Doped substantially single-phase rare earth oxide-zirconia materials and methods of making the same

A method comprising:

• (a) pressing a powder into a shaped component, wherein the powder comprises (i) 0.01-20 mol. % zirconia, (ii) at least 80 mol. % yttria, and (iii) from 40 to 7000 ppm of aluminum;
• (b) sintering the shaped component at a sintering temperature of from 1200-1800° C., thereby forming a sintered component, wherein the sintered component is polycrystalline, wherein the sintered component is substantially single-phase realizing at least 95 wt. % of a solid-solution of yttria-zirconia as measured by x-ray diffraction, and wherein the sintered component realizes a density of at least 95% of theoretical.

A substantially single-phase polycrystalline material comprising 0.1 to 20 mol. % zirconia (ZrO2) and at least 80 wt. % of at least one rare earth oxide (REO), wherein the at least one rare earth oxide is selected from the group consisting of yttria, oxides of the Lanthanide series of elements, or combinations thereof, wherein the substantially single-phase polycrystalline material further comprises from 40 to 7000 ppm aluminum by weight, wherein the substantially single-phase polycrystalline material comprises at least 95 wt. % of a solid-solution of REO-zirconia as measured by x-ray diffraction.

A method comprising:

• (a) pressing a powder into a shaped component, wherein the powder comprises (i) 0.01-20 mol. % zirconia, (ii) at least 80 wt. % of at least one rare earth oxide (REO), wherein the at least one rare earth oxide is selected from the group consisting of yttria, oxides of the Lanthanide series of elements, or combinations thereof, and (iii) from 40 to 7000 ppm of aluminum;
• (b) sintering the shaped component at a sintering temperature of from 1200-1800° C., thereby forming a sintered component, wherein the sintered component is polycrystalline, wherein the sintered component is substantially single-phase realizing at least 95 wt. % of a solid-solution of REO-zirconia as measured by x-ray diffraction, and wherein the sintered component realizes a density of at least 95% of theoretical, wherein the rare earth oxide comprises at least one of ytterbium oxide, erbium oxide, and ytterbium oxide.