matter
  • the additional oxide content, preferably a manganese oxide is between 0.3% and 2% in mass percentage on the basis of the dry matter
  • the content in the content first binder is between 2.5% and 4% by weight percentage on the basis of dry matter
  • the impurity content is less than 0.5%, preferably less than 0.1% by weight percentage on the base of the dry matter
  • 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
  • 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:
  • 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.
  • 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 them into a mold (especially under industrial conditions), without break.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 .
  • 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.
  • 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.
  • relative density of a granule powder is meant the ratio of the actual density divided by the absolute density, expressed as a percentage.
  • 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 the publication Polymer Handbook (4 th Edition) 1999; 2005 John Wiley & Sons.
  • the amplitude of a transition domain is typically about 5 to 10 ° C.
  • the percentiles or "percentiles" (D 10 ), 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 granules of powder have a size less than D lo and 90% of mass into granules have a size greater than D lo. 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".
  • organic constituent conventionally means a constituent containing only the elements carbon, oxygen, nitrogen and hydrogen.
  • Hf0 2 is not chemically separable from ZrC> 2 .
  • Zr0 2 conventionally refers to the total content of these two oxides.
  • HfC> 2 is not voluntarily added to the feedstock.
  • HfO 2 therefore only designates traces of hafnium oxide, this oxide always being naturally present in zirconia sources at levels generally less than 5%, or even less than 2%.
  • the zirconia and trace element content of hafnium oxide can be referred to either as "Zr0 2 + HfC> 2 " or "ZrC> 2 ", or as "zirconia content”.
  • 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). ° C, respectively) .
  • a “stabilizer” or a “temporary additive” may correspond to mixtures of several compounds each constituting a stabilizer or a temporary additive, respectively.
  • 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.
  • 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:
  • step b) 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
  • step b) optionally, sieving the granules obtained in step b);
  • step a) optionally, drying the granules obtained in step b) or c).
  • step a) the raw materials are mixed in a liquid, for example distilled water, so as to form a 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).
  • zirconia and alumina are introduced into the feedstock so that the granule powder according to the invention has a sum of zirconia and alumina contents greater than 50%, preferably greater than 60%. or even more than 70%.
  • the zirconia introduced can be stabilized with said stabilizer.
  • the stabilizer can also be added independently of the zirconia.
  • 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.
  • the zirconia is introduced in the form of stabilized zirconia particles, i.e. the stabilizer is in solid solution in the zirconia particles.
  • the zirconia is introduced in the form of particles in which the stabilized zirconia and alumina are intimately mixed.
  • 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.
  • the manufacture of granules uses binders of the APV ("PVA" in English) or PEG type, the APV type 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.
  • Tg glass transition temperature
  • 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.
  • 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 (4th Edition)", 1999; 2005 John Wiley & Sons.
  • the first binder is chosen from amorphous organic polymers and their mixtures.
  • the polymer can thus be an acrylic resin.
  • 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 DIN534 5.
  • 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.
  • 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).
  • 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.
  • the content of the first binder is determined so as 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.
  • the additional binder content is less than 3%, preferably less than 2%, more preferably less than 1% and / or greater than 0.5%.
  • the additional binder is a polymer containing no inorganic elements, in particular the elements of columns 1 and 17.
  • the content of impurities is reduced and the mechanical strength of the parts made from the granules according to the invention is increased.
  • the additional binder is chosen from amorphous organic polymers and their mixtures.
  • the additional binder is chosen from compounds based on alcohols.
  • 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%, in percent by weight on the basis of the dry matter.
  • the organic additive is chosen from dispersants or surfactants, thickeners, anti-foaming agents, preservatives or biocides, lubricants, and mixtures thereof.
  • the dispersants or surfactants may be polyacrylates or ionic or nonionic surfactants, family DOLAPIX marketed by Zschimmer-Schwarz or DARVAN or methacrylic acid marketed by RT 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 can be those of the range marketed by Zschimmer-Schwarz.
  • the granules contain an additional oxide selected from manganese oxide, ZnO, La 2 C3, SrO, BaO and mixtures thereof.
  • an additional oxide selected from manganese oxide, ZnO, La 2 C3, SrO, BaO and mixtures thereof.
  • the presence of an additional said oxide increases the amount of elongated grains contained in the parts obtained after sintering and improves the mechanical performance.
  • the additional oxide may be chosen from MnO, ⁇ 0 2 , ⁇ 2 ⁇ 3 , Mn 3 O 4, ZnO, La 2 O 3, SrO, and mixtures thereof.
  • the additional oxide may in particular be chosen from manganese oxides MnO, MnO 2 , ⁇ 2 ⁇ 3, ⁇ 3 ⁇ 4O 4 and mixtures thereof.
  • the additional oxide is selected from MnO, Mn 3, and mixtures thereof.
  • the additional oxide content in the powder is preferably greater than 0.2%, preferably greater than 0.3%, or even greater than 0.5% and / or less than 5%, or even less than 4%, or even less. at 3%, or even less than 2.5%, or even less than 2%, or even less than 1.5%, or even less than 1%, as a percentage by mass on the basis of the dry matter.
  • the additional oxide powders may also be replaced, at least partially, by precursor powders of these oxides, introduced in equivalent amounts.
  • the alumina, sinter additive and additional oxide may be introduced in the form of particles in which these elements are intimately mixed.
  • the granules do not contain additional oxide.
  • 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%.
  • Colium oxide is not considered an impurity.
  • the impurities are oxides.
  • the raw materials are chosen so that the granules contain no constituent other than zirconia, the zirconia stabilizer, the alumina, the alumina sintering additive, the additional oxide, the binders, temporary additive, residual moisture and impurities.
  • the powders of zirconia, alumina, alumina sintering additive, additional oxide, and stabilizer are introduced into the slip before the binder (s) and the temporary additive.
  • additional oxide, and stabilizer are introduced into the slip before the binder (s) and the 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 ⁇ , preferably less than 20 ⁇ , preferably less than 10 ⁇ , and / or a specific surface area of preference. less than 30 m 2 / g, preferably less than 20 m 2 / g.
  • the dry matter of the prepared slurry preferably has a median diameter of less than 1 ⁇ , preferably less than 0.5 ⁇ , more preferably less than 0.3 ⁇ 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.
  • 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).
  • this step leads to a substantially homogeneous distribution of the first binder within the granules of the powder.
  • 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.
  • the atomization leads to particles having a low relative density of between 30 and 60%, unlike processes such as rolling granulation, or “casting". in “drop”, “drip casting” in English, which classically lead to high relative densities.
  • the atomization is carried out in such a way that the granules contain residual moisture, the moisture content preferably being less than 1%, preferably less than 0.6%, and / or greater than 0.2%, in percent by weight based on the wet powder.
  • 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.
  • step c) the optional sieving is preferably carried out using sieves of less than 500 ⁇ opening, or even less than 400 ⁇ .
  • this step makes it possible to eliminate the larger granules, which may be useful for certain applications.
  • step d) the optional drying is preferably carried out at a temperature between 80 ° C and 110 ° C, for a period of preferably greater than 2 hours.
  • the process does not contain step d).
  • 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 1.3 g / cm 3 , preferably greater than 1.4 g / cm 3 , preferably greater than 1.5 g / cm 3 and / or less than 1.8. 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.
  • the feedstock may comprise a powder of granules according to the invention and one or more other powders.
  • the granule powder according to the invention represents at least minus 60%, preferably at least 75%, preferably at least 90%, preferably at least 95% of the mass of the feedstock.
  • step B) the shaping is preferably carried out by pressing, plastic injection or extrusion, preferably by pressing.
  • the pressing is selected from cold pressing and cold isostatic pressing techniques.
  • 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".
  • 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.
  • the preform can be machined, according to any technique known to those skilled in the art.
  • 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 of between 1400 ° C and 1600 ° C, preferably greater than 1450 ° C and / or less than 1550 ° C, so as to constitute a sintered part.
  • hot pressing atmospheric pressure or under pressure
  • Hot Isostatic Pressing hot isostatic pressing
  • Steps B) and D) can be carried out in a single step, for example by hot pressing.
  • step E) the sintered part can be machined, according to any technique known to those skilled in the art.
  • Step A) presents the following steps a), b) and c).
  • step a for each of the examples made, the zirconia powder, the main characteristics of which are shown in Table 1 below, is dispersed by micromilling with alumina powder, the main characteristics of which are shown in Table 2 below. -Dessous.
  • This microbrilling is carried out in a wet ball mill (zirconia beads 3 mol% Y203, diameter 0.8 mm) or attritor mill. After the micromilling, the powder has a median diameter equal to 0.3 ⁇ . The solids content of the suspension is 50% by mass.
  • 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.
  • step c) the granule powder is screened with a 400 ⁇ sieve.
  • 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 bulk 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,
  • step D said preforms have been sintered according to the following cycle:
  • 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 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 in evaluating the mass of granules powder introduced after filling a container of dimensions standard. 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:
  • 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 with a diameter of 30 mm and a thickness of 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: mounted at 500 ° C at a speed of 100 ° C / h, 2 hours at 500 ° C, mounted at 1500 ° C at a speed of 100 ° C / h, 2 hours at 1500 ° C, down to 500 ° C at a speed 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: rise at 00 ° C. a speed of 100 ° C / h, 2 hours at 500 ° C, mounted at 1500 ° C at a speed of 100 ° C / h, 2 hours at 1500 ° 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.
  • - 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 3G 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 sphericity determined, a statistical count is made on the granules observed over 500 to 1000 shots.
  • 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 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
  • 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.
  • Acrylic resin (Tg 10 ° C) 2.5 2.5
  • 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 3 makes the following observations: The granule powder of Example 1, using the same binders as the powder of Example 3 has a loose density and a lower flowability value. Its ability to fill a mold is lower than those of the powders of Examples 2 to 4. The production yield of pieces of dimensions 10 ⁇ 5 ⁇ 4 cm 3 (volume 200 cm 3 ) is much lower than that obtained with the powder of granules of Example 3, which illustrates the interest of a median diameter D50 greater than 80 ⁇ .
  • the granule powder of Example 2 using binders which do not have a glass transition temperature below 25 ° C. does not make it possible, after pressing and sintering, to obtain a sintered part having a high density and a modulus of rupture. in high 3-point flexion.
  • the granule powder of Example 4 according to the invention contains 2.5% of an acrylic resin having a glass transition temperature of -10 ° C.
  • the granule powder of Example 3 according to the invention allows the manufacture with high yields of sintered parts of large volume and having remarkable mechanical properties.
  • the bulk density of a sintered part according to the invention is not limiting.

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PCT/IB2010/055992 2009-12-24 2010-12-21 Poudre de granules de zircone et d'alumine Ceased WO2011077380A2 (fr)

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EP10814705.9A EP2516353B1 (fr) 2009-12-24 2010-12-21 Poudre de granules de zircone et d'alumine
CN201080059254.0A CN102686537B (zh) 2009-12-24 2010-12-21 含氧化锆和氧化铝粒料的粉末
US13/517,129 US20120328879A1 (en) 2009-12-24 2010-12-21 Powder comprising zirconia and alumina granules
JP2012545515A JP2013515665A (ja) 2009-12-24 2010-12-21 ジルコニアおよびアルミナの顆粒を含む粉末

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FR3039540A1 (fr) * 2015-07-30 2017-02-03 Saint-Gobain Centre De Rech Et D'Etudes Europeen Produit fritte a base d'alumine et de zircone
WO2018050925A1 (fr) * 2016-09-19 2018-03-22 Saint-Gobain Centre De Recherches Et D'etudes Europeen Produit fritte colore a base d'alumine et de zircone
FR3056208A1 (fr) * 2016-09-19 2018-03-23 Saint-Gobain Centre De Recherches Et D'etudes Europeen Produit fritte colore a base d'alumine et de zircone
WO2019016270A1 (fr) * 2017-07-20 2019-01-24 Saint-Gobain Centre De Recherches Et D'etudes Europeen Billes frittees de zircon
FR3069243A1 (fr) * 2017-07-20 2019-01-25 Saint-Gobain Centre De Recherches Et D'etudes Europeen Billes frittees de zircon
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EP2516353A2 (fr) 2012-10-31
JP2013515665A (ja) 2013-05-09
FR2954767A1 (fr) 2011-07-01
EP2516353B1 (fr) 2015-02-25
CN102686537B (zh) 2014-10-22
CN102686537A (zh) 2012-09-19
WO2011077380A3 (fr) 2011-08-18
US20120328879A1 (en) 2012-12-27
FR2954767B1 (fr) 2014-01-24

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