Al2O3-rare earth oxide-ZrO2/HfO2 materials, and methods of making and using the same
Assignee3M Innovative Properties Company
InventorAnatoly Z. Rosenflanz
Life of this patent
Estimating the term…
Abstract
Al2O3-rare earth oxide-ZrO2/HfO2 ceramics (including glasses, crystalline ceramics, and glass-ceramics) and methods of making the same. Ceramics according to the present invention can be made, formed as, or converted into glass beads, articles (e.g., plates), fibers, particles, and thin coatings. The particles and fibers are useful, for example, as thermal insulation, filler, or reinforcing material in composites (e.g., ceramic, metal, or polymeric matrix composites). The thin coatings can be useful, for example, as protective coatings in applications involving wear, as well as for thermal management. Certain ceramic particles according to the present invention can be are particularly useful as abrasive particles.
Claims82
Glass comprising Al2O3, REO, and ZrO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and ZrO2, and wherein the glass comprise at least 30 percent by weight Al2O3, at least 20 percent by weight REO, and ZrO2 in a range from 15 to 30 percent by weight, based on the total weight of the glass.
A method for making glass comprising Al2O3, REO, and ZrO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and ZrO2, and wherein the glass comprise at least 30 percent by weight Al2O3, at least 20 percent by weight REO, and ZrO2 in a range from 15 to 30 percent by weight, based on the total weight of the glass, the method comprising:
- melting sources of at least Al2O3, REO, and at ZrO2 to provide a melt;
- and
- cooling the melt to provide the glass.
A method for making ceramic comprising glass, wherein the glass comprises Al2O3, REO, and ZrO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and ZrO2, and wherein the glass comprise at least 30 percent by weight Al2O3, at least 20 percent by weight REO, and ZrO2 in a range from 15 to 30 percent by weight, based on the total weight of the glass, the method comprising:
- melting sources of at least Al2O3, REO, and ZrO2 to provide a melt;
- and
- cooling the melt to provide the ceramic.
A method for making an article comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, the method comprising:
- melting at least sources of Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- cooling the melt to provide glass beads comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, the glass having a Tg;
- heating the glass beads above the Tg such that the glass beads coalesce to form a shape;
- and
- cooling the coalesced shape to provide the article.
A method for making an article comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass, the method comprising:
- melting at least sources of Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- cooling the melt to provide glass beads comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass, the glass having a Tg;
- heating the glass beads above the Tg such that the glass beads coalesce to form a shape;
- and
- cooling the coalesced shape to provide the article.
A method for making an article comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, the method comprising:
- melting at least sources of Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- cooling the melt to provide glass beads comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, the glass having a Tg;
- heating the glass beads above the Tg such that the glass beads coalesce to form a shape;
- and
- cooling the coalesced shape to provide the article.
A method for making an article comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, the method comprising:
- melting at least sources of Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- cooling the melt to provide glass beads comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, the glass having a Tg;
- converting the glass beads to provide glass powder;
- heating the glass powder above the Tg such that the glass powder coalesces to form a shape;
- and
- cooling the coalesced shape to provide the article.
A method for making an article comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass, the method comprising:
- melting at least sources of Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- cooling the melt to provide glass beads comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass, the glass having a Tg;
- converting the glass beads to provide glass powder;
- heating the glass powder above the Tg such that the glass powder coalesces to form a shape;
- and
- cooling the coalesced shape to provide the article.
A method for making an article comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, the method comprising:
- melting at least sources of Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- cooling the melt to provide glass beads comprising glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, the glass having a Tg;
- converting the glass beads to provide glass powder;
- heating the glass powder above the Tg such that the glass powder coalesces to form a shape;
- and
- cooling the coalesced shape to provide the article.
Ceramic comprising at least 75 percent by volume glass, the glass comprising Al2O3, REO, and ZrO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and ZrO2, and wherein the glass comprise at least 30 percent by weight Al2O3, at least 20 percent by weight REO, and ZrO2 in a range from 15 to 30 percent by weight, based on the total weight of the glass.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass-ceramic.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass-ceramic.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass-ceramic.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass-ceramic, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass to provide the glass-ceramic.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass-ceramic, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass to provide the glass-ceramic.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass-ceramic, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass to provide the glass-ceramic.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass-ceramic, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass to provide the glass-ceramic.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass-ceramic, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass to provide the glass-ceramic.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass-ceramic, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass to provide the glass-ceramic.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2 to provide the glass-ceramic, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features.
A method for making glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2 to provide the glass-ceramic wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features.
A method for making a glass-ceramic article, the method comprising:
- converting glass to provide glass powder, the glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, the glass having a Tg;
- heating the glass powder above the Tg such that the glass powder coalesces to form a shape;
- cooling the coalesced shape to provide a glass article;
- and
- heat-treating the glass article to provide a glass-ceramic article.
A method for making a glass-ceramic article, the method comprising:
- converting glass to provide glass powder, the glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass, the glass having a Tg;
- heating the glass powder above the Tg such that the glass powder coalesces to form a shape;
- cooling the coalesced shape to provide a glass article;
- and
- heat-treating the glass article to provide a glass-ceramic article.
A method for making a glass-ceramic article, the method comprising:
- converting glass to provide glass powder, the glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, the glass having a Tg;
- heating the glass powder above the Tg such that the glass powder coalesces to form a shape;
- cooling the coalesced shape to provide a glass article;
- and
- heat-treating the glass article to provide a glass-ceramic article.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 200 nanometers and (b) has a density of at least 90% of theoretical density.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites, wherein none of the crystallites are greater than 200 nanometers in size and (b) has a density of at least 90% of theoretical density.
Glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites, wherein at least a portion of the crystallites are not greater than 150 nanometers in size and (b) has a density of at least 90% of theoretical density.
Ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 200 nanometers and (b) has a density of at least 90% of theoretical density.
Ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites, wherein none of the crystallites are greater than 200 nanometers in size and (b) has a density of at least 90% of theoretical density.
Ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites, wherein at least a portion of the crystallites are not greater than 150 nanometers in size and (b) has a density of a 90% of theoretical density.
Ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size not greater than 200 nanometer, in size and (b) has a density of at least 90% of theoretical density.
Abrasive particle comprising a glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass-ceramic.
Abrasive particle comprising a glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass-ceramic.
Abrasive particle comprising a glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass-ceramic collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass-ceramic.
A method for making abrasive particles, the method comprising:
- heat-treating glass particles comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass particles, to provide glass-ceramic abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating particles comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass particles, to provide glass-ceramic abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, to provide glass-ceramic;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, to provide glass-ceramic;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating glass particles comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass particles, to provide glass-ceramic abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating particles comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2, and less than 15 percent by weight B2O3, based on the total weight of the glass particles, to provide glass-ceramic abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass, to provide glass-ceramic;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 15 percent by weight SiO2 and less than 15 percent by weight B2O3, based on the total weight of the glass, to provide glass-ceramic;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating glass particles comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass particles, to provide glass-ceramic abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating particles comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass particles, to provide glass-ceramic abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, to provide glass-ceramic;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 70 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, and less than 30 percent by weight collectively SiO2, B2O3, and P2O5, based on the total weight of the glass, to provide glass-ceramic;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating glass particles comprising Al2O3, REO, and at least one of ZrO2 or HfO2 to provide glass-ceramic abrasive particles, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features.
A method for making abrasive particles, the method comprising:
- heat-treating particles comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2 to provide glass-ceramic abrasive particles, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features.
A method for making abrasive particles, the method comprising:
- heat-treating glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2 to provide glass-ceramic, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features;
- and
- converting the glass-ceramic to provide abrasive particles.
A method for making abrasive particles, the method comprising:
- heat-treating ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2 to provide glass-ceramic, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 1 micrometer, and (b) is free of eutectic microstructure features;
- and
- converting the glass-ceramic to provide abrasive particles.
Abrasive particle comprising a glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 200 nanometers and (b) a density of at least 90% of theoretical density.
Abrasive particle comprising a glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2 wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites, wherein none of the crystallites are greater than 200 nanometers in size and (b) a density of at least 90% of theoretical density.
Abrasive particle comprising a glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the glass-ceramic (a) exhibits a microstructure comprising crystallites, wherein at least a portion of the crystallites are not greater than 150 nanometers in size and (b) a density of at least 90% of theoretical density.
Abrasive particle comprising ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size of less than 200 nanometers and (b) a density of at least 90% of theoretical density.
Abrasive particle comprising ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites, wherein none of the crystallites are greater than 200 nanometers in size and (b) a density of at least 90% of theoretical density.
Abrasive particle comprising ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites, wherein at least a portion of the crystallites are not greater than 150 nanometers in size and (b) a density of at least 90% of theoretical density.
Abrasive particle comprising ceramic comprising at least 75 percent by volume glass-ceramic, the glass-ceramic comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein the ceramic (a) exhibits a microstructure comprising crystallites having an average crystallite size not greater than 200 nanometer, in size and (b) a density of at least 90% of theoretical density.
A plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles comprise alpha Al2O3, crystalline ZrO2, and a first complex Al2O3.REO, wherein at least one of the alpha Al2O3, the crystalline ZrO2, or the first complex Al2O3-REO has an average crystal size not greater than 150 nanometers, and wherein the abrasive particles of the portion have a density of at least 90 percent of theoretical density.
An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of the abrasive particles comprise alpha Al2O3, crystalline ZrO2, and a first complex Al2O3.REO, wherein at least one of the alpha Al2O3, the crystalline ZrO2, or the first complex Al2O3.REO has an average crystal size not greater than 150 nanometers, and wherein the abrasive particles of the portion have a density of at least 90 percent of theoretical density.
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 comprise alpha Al2O3, crystalline ZrO2, and a first complex Al2O3.REO, wherein at least one of the alpha Al2O3, the crystalline ZrO2, or the first complex Al2O3.REO has an average crystal size not greater than 150 nanometers, and wherein the abrasive particles of the portion have a density of at least 90 percent of theoretical density;
- contacting at least one of the abrasive particles comprising the alpha Al2O3, the crystalline ZrO2, and the first complex Al2O3.REO with a surface of a workpiece;
- and
- moving at least one of the contacted abrasive particles comprising the alpha Al2O3, the crystalline ZrO2, and the first complex Al2O3.REO or the contacted surface to abrade at least a portion of the surface with the contacted abrasive particle comprising the alpha Al2O3, the crystalline ZrO2, and the first complex Al2O3.REO.
A plurality of abrasive particles having a specified nominal grade, wherein at least a portion of the plurality of abrasive particles comprise a first complex Al2O3.REO, a second, different complex Al2O3.REO, and crystalline ZrO2, wherein for at least one of the first complex Al2O3.REO, the second complex Al2O3.REO, or the crystalline ZrO2, wherein at least 90 percent by number of crystal sizes thereof are not greater than 200 nanometers, and wherein the abrasive particles of the portion have a density of at least 90 percent of theoretical density.
An abrasive article comprising a binder and a plurality of abrasive particles, wherein at least a portion of the abrasive particles comprise a first complex Al2O3.REO, a second, different complex Al2O3.REO, and crystalline ZrO2, wherein in such portion, for at least one of the first complex Al2O3.REO, the second complex Al2O3.REO, or the crystalline ZrO2, wherein at least 90 percent by number of crystal sizes thereof are not greater than 200 nanometers, and wherein the abrasive particles of the portion have a density of at least 90 percent of theoretical density.
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 comprise a first complex Al2O3.REO, a second, different complex Al2O3.REO, and crystalline ZrO2, wherein in such portion, for at least one of the first complex Al2O3.REO, the second complex Al2O3.REO, or the crystalline ZrO2, wherein at least 90 percent by number of crystal sizes thereof are not greater than 200 nanometers, and wherein the abrasive particles of the portion have a density of at least 90 percent of theoretical density;
- contacting at least one of the abrasive particles comprising the first complex Al2O3.REO, the second complex Al2O3.REO, and the crystalline ZrO2 with a surface of a workpiece;
- and
- moving at least one of the contacted abrasive particles comprising the first complex Al2O3.REO, the second complex Al2O3.REO, and the crystalline ZrO2 or the contacted surface to abrade at least a portion of the surface with the contacted abrasive particle comprising the first complex Al2O3.REO, the second complex Al2O3.REO, and the crystalline ZrO2.
Glass comprising Al3O2, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, wherein the glass has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 5 mm.
A method for making glass comprising Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, the method comprising:
- melting sources of at least Al2O2, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- and
- cooling the melt to provide the glass, wherein the glass has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 5 mm.
A method for making ceramic comprising glass, wherein the glass comprises Al2O3, REO, and at least one of ZrO2 or HfO2, wherein at least 85 percent by weight of the glass collectively comprises the Al2O3, REO, and at least one of ZrO2 or HfO2, based on the total weight of the glass, wherein the glass has x, y, and z dimensions each perpendicular to each other, and wherein each of the x, y, and z dimensions is at least 5 mm the method comprising:
- melting sources of at least Al2O3, REO, and at least one of ZrO2 or HfO2 to provide a melt;
- and
- cooling the melt to provide the ceramic.
Dependencies are inferred from the claim text.