Alumina-zirconia, and methods of making and using the same

A method for making glass-ceramic, the method comprising:

• heat-treating amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, ZrO2, and a metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 forms a distinct crystalline phase during the heat-treating, wherein the amorphous material comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the amorphous material, wherein the amorphous material contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material, wherein the amorphous material has x, y, and z dimensions each perpendicular to each other, wherein each of the x, y, and z dimensions is at least 25 micrometers, wherein the glass-ceramic comprises Al2O3, ZrO2, and a metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 is present as at least one distinct crystalline phase, wherein the glass-ceramic comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the glass-ceramic, wherein the glass-ceramic contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic, wherein the glass-ceramic has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers.

A method for making abrasive particles, the method comprising:

• providing a plurality of particles having a specified nominal grade, wherein at least a portion of the particles is a plurality of particles comprising an amorphous material, wherein the amorphous material comprises Al2O3, ZrO2, and a metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 forms a distinct crystalline phase during heat-treating, wherein the amorphous material comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the amorphous material, wherein the amorphous material contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, V2O5, based on the total weight of the amorphous material;
• and
• heat-treating the particles comprising amorphous material to provide abrasive particles comprising a glass-ceramic such that at least a portion of the amorphous material is converted to a glass-ceramic and such that a plurality of abrasive particles having a specified nominal grade is provided, wherein at least a portion of the abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic, wherein the glass-ceramic comprises the Al2O3, the ZrO2, and the metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 is present as at least one distinct crystalline phase, wherein the glass-ceramic of each particle of the portion collectively comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the glass-ceramic of each particle of the portion, wherein the glass-ceramic of each particle of the portion contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic of each particle of the portion.

A method for making abrasive particles, the method comprising:

• heat-treating particles comprising an amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, ZrO2, and a metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 forms a distinct crystalline phase during the heat-treating, wherein the amorphous material comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the amorphous material, wherein the amorphous material contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material, wherein the glass-ceramic comprises the Al2O3, the ZrO2, and the metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 is present as at least one distinct crystalline phase, wherein the glass-ceramic of each particle of the portion collectively comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the glass-ceramic of each particle of the portion, wherein the glass-ceramic of each particle of the portion contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic of each particle of the portion;
• and
• grading the abrasive particles comprising the glass-ceramic to provide a plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic.

A method for making abrasive particles, the method comprising:

• heat-treating ceramic comprising an amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, ZrO2, and a metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 forms a distinct crystalline phase during the heat-treating, wherein the amorphous material comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the amorphous material, wherein the amorphous material contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material, wherein the glass-ceramic comprises the Al2O3, the ZrO2, and the metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 is present as at least one distinct crystalline phase, wherein the glass-ceramic comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the glass-ceramic, wherein the glass-ceramic contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic;
• crushing the glass-ceramic to provide abrasive particles comprising the glass-ceramic;
• and
• grading the abrasive particles comprising the glass-ceramic to provide a plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic.

A method for making abrasive particles, the method comprising:

• heat-treating ceramic comprising an amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the amorphous material, and Y2O3, wherein at least a portion of the Y2O3 forms a distinct crystalline phase during the heat-treating, wherein the glass-ceramic comprises the Al2O3, the at least 15 percent by weight ZrO2, based on the total weight of the amorphous material, and the Y2O3, wherein at least a portion of the Y2O3 is present as at least one distinct crystalline phase;
• crushing the glass-ceramic to provide abrasive particles comprising the glass-ceramic;
• and
• grading the abrasive particles comprising the glass-ceramic to provide a plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic.

A method for making abrasive particles, the method comprising:

• heat-treating ceramic comprising an amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the amorphous material, and REO, wherein at least a portion of the REO forms a distinct crystalline phase during the heat-treating, wherein the glass-ceramic comprises the Al2O3, the at least 15 percent by weight ZrO2, based on the total weight of the amorphous material, and the REO, wherein at least a portion of the REO is present as at least one distinct crystalline phase;
• crushing the glass-ceramic to provide abrasive particles comprising the glass-ceramic;
• and
• grading the abrasive particles comprising the glass-ceramic to provide a plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic.

A method for making abrasive particles, the method comprising:

• providing a plurality of particles having a specified nominal grade, wherein at least a portion of the particles is a plurality of particles comprising an amorphous material, wherein the amorphous material comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the amorphous material of each particle of the portion, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material of each particle of the portion, wherein the amorphous material of at least some of the portion of particles has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers;
• and
• heat-treating the particles comprising the amorphous material to provide abrasive particles comprising a glass-ceramic such that at least a portion of the amorphous material is converted to a glass-ceramic and such that a plurality of abrasive particles having a specified nominal grade is provided, wherein at least a portion of the abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic, wherein the glass-ceramic comprises the Al2O3, the at least 15 percent by weight ZrO2, based on the total weight of the glass-ceramic of each particle of the portion, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, weight of the glass-ceramic of each particle of the portion, wherein the glass-ceramic of at least some of the portion of abrasive particles has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers.

A method for making abrasive particles, the method comprising:

• heat-treating particles comprising an amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the amorphous material of each particle comprising the amorphous material, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material of each particle comprising the amorphous material, wherein the amorphous material of at least some of the particles has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers, wherein the glass-ceramic comprises the Al2O3, the at least 15 percent by weight ZrO2, based on the total weight of the glass-ceramic of each particle comprising the glass-ceramic, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material of each particle of the portion, wherein the glass-ceramic of at least some of the particles has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers;
• and
• grading the abrasive particles comprising the glass-ceramic to provide a plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic.

A method for making abrasive particles, the method comprising:

• heat-treating ceramic comprising an amorphous material such that at least a portion of the amorphous material is converted to a glass-ceramic, wherein the amorphous material comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the amorphous material, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the amorphous material, wherein the amorphous material has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers, wherein the glass-ceramic comprises the Al2O3, the at least 15 percent by weight ZrO2, based on the total weight of the glass-ceramic, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic, wherein the glass-ceramic has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 25 micrometers;
• crushing the glass-ceramic to provide abrasive particles comprising the glass-ceramic;
• and
• grading the abrasive particles comprising the glass-ceramic to provide a plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles is a plurality of the abrasive particles comprising the glass-ceramic.

A method of abrading a surface, the method comprising:

• providing an abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of the abrasive particles is a plurality of abrasive particles comprising a glass-ceramic, wherein the glass-ceramic comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the glass-ceramic of each particle of the portion, and Y2O3, wherein at least a portion of the Y2O3 is present as at least one distinct crystalline phase;
• contacting at least one of the abrasive particles comprising the glass-ceramic with a surface of a workpiece;
• and
• moving at least one of the contacted abrasive particles comprising the glass-ceramic or the contacted surface to abrade at least a portion of the surface with the contacted abrasive particles comprising the glass-ceramic.

A method of abrading a surface, the method comprising:

• providing an abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of the abrasive particles is a plurality of abrasive particles comprising a glass-ceramic, wherein the glass-ceramic comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the glass-ceramic of each particle of the portion, and REO, wherein at least a portion of the REO is present as at least one distinct crystalline phase;
• contacting at least one of the abrasive particles comprising the glass-ceramic with a surface of a workpiece;
• and
• moving at least one of the contacted abrasive particles comprising the glass-ceramic or the contacted surface to abrade at least a portion of the surface with the contacted abrasive particles comprising the glass-ceramic.

A method of abrading a surface, the method comprising:

• providing an abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of the abrasive particles is a plurality of abrasive particles comprising a glass-ceramic, wherein the glass-ceramic comprises Al2O3, at least 15 percent by weight ZrO2, based on the total weight of the glass-ceramic of each particle comprising the glass-ceramic of each particle of the portion, and contains not more than 10 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic of each particle comprising the glass-ceramic of each particle of the portion, wherein the glass-ceramic of at least some of the particles has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions are at least 25 micrometers;
• contacting at least one of the abrasive particles comprising the glass-ceramic with a surface of a workpiece;
• and
• moving at least one of the contacted abrasive particles comprising the glass-ceramic or the contacted surface to abrade at least a portion of the surface with the contacted abrasive particles comprising the glass-ceramic.

A method of abrading a surface, the method comprising:

• providing an abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of the abrasive particles is a plurality of abrasive particles comprising a glass-ceramic, wherein the glass-ceramic comprises Al2O3, ZrO2, and a metal oxide other than Al2O3 or ZrO2, wherein at least a portion of the metal oxide other than Al2O3 or ZrO2 is present as at least one distinct crystalline phase, wherein the glass-ceramic of each particle of the portion collectively comprises at least 50 percent by weight collectively of the Al2O3 and the ZrO2, based on the total weight of the glass-ceramic, wherein the glass-ceramic of each particle of the portion contains not more than 20 percent by weight collectively As2O3, B2O3, GeO2, P2O5, SiO2, TeO2, and V2O5, based on the total weight of the glass-ceramic, wherein the glass-ceramic of at least some of the portion of abrasive particles has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions are at least 25 micrometers;
• contacting at least one of the abrasive particles comprising the glass-ceramic with a surface of a workpiece;
• and
• moving at least one of the contacted abrasive particles comprising the glass-ceramic or the contacted surface to abrade at least a portion of the surface with the contacted abrasive particles comprising the glass-ceramic.