Non-fused aluminum oxide-based abrasive mineral
AssigneeMinnesota Mining and Manufacturing Company
InventorsMelvin A. Leitheiser, Harold G. Sowman
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Abstract
The invention relates to synthetic, non-fused, aluminum oxide-based abrasive mineral having a microcrystalline structure of randomly oriented crystallites comprising a dominant continuous phase of .alpha.-alumina and a secondary phase, to a method of making the same employing chemical ceramic technology, and to abrasive articles made with the abrasive mineral.
Claims22
Method of making dense, synthetic, aluminum oxide-based granular abrasive mineral having a substantially homogeneous microcrystalline structure of randomly oriented crystallites comprising modifying component in a dominant continuous alumina phase comprising alpha-alumina, said
- (a) gelling a substantially calcium ion- and alkali metal ion-free homogeneous mixture of an alumina source compound and at least one precursor of at least one modifying component selected from
- (i) zirconia, hafnia, or a combination of zirconia and hafnia, and
- (ii) a spinel derived from alumina and at least one oxide of a metal selected from cobalt, nickel, zinc, or magnesium,
- said precursor being present in an amount to provide in said mineral a dominant continuous alumina phase comprising alpha-alumina and a modifying component content, on a volume percent of fired solids of the mineral, of either (a) at least 10% of said (i), (b), at least 1% of said (ii), or (c) at least 1% of said (ii) and 1-45% of said (i),
- (b) drying the gelled mixture to form chunky pieces of solid material, and
- (c) firing said solid material in a non-reducing atmosphere to a temperature of at least 1250.degree. C., but not above the melting point of said mineral, to remove fugitive materials and to nondestructively convert said solid material to a dense aluminum oxide-based mineral.
Substantially calcium ion- and alkali metal ion-free, dense, non-fused synthetic, aluminum oxide-based granular abrasive mineral, having a substantially homogeneous microcrystalline structure comprising a secondary phase of randomly oriented crystallites comprising modifying component in a dominant continuous alumina phase comprising alpha-alumina, said modifying component, on a volume percent of fired solids of the mineral, being selected from:
- (i) at least 10% of zirconia, hafnia, or a combination of zirconia and hafnia,
- (ii) at least 1% of a spinel derived from alumina and at least one oxide of a metal selected from cobalt, nickel, zinc, or magnesium, or
- (iii) 1-45% of said zirconia, hafnia, or the combination of zirconia and hafnia and at least 1% of said spinel.
Dependencies are inferred from the claim text.