Patent Application
20230183137
Zirconia-based sintered products are commonly used notably for the manufacture of decorative articles such as jewelry, watches, bracelets, brooches, tie pins, necklaces, handbags, telephones, furniture, or household utensils, and also for structural parts.
To obtain a color, an oxide pigment may be added to the zirconia. For example, US 2007/270304 describes a zirconia product incorporating an oxide pigment having a spinel structure based on cobalt, zinc, iron and aluminum. JP 2005-289721, EP 0 678 490 and EP 2 448 881 provide further examples of oxide pigments.
Colored zirconia products must have good impact strength and also good resistance to hydrothermal aging, i.e. good resistance to degradation in a humid environment and at a temperature greater than or equal to 50° C., such conditions notably being encountered during the step of machining or polishing of the colored zirconia product. The resistance to hydrothermal aging is an important property because it enables the production of colored zirconia products with high toughness after machining or polishing.
Sintered products of colored yttriated zirconia typically including a molar amount of Y2O3 equal to 3% have good resistance to hydrothermal aging but low toughness. Sintered products of colored yttriated zirconia typically including a molar amount of Y2O3 equal to 2% have good toughness, but low resistance to hydrothermal aging.
There is thus a need for a sintered colored zirconia product which has a better compromise between toughness and resistance to hydrothermal aging.
One aim of the invention is to at least partially meet this need.
According to the invention, this aim is achieved by means of a particle mixture having the following chemical composition, as mass percentages on the basis of the oxides:
ZrO2+HfO2+Y2O3+CeO2: the remainder to 100%;
0%≤Al2O2≤1.5%;
oxides other than ZrO2, HfO2, Y2O3, CeO2 and Al2O3, or “other oxides”: between 0.5% and 12%;
the contents of Y2O3 and CeO2, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2, being such that 1.8% Y2O3≤3% and 0.1% CeO2≤0.9%, the particle mixture including between 0.5% and 10% of an oxide pigment, as a mass percentage on the basis of the oxides,
the content of oxides which are “other oxides” and which are not included in the oxide pigment being less than 2%, as a mass percentage on the basis of the oxides,
in which particle mixture the particles of the oxide pigment include, preferably consist, for more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99% of their mass, of a material chosen from:
oxide(s) of perovskite structure, optionally replaced, totally or partially, with an equivalent amount of precursor(s) of these oxides,
oxides of spinel structure, optionally replaced, totally or partially, with an equivalent amount of precursor(s) of these oxides,
oxides of hematite structure E2O3, the element E being chosen from the group GE(1) formed by iron, chromium and mixtures of iron and chromium,
oxides of rutile structure FO2, the element F being chosen from the group GF(1) formed by mixtures of tin and vanadium, mixtures of titanium and chromium and niobium, mixtures of titanium and chromium and tungsten, mixtures of titanium and niobium and manganese, mixtures of tin and chromium, mixtures of chromium and titanium and antimony, mixtures of nickel and antimony and titanium, and mixtures thereof,
and mixtures thereof.
As will be seen in greater detail later in the description, the inventors have discovered that a low CeO2 content unexpectedly allows the manufacture, with a particle mixture according to the invention, of a sintered colored zirconia product which has an excellent compromise between toughness and resistance to hydrothermal aging, irrespective of the Y2O3 content, provided that it remains between 1.8% and 3%.
Among the “other oxides”, a distinction is made between other oxides that are included in the oxide pigment and other oxides that are not included in the oxide pigment.
The other oxides that are not included in the oxide pigment preferably represent less than 1.5%, preferably less than 1%, more preferably less than 0.5%, preferably less than 0.2%, preferably less than 0.1%, as a mass percentage on the basis of the oxides. The other oxides that are not included in the oxide pigment are preferably impurities.
In the particle mixture, ZrO2 and/or HfO2 are preferably provided, for more than 90%, more than 95%, preferably 100%, as a mass percentage on the basis of the oxides, in the form of zirconia and/or hafnia, preferably partially or fully stabilized with Y2O3 and/or CeO2. ZrO2 and/or HfO2 may also be provided, totally or partially, in the form of a zirconia and/or hafnia precursor, a zirconia or hafnia precursor being a combination of one or more constituents, which, during sintering in a process according to the invention, is converted into zirconia or hafnia, respectively.
In the particle mixture, Y2O3 and/or CeO2 may be provided, for more than 90%, more than 95%, preferably 100%, as a mass percentage on the basis of the oxides, in the form of yttria and/or ceria. Y2O3 and/or CeO2 may also be provided, totally or partially, in the form of an yttria and/or ceria precursor, an yttria and/or ceria precursor being a combination of one or more constituents, which, during sintering in a process according to the invention, is converted into yttria and/or ceria, respectively.
The particle mixture according to the invention may also include one or more of the following optional and preferred features:
The invention also relates to an intermediate product consisting of particles bound by means of an organic binder, said particles forming together, after debinding of the intermediate product, a particle mixture according to the invention.
Needless to say, the debinding must be performed under conditions which do not substantially modify the features (composition, dimensions, specific surface area, etc.) of the particles of the particle mixture. In particular, the debinding may be performed at a sufficiently low temperature to not modify said particles. The debinding may also be, for example, solvent debinding.
The invention also relates to a process for manufacturing a sintered colored zirconia product, said process including the following steps:
a) preparing a starting feedstock including a particle mixture according to the invention, optionally in the form of an intermediate product according to the invention, and optionally one or more organic constituents;
b) forming said starting feedstock so as to obtain a preform;
c) sintering said preform at a temperature greater than or equal to 1300° C., so as to obtain a sintered colored zirconia product.
The invention also relates to a sintered colored zirconia product having a chemical analysis such that, as mass percentages on the basis of the oxides:
ZrO2+HfO2+Y2O3+CeO2: the remainder to 100%;
0%≤Al2O3≤1.5%;
oxides other than ZrO2, HfO2, Y2O3, CeO2 and Al2O3, or “other oxides”: between 0.5% and 12%;
the contents of Y2O3 and CeO2, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2, being such that 1.8%≤Y2O3≤3% and 0.1% CeO2≤0.9%, between 0.5% and 10% of the oxide phases being in an oxide pigment, as mass percentages on the basis of the oxides,
the content of oxides which are “other oxides” and which are not included in the oxide pigment, preferably impurities, being less than 2%, as a mass percentage on the basis of the oxides,
in which sintered product the oxide pigment includes, preferably consists for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of a material chosen from:
A sintered colored zirconia product according to the invention may also include one or more of the following optional and preferred features:
The invention also relates to a sintered colored zirconia product obtained or capable of being obtained by means of a manufacturing process according to the invention.
The invention also relates to a device chosen from the group consisting of an item of jewelry, a watch, a bracelet, a necklace, a ring, a brooch, a tie pin, a handbag, a telephone, an item of furniture, a household utensil, a handle, a switch, a button, a plating, a visible part of a consumer goods equipment, a spectacle frame part, a tableware item, a welding pin and a frame, said device including a sintered product according to the invention or manufactured according to a process according to the invention.
Definitions
T=100*(APIG)/(APIG+Asecondary phase) (1)
It is considered that a total impurity content of less than 2% does not substantially alter the results obtained.
[HM(−111)+HM(111)]/[HM(−111)+HM(111)+HS(111)].
AD=100/[(x/3.987)+(100−x)/ADz] (1)
The particle mixture according to the invention is noteworthy as regards its composition.
Composition
A particle mixture according to the invention preferably consists of oxides for more than 98%, preferably for more than 99%, preferably for more than 99.5%, preferably for more than 99.9%, of its mass. Preferably, the particle mixture according to the invention consists substantially entirely of oxides.
Preferably, more than 90%, preferably more than 95%, preferably 100% of the zirconium is non-pigment zirconium, as a mass percentage.
Preferably, more than 90%, preferably more than 95%, preferably 100% of the zirconium is in the form of zirconia, as a mass percentage.
Y2O3 and CeO2 are known stabilizers of zirconia. In the particle mixture according to the invention, they may or may not stabilize the zirconia. According to the invention, however, the particle mixture must lead to a sintered product in which the zirconia is at least partially stabilized, preferably fully stabilized with these oxides.
In the particle mixture, the zirconia is preferably at least partially stabilized with Y2O3. Preferably then, a ceria CeO2 powder is used as the CeO2 source.
In one embodiment,
more than 90%, preferably more than 95%, preferably 100% of the cerium is in the form of ceria and/or a precursor of ceria, preferably in the form of ceria, as a mass percentage, and
more than 90%, preferably more than 95%, preferably 100% of the yttrium is in the form of yttria and/or an yttria precursor, as a mass percentage.
The ceria and/or ceria precursor and/or the yttria and/or yttria precursor may, partially or totally, be incorporated into the particle mixture in the form of a powder, i.e. in a form separate from the zirconia, such that, after sintering, the zirconia is at least partially stabilized. In this embodiment, the median size of the powder of yttria and/or the yttria and ceria precursor and/or of the ceria precursor is preferably less than 1 μm, preferably less than 0.5 μm, more preferably less than 0.3 μm. The stabilization efficiency of the zirconia during sintering is thereby advantageously improved.
In one embodiment, the particle mixture includes particles in which stabilized or non-stabilized zirconia and yttria and/or ceria are intimately mixed. Such an intimate mixture may be obtained, for example, by co-precipitation, thermal hydrolysis or atomization, and possibly consolidated by heat treatment. In a said mixture, the yttria and/or ceria may be replaced with an equivalent amount of precursor(s).
Preferably, the particle mixture does not include any yttria precursor.
Preferably, the particle mixture does not include any ceria precursor.
Preferably, the particle mixture does not include any zirconia precursor, or any hafnia precursor.
Preferably, substantially all of the cerium is present in the form of ceria CeO2. Thus, the particle mixture has substantially no cerium in the form of Ce2O3. Advantageously, the development of the desired colors is thereby improved.
Preferably, the monoclinic zirconia fraction in the particle mixture is less than 50%, preferably less than 40%, preferably less than 30%, preferably less than 20%.
Preferably, the Y2O3 content is greater than or equal to 1.9%, preferably greater than or equal to 2% and/or preferably less than or equal to 2.5%, preferably less than or equal to 2.4%, preferably less than or equal to 2.2%, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2.
Preferably, the Y2O3 content outside the oxide pigment is greater than or equal to 1.9%, preferably greater than or equal to 2% and/or preferably less than or equal to 2.5%, preferably less than or equal to 2.4%, preferably less than or equal to 2.2%, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2.
Preferably, the CeO2 content is greater than or equal to 0.2%, preferably greater than or equal to 0.3%, preferably greater than or equal to 0.4% and/or preferably less than 0.8%, preferably less than 0.7%, preferably less than 0.6%, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2.
Preferably, the CeO2 content outside the oxide pigment is greater than or equal to 0.2%, preferably greater than or equal to 0.3%, preferably greater than or equal to 0.4% and/or preferably less than 0.8%, preferably less than 0.7%, preferably less than 0.6%, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2.
Preferably, the Y2O3 content is greater than or equal to 1.9%, preferably greater than or equal to 2% and/or preferably less than or equal to 2.5%, preferably less than or equal to 2.4%, preferably less than or equal to 2.2%, and the CeO2 content is greater than or equal to 0.2%, preferably greater than or equal to 0.3%, preferably greater than or equal to 0.4% and less than 0.8%, preferably less than 0.7%, preferably less than 0.6%, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2. Advantageously, the sintered product obtained from the particle mixture has an excellent compromise between toughness and resistance to hydrothermal aging.
Preferably, the Y2O3 content outside the oxide pigment is greater than or equal to 1.9%, preferably greater than or equal to 2% and/or preferably less than or equal to 2.5%, preferably less than or equal to 2.4%, preferably less than or equal to 2.2%, and the CeO2 content outside the oxide pigment is greater than or equal to 0.2%, preferably greater than or equal to 0.3%, preferably greater than or equal to 0.4% and less than 0.8%, preferably less than 0.7%, preferably less than 0.6%, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2.
Preferably, the particle mixture according to the invention has an average size of stabilized zirconia crystallites of greater than 10 nm, preferably greater than 20 nm and less than 60 nm. The average crystallite size is conventionally determined by X-ray diffraction according to the method described later in the present description.
In a preferred embodiment, the Al2O3 content is greater than or equal to 0.2%, preferably greater than or equal to 0.25% and preferably less than or equal to 1.2%, preferably less than or equal to 1%, preferably less than or equal to 0.8%, as mass percentages on the basis of the oxides. Advantageously, the sinterability of the particle mixture is thereby improved.
In a preferred embodiment, the Al2O3 content outside the oxide pigment is greater than or equal to 0.2%, preferably greater than or equal to 0.25% and preferably less than or equal to 1.2%, preferably less than or equal to 1%, preferably less than or equal to 0.8%, as mass percentages on the basis of the oxides.
However, tests have shown that the presence of Al2O3 is not essential. In one embodiment, the Al2O3 content may in particular be less than 0.1%, less than 0.005%, less than 0.003%, less than 0.002%, or substantially zero, as mass percentages on the basis of the oxides. Preferably, more than 90%, more than 95%, preferably 100% of the Al2O3 is in the form of alumina, as a mass percentage on the basis of Al2O3.
The alumina may be replaced, partially or totally, with an alumina precursor. Preferably, Al2O3 is substantially present in the form of corundum.
According to the invention, the particle mixture also includes an oxide pigment.
The particles of said oxide pigment include, preferably consist for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of their mass, of a material chosen from:
The particles of said oxide pigment of a particle mixture according to the invention may be obtained by various processes, such as melting, solid phase synthesis, pyrolysis of salts, precipitation of hydroxides and calcination thereof, or sol-gel synthesis.
Preferably, the constituents of said oxide of perovskite, spinel, hematite or rutile structure represent more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99%, or even substantially 100% by mass of said material. Preferably, the remainder to 100% of the constituents of said oxide of perovskite, spinel, hematite or rutile structure consists of impurities.
The inventors have found that if the particle mixture includes more than 10% by mass of said oxide pigment, the mechanical properties, notably the toughness and bending stress, of the sintered products are degraded.
A minimum content of 0.5% of said oxide pigment in the particle mixture is considered essential to obtain a sintered product having a good appearance with well developed and homogeneous colors.
The oxide pigment used preferably has a median size of less than 5 μm, preferably less than 3 μm, preferably less than 2 μm, preferably less than 1 μm. Advantageously, the efficiency of said oxide pigment in the sintered product is thereby improved.
Preferably, the content of oxide pigment is greater than 2%, preferably greater than 3% and/or less than 9%, preferably less than 8%, preferably less than 7%, as a mass percentage on the basis of the oxides in the particle mixture.
Preferably, the particle mixture does not contain any oxide pigment containing the element zirconium.
Preferably, the particle mixture does not contain any oxide pigment containing the element cerium.
Preferably, the particle mixture does not contain any oxide pigment containing the element yttrium.
Preferably, the particle mixture does not contain any oxide pigment containing the element aluminum.
In a first embodiment, the oxide pigment consists for more than 95%, preferably more than 97%, preferably more than 98%, preferably more than 99% of its mass of an oxide of the ABO3 perovskite structure, and the particle mixture according to the invention may also include one or more of the following optional features:
In a second embodiment, the oxide pigment consists for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of an oxide of spinel structure CD2O4 or D(C,D)O4 and the particle mixture according to the invention may also include one or more of the following optional features:
In a third embodiment, the oxide pigment consists for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of an oxide of hematite structure E2O3, the element E being chosen from the group GE(1) formed by iron, chromium and a mixture of iron and chromium. Preferably, the hematite content in the 0.5% to 10% of pigment as oxide(s) of hematite structure is greater than 90%, preferably greater than 95%, preferably greater than 99%. Preferably, the hematite content in said pigment is substantially equal to 100%.
In a fourth embodiment, the oxide pigment consists for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of an oxide of rutile structure FO2, the element F being chosen from the group GF(1) formed by mixtures of tin and vanadium, mixtures of titanium and chromium and niobium, mixtures of titanium and chromium and tungsten, mixtures of titanium and niobium and manganese, mixtures of tin and chromium, mixtures of chromium and titanium and antimony, mixtures of nickel and antimony and titanium, and mixtures thereof. Preferably, the rutile content in the 0.5% to 10% of oxide pigment as oxide(s) of rutile structure is greater than 90%, preferably greater than 95%, preferably greater than 99%. Preferably, the rutile content in said oxide pigment is substantially equal to 100%.
In one embodiment, the oxide pigment is a mixture of several oxide pigments according to the first to fourth embodiments above.
When the color black is desired for the sintered product to be manufactured, a particle mixture according to the invention preferably includes an oxide pigment consisting for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of an oxide of spinel structure chosen from an iron-chromium spinel, an iron-cobalt spinel, an iron-chromium-cobalt spinel, a cobalt-nickel-iron-chromium spinel, a nickel-manganese-iron-chromium spinel, a manganese-iron spinel, a chromium-iron-nickel spinel, a copper-chromium spinel, and mixtures thereof, preferably chosen from an iron-chromium spinel, an iron-cobalt spinel, an iron-chromium-cobalt spinel, and mixtures thereof.
Preferably, said spinel is chosen from an iron-chromium spinel having a mass ratio of iron expressed as Fe2O3 to chromium expressed as Cr2O3, Fe2O3/Cr2O3 of greater than 0.3, preferably greater than 0.7, preferably greater than 1 and preferably less than 3, an iron-cobalt spinel having a mass ratio of iron expressed as Fe2O3 to cobalt expressed as Co3O4, Fe2O3/Co3O4 of greater than 0.5, preferably greater than 1, preferably greater than 1.5 and preferably less than 4, an iron-chromium-cobalt spinel having a mass ratio of iron expressed as Fe2O3 to chromium expressed as Cr2O3, Fe2O3/Cr2O3 of greater than 0.5, preferably greater than 1, preferably greater than 1.3 and preferably less than 3, preferably less than 2.5, preferably less than 2 and a mass ratio of iron expressed as Fe2O3 to cobalt expressed as Co3O4, Fe2O3/Co3O4 of greater than 0.5, preferably greater than 1 and preferably less than 3, preferably less than 2.5, preferably less than 2, preferably less than 1.5, and mixtures thereof.
Preferably, the content of said oxide of spinel structure is greater than 3%, preferably greater than 4% and preferably less than 9%, preferably less than 8%, as a mass percentage on the basis of the mass of the oxides.
The “other oxides” that are not included in the oxide pigment are preferably impurities. They preferably represent less than 1.5%, preferably less than 1%, more preferably less than 0.5%, preferably less than 0.2%, preferably less than 0.1%, as a mass percentage on the basis of the oxides.
A particle mixture according to the invention may also include one or more deflocculant(s) and/or binder(s) and/or lubricant(s), which are preferably temporary, conventionally used in forming processes for the manufacture of preforms to be sintered, for example an acrylic resin, polyethylene glycol (PEG), or polyvinyl alcohol (PVA).
Specific Surface Area and Median Size
Preferably, the particle mixture according to the invention has a median size (D50) of less than 2 μm, preferably less than 1.5 μm, preferably less than 1 μm, preferably less than 0.8 μm, preferably less than 0.6 μm, preferably less than 0.5 μm, preferably less than 0.4 μm, preferably less than 0.3 μm and/or preferably greater than 0.05 μm.
Preferably, the particle mixture has a ratio (D90-D10)/D50 of less than 2, preferably less than 1.5.
Preferably, the particle mixture has a specific surface area, calculated via the BET method, of greater than 5 m2/g and/or preferably less than 20 m2/g, preferably less than 15 m2/g.
The particle mixture may be in dry form, i.e. obtained directly by mixing the appropriate starting materials. It may also have undergone an additional step, for example an atomization step, notably to improve its chemical homogeneity.
In a preferred embodiment, the particle mixture according to the invention has the following chemical composition, as mass percentages on the basis of the oxides:
the contents of Y2O3 and CeO2, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2, being such that the Y2O3 content is greater than or equal to 1.9%, preferably greater than or equal to 2% and/or preferably less than or equal to 2.5%, preferably less than or equal to 2.4%, preferably less than or equal to 2.2%, and the CeO2 content is greater than or equal to 0.2%, preferably greater than or equal to 0.3%, preferably greater than or equal to 0.4% and less than 0.8%, preferably less than 0.7%, preferably less than 0.6%; and the particle mixture includes, as a mass percentage on the basis of the particle mixture, between 3% and 7% of an oxide pigment consisting for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of an oxide of spinel structure chosen from an iron-chromium spinel, an iron-cobalt spinel, an iron-chromium-cobalt spinel, a cobalt-nickel-iron-chromium spinel, a nickel-manganese-iron-chromium spinel, a manganese-iron spinel, a chromium-iron-nickel spinel, a copper-chromium spinel, and mixtures thereof, preferably chosen from an iron-chromium spinel, an iron-cobalt spinel, an iron-chromium cobalt spinel, and mixtures thereof,
the content of oxides which are “other oxides” and which are not included in the oxide pigment, preferably the content of impurities, being less than 2%, preferably less than 1.5%, preferably less than 1%, more preferably less than 0.5%, preferably less than 0.2%, preferably less than 0.1% as a mass percentage on the basis of the oxides.
In this embodiment, the oxides which constitute the oxide pigment are thus counted as “other oxides”.
Preferably, said spinel is chosen from an iron-chromium spinel having a mass ratio of iron expressed as Fe2O3 to chromium expressed as Cr2O3, Fe2O3/Cr2O3 of greater than 0.3, preferably greater than 0.7, preferably greater than 1 and preferably less than 3, an iron-cobalt spinel having a mass ratio of iron expressed as Fe2O3 to cobalt expressed as Co3O4, Fe2O3/Co3O4 of greater than 0.5, preferably greater than 1, preferably greater than 1.5 and preferably less than 4, an iron-chromium-cobalt spinel having a mass ratio of iron expressed as Fe2O3 to chromium expressed as Cr2O3, Fe2O3/Cr2O3 of greater than 0.5, preferably greater than 1, preferably greater than 1.3 and preferably less than 3, preferably less than 2.5, preferably less than 2 and a mass ratio of iron expressed as Fe2O3 to cobalt expressed as Co3O4, Fe2O3/Co3O4 of greater than 0.5, preferably greater than 1 and preferably less than 3, preferably less than 2.5, preferably less than 2, preferably less than 1.5, and mixtures thereof.
In said preferred embodiment, the particle mixture has a median size (D50) of less than 2 μm, preferably less than 1.5 μm, preferably less than 1 μm, preferably less than 0.8 μm, preferably less than 0.6 μm, preferably less than 0.5 μm, preferably less than 0.4 μm, preferably less than 0.3 μm and/or preferably greater than 0.05 μm, and a ratio (D90-D10)/D50 of less than 2, preferably less than 1.5.
Process for Manufacturing the Particle Mixture
The particle mixture according to the invention may be conventionally obtained by, for example, mixing starting materials.
Grinding may be necessary to obtain a particle mixture with a median size of less than 2.0 μm.
In particular, the starting material powders providing the oxides may be ground individually or, preferably, co-milled, if they do not meet the desired particle size distribution. The grinding may be performed by wet grinding, for example in an attrition mill. After wet grinding, the ground particle mixture is preferably dried.
Preferably, the powders used, notably the zirconia ZrO2, alumina Al2O3, yttria Y2O3, ceria CeO2, and oxide pigment powders, each have a median size of less than 5 μm, less than 3 μm, less than 2 μm, less than 1 μm, less than 0.7 μm, preferably less than 0.6 μm, preferably less than 0.5 μm. Advantageously, when each of these powders has a median size of less than 2 μm, preferably less than 1 μm, preferably less than 0.8 μm, preferably less than 0.6 μm, preferably less than 0.5 μm, or even less than 0.3 μm, or even less than 0.2 μm, grinding is optional.
The use of powders with a small median size also makes it possible, advantageously, to reduce the sintering temperature.
These powders may also be replaced, at least partially, with powders of precursors of these oxides, introduced in equivalent amounts.
Preferably, the zirconia powder used has a specific surface area, calculated via the BET method, of greater than 5 m2/g, preferably greater than 6 m2/g, and less than 20 m2/g, preferably less than 15 m2/g. Advantageously, the sintering temperature in step d) is reduced. The grinding, generally in suspension, and slurrying are also thereby facilitated. Preferably, an alumina powder, preferably corundum, is used.
The powders providing the oxides or precursors are preferably chosen so that the total impurity content is less than 2%, as a mass percentage on the basis of the oxides.
A particle mixture according to the invention may also include one or more deflocculant(s) and/or binding agent(s) and/or lubricant(s), which are preferably temporary, conventionally used in forming processes for the manufacture of preforms to be sintered, for example an acrylic resin, polyethylene glycol (PEG), or polyvinyl alcohol (PVA).
Advantageously, such a particle mixture is ready to use.
A particle mixture according to the invention may in particular be packaged in bags.
Intermediate Product
The particle mixture according to the invention is preferably placed in an intermediate form suitable for its intended use.
The particle mixture according to the invention may in particular be placed in the form of a feed powder generally in the form of granules or “pellets”, known as a feedstock, more particularly intended for forming by injection molding, in the form of a printing paste more particularly intended for forming by 3D printing or in the form of a granule powder more particularly intended for forming by pressing. Preferably, the granule powder has a median size greater than 1 mm and less than 8 mm. Preferably, the granule powder has a median size greater than 20 μm and less than 100 μm.
All the conventional processes may be used for the intermediate forming of the particle mixture according to the invention.
The particle mixture according to the invention, or the intermediate product resulting from its intermediate forming (granules, printing paste, pellets, etc.), is preferably packaged, for example in bags, jars, drums or buckets, to be ready for use.
Process for Manufacturing a Sintered Colored Zirconia Product According to the Invention
The process for manufacturing, according to the invention, a sintered colored zirconia product includes steps a) and b) described above.
In step a), a starting feedstock suitable for the manufacture of a sintered colored zirconia product is prepared.
The starting feedstock includes a particle mixture according to the invention, optionally in the form of an intermediate product according to the invention, and optional constituents.
The amount of the optional constituents is preferably greater than 0.1% and/or less than 70%, as a mass percentage on the basis of the mass of the dry starting feedstock, the particle mixture according to the invention and/or the intermediate product according to the invention constituting the remainder to 100% of the dry starting feedstock.
Depending on the process used for the forming, a solvent, preferably water, may be added to the starting feedstock.
The optional constituents are the constituents conventionally used for the manufacture of sintered ceramic products. In particular, they comprise organic constituents.
In one embodiment, in particular when the forming process in step b) is slip casting, the organic constituents are preferably chosen from dispersants, viscosity modifiers, antifoam agents, and mixtures thereof, in an amount preferably greater than 0.1% and less than 5%, as a mass percentage on the basis of the mass of the dry starting feedstock.
In one embodiment, in particular when the forming process in step b) is pressing, the organic constituents are preferably chosen from binders, lubricants, resins, plasticizers, in an amount preferably greater than 0.2% and less than 10%, as a mass percentage on the basis of the mass of the dry starting feedstock.
In one embodiment, particularly when the forming process in step b) is a plastic injection molding process, the organic constituents are preferably chosen from surfactants, waxes, polymers, resins, plasticizers, and mixtures thereof, in an amount preferably greater than 25% and less than 65%, as a mass percentage on the basis of the mass of the dry starting feedstock.
In one embodiment, particularly when the particle mixture according to the invention is in the form of an intermediate product according to the invention, no organic constituents are added to the starting feedstock.
In step b), the forming of the starting feedstock including a particle mixture according to the invention, optionally in the form of an intermediate product, may be performed conventionally, via any technique known to those skilled in the art, in particular by slip casting, by pressing, notably uniaxial pressing or cold isostatic pressing, by injection molding, notably by plastic injection molding or by printing, notably by 3D printing.
Preferably, the pressure applied during uniaxial pressing is greater than 40 MPa and preferably less than or equal to 150 MPa.
A preform is thus obtained.
In step c), the preform is sintered, preferably under oxidizing conditions, preferably in air, preferably at atmospheric pressure or under pressure (hot pressing or hot isostatic pressing, or HIP), preferably at atmospheric pressure. Preferably, the preform is sintered at a temperature above 1350° C. and/or preferably below 1600° C., preferably below 1550° C., preferably below 1500° C., preferably below 1450° C., so as to obtain a sintered colored zirconia product.
Sintering under oxidizing conditions advantageously avoids conversion of the CeO2 into Ce2O3, which modifies the coloration obtained.
The maintenance time at the temperature steady stage is preferably more than 1 hour and/or preferably less than 10 hours, preferably less than 7 hours, preferably less than 5 hours, preferably less than 3 hours. Preferably, the sintering time is between 1 and 3 hours.
The temperature increase rate is conventionally between 10 and 100° C./hour. The temperature decrease rate may be free. If organic constituents, notably deflocculants and/or binders and/or lubricants are used, the sintering cycle preferably comprises a steady stage of 1 to 4 hours at a temperature of between 300° C. and 600° C. so as to promote the removal of said products.
The sintered colored zirconia product obtained at the end of step c) may be machined and/or may undergo a surface treatment, for instance polishing or sandblasting, according to any technique known to those skilled in the art.
Sintered Colored Zirconia Product According to the Invention
A sintered colored zirconia product according to the invention may be manufactured by means of a manufacturing process according to the invention.
Surprisingly, and without being able to explain it theoretically, the inventors have discovered that the simultaneous presence of Y2O3 and CeO2, in the contents present in the invention, makes it possible to achieve an excellent compromise between toughness and resistance to hydrothermal aging.
The composition of a sintered product according to the invention may be identical to that of a particle mixture according to the invention, not considering the temporary constituents, in particular, considering only the oxides. In particular, the amount of the various constituents and the nature of the oxide pigment are identical to those described above for the particle mixture.
In the sintered colored zirconia product according to the invention, the zirconia is at least partially stabilized with Y2O3 and CeO2. Preferably, the monoclinic zirconia fraction is less than 10%, preferably less than 5%, preferably less than 1%. Preferably, the zirconia is fully stabilized with Y2O3 and CeO2, preferably substantially fully in the quadratic form.
Preferably, the sintered colored zirconia product according to the invention has less than 5%, preferably less than 1%, or has substantially no cerium in the form of Ce2O3, as a mass percentage on the basis of the cerium. Advantageously, the color of the sintered product according to the invention is close to the desired color.
The sintered colored zirconia product according to the invention preferably consists for more than 98%, preferably more than 99%, preferably more than 99.5%, preferably more than 99.9%, or even substantially 100% of oxides.
The sintered colored zirconia product according to the invention has an average grain size of less than 2 μm, preferably less than 1.5 μm, preferably less than 1 μm, preferably less than 0.9 μm, preferably less than 0.8 μm, preferably less than 0.6 μm, preferably less than 0.5 μm, and preferably greater than 0.1 μm, preferably greater than 0.2 μm. Advantageously, a better compromise between toughness and resistance to hydrothermal aging is obtained. Preferably, the sintered colored zirconia product according to the invention has a grain size distribution with a standard deviation of less than 0.15 μm, preferably less than 0.1 μm. The grains of the oxide pigment of the sintered colored zirconia product according to the invention include, preferably consist for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of a material chosen from:
In a preferred embodiment, the sintered colored zirconia product according to the invention is black in color and has the following chemical composition, as mass percentages on the basis of the oxides:
the contents of Y2O3 and CeO2, as molar percentages on the basis of the sum of ZrO2, HfO2, Y2O3 and CeO2, being such that the Y2O3 content is greater than or equal to 1.9%, preferably greater than or equal to 2% and/or preferably less than or equal to 2.5%, preferably less than or equal to 2.4%, preferably less than or equal to 2.2%, and the CeO2 content is greater than or equal to 0.2%, preferably greater than or equal to 0.3%, preferably greater than or equal to 0.4% and less than 0.8%, preferably less than 0.7%, preferably less than 0.6%; and the particle mixture includes, as a mass percentage on the basis of the particle mixture, between 3% and 7% of an oxide pigment consisting for more than 95%, preferably for more than 97%, preferably for more than 98%, preferably for more than 99% of its mass of an oxide of spinel structure chosen from an iron-chromium spinel, an iron-cobalt spinel, an iron-chromium-cobalt spinel, a cobalt-nickel-iron-chromium spinel, a nickel-manganese-iron-chromium spinel, a manganese-iron spinel, a chromium-iron-nickel spinel, a copper-chromium spinel, and mixtures thereof, preferably chosen from an iron-chromium spinel, an iron-cobalt spinel, an iron-chromium-cobalt spinel, and mixtures thereof, the content of oxides which are “other oxides” and which are not included in the oxide pigment, preferably the content of impurities, being less than 2%, preferably less than 1.5%, preferably less than 1%, more preferably less than 0.5%, preferably less than 0.2%, preferably less than 0.1% as a mass percentage on the basis of the oxides. In this embodiment, the oxides that constitute the oxide pigment are thus counted as “other oxides”.
Preferably, said spinel is chosen from an iron-chromium spinel having a mass ratio of iron expressed as Fe2O3 to chromium expressed as Cr2O3, Fe2O3/Cr2O3 of greater than 0.3, preferably greater than 0.7, preferably greater than 1 and preferably less than 3, an iron-cobalt spinel having a mass ratio of iron expressed as Fe2O3 to cobalt expressed as Co3O4, Fe2O3/Co3O4 of greater than 0.5, preferably greater than 1, preferably greater than 1.5 and preferably less than 4, an iron-chromium-cobalt spinel having a mass ratio of iron expressed as Fe2O3 to chromium expressed as Cr2O3, Fe2O3/Cr2O3 of greater than 0.5, preferably greater than 1, preferably greater than 1.3 and preferably less than 3, preferably less than 2.5, preferably less than 2 and a mass ratio of iron expressed as Fe2O3 to cobalt expressed as Co3O4, Fe2O3/Co3O4 greater than 0.5, preferably greater than 1 and preferably less than 3, preferably less than 2.5, preferably less than 2, preferably less than 1.5, and mixtures thereof.
The oxides preferably represent more than 98%, preferably more than 99%, preferably more than 99.5%, preferably more than 99.9%, or even substantially 100% of the mass of such a black sintered zirconia product.
In said preferred embodiment, the sintered colored zirconia product has an average grain size of less than 2 μm, preferably less than 1.5 μm, preferably less than 1 μm, preferably less than 0.9 μm, preferably less than 0. 8 μm, preferably less than 0.6 μm, preferably less than 0.5 μm, and preferably greater than 0.1 μm, preferably greater than 0.2 μm, and a grain size distribution with a standard deviation of less than 0.15 μm, preferably less than 0.1 μm.
Preferably, the sintered colored zirconia product according to the invention has a relative density greater than 99.5%, preferably greater than 99.6%, preferably greater than 99.7%, preferably greater than 99.8%, preferably greater than 99.9%, the absolute density being calculated according to the method described previously.
Preferably, in particular when it has a black color, the sintered colored zirconia product according to the invention has a bulk density of greater than 5.98 g/cm3, preferably greater than 5.99 g/cm3, preferably greater than 6.00 g/cm3 and preferably less than 6.02 g/cm3.
Preferably, the sintered colored zirconia product according to the invention has a toughness of greater than 12 MPa·m1/2, preferably greater than 13 MPa·m1/2, preferably greater than 13.5 MPa·m1/2.
Device According to the Invention
The invention finally relates to a device chosen from the group consisting of an item of jewelry, a watch, a bracelet, a necklace, a ring, a brooch, a tie pin, a handbag, a telephone, an item of furniture, a household utensil, a handle, a switch, a button, a plating, a visible part of a consumer goods equipment, a part of an spectacle frame, a tableware article, a welding pin and a frame, said device including a part of a sintered colored zirconia product according to the invention or made from a particle mixture according to the invention.
Preferably, the sintered zirconia product is a black colored product as described above.
Said device may have a support onto which a part made of a sintered colored zirconia product according to the invention is bonded, clipped, sewn, or forcefully inserted. Said part may also be co-sintered with its support.
In one embodiment, the device is packaged, for example in a bag, box, or container, for example in a package including, or even consisting of, paper and/or cardboard and/or plastic or metal, preferably as foil, preferably as flexible foil. Preferably, the packaging bears information specifying the intended use of the device and/or technical features of the device.
The following nonlimiting examples are given for the purpose of illustrating the invention.
Measurement Protocols
The following methods were used to determine certain properties of particle mixtures and sintered products obtained from said particle mixtures. They allow an excellent simulation of the real behavior in service.
The bulk density of the sintered products is measured by hydrostatic weighing.
The unit cell parameters required for calculating the absolute density of the at least partially stabilized zirconia are determined by X-ray diffraction on the surface of the sample to be characterized (the sample not being ground in the form of a powder) by means of a D8 Endeavor machine from the company Broker. The parameters required for the acquisition of the diffraction pattern are identical to those used for the acquisition of the diffraction pattern required for the determination of the monoclinic zirconia fraction.
The unit cell parameters a and c are determined after having performed a refinement of the diffraction pattern using the Fullprof software available from https://www.ill.eu/sites/fullprof/, using a pseudo-Voigt profile (with npr=5), the refined parameters being as follows:
the space group of the partially substituted quadratic zirconia unit cell being P 42/n m c (137), considered identical to that of the non-substituted quadratic zirconia unit cell.
The chemical analysis of the sintered products is measured by “Inductively Coupled Plasma” (ICP) spectrometry, for the elements whose content does not exceed 0.5%. To determine the content of other elements, a bead of the product to be analyzed is made by melting the product, and the chemical analysis is then performed by X-ray fluorescence.
The average grain size of the sintered products is measured by means of the Mean Linear Intercept method. A method of this type is described in the standard ASTM E1382. According to this standard, analysis lines are drawn on images of the sintered products, and then, along each analysis line, the lengths, called “intercepts”, between two consecutive grain boundaries intersecting said analysis line are measured.
The average length “I′” of the intercepts “I” is then determined.
For the tests below, the intercepts were measured on images, obtained by scanning electron microscopy, of sintered product samples, said sections having been polished beforehand to mirror quality and then thermally etched, at a temperature 50° C. below the sintering temperature, to reveal the grain boundaries. The magnification used to take the images is chosen so as to visualize approximately 100 grains on one image. Five images per sintered product were taken.
The average size “d” of the grains of a sintered product is given by the relationship: d=1.56.I′. This formula is derived from formula (13) of the article “Average Grain Size in Polycrystalline Ceramics”, M. I. Mendelson, J. Am. Ceram. Soc., Vol. 52, No. 8, pages 443-446.
The standard deviation of the grain size distribution is 1.56 times the standard deviation of the intercept distribution “I”.
The specific surface area of a powder is measured via the BET (Brunauer Emmett Teller) method described in the Journal of the American Chemical Society, 60 (1938), pages 309 to 316.
The 10, 50 and 90 percentiles of powders and particle mixtures are conventionally measured using an LA950V2 model laser granulometer sold by the company Horiba.
The average size of the stabilized zirconia crystallites, D, of a zirconia powder is determined by X-ray diffraction on the surface of the sample to be characterized (the sample not being ground in the form of a powder) using a D8 Endeavor machine from the company Brüker, by means of the following equation:
K being equal to 0.89, A being the X-ray wavelength, in this case equal to 1.5418 Ångströms, B being the width at half-height of the peak of the (111) plane of the stabilized zirconia, in degrees, b being the width at half-height of the peak of the single-crystal silicon standard used, and 2θ being the angle of the maximum intensity of the peak corresponding to the (111) plane of the stabilized zirconia, in degrees.
The diffraction patterns of the single-crystal silicon standard and of the example are acquired, over an angular range 2θ between 5° and 100°, with a step size of 0.01°, and a counting time of 0.34 s/step. The front optics include a 0.3° primary slit and a 2.5° Soller slit. The characterized sample is rotating on itself at a speed equal to 15 rpm, using the automatic knife. The rear optics include a 2.5° Soller slit, a nickel filter of 0.0125 mm and a 1D detector with an aperture equal to 4°.
After removing the Kα2 line, the width at half-height of the peaks is determined using the HighScore Plus software. The deconvolution function used is a pseudo-Voigt with a Split Width skewness. The standard and the samples are deconvolved under the same conditions.
The resistance to hydrothermal aging of the sintered products of the examples is evaluated by the following method.
Each sample, in the form of a disk with a diameter of 25 mm and a thickness of 2 mm, is polished on one of the large faces using an abrasive paper disk with an abrasive particle size of 3 μm. The polishing is performed in such a way that no monoclinic zirconia is generated on the polished surface.
The polished samples are then subjected to an accelerated aging test according to the following protocol: the samples are placed in a Teflon crucible with a diameter equal to 80 mm and a capacity equal to 0.5 liter. Said crucible is placed in an autoclave with a diameter of 100 mm and a capacity of 1 liter. 100 ml of water are added to the autoclave, outside the crucible. The autoclave is closed and the system is heated at 135° C. for 5 hours, at the autogenous pressure.
Before testing, all the sintered products in the examples are completely stabilized. Measurement of the monoclinic zirconia fraction, as described previously, on the autoclaved samples thus directly gives a measure of the resistance to hydrothermal aging.
The toughness of the sintered products of the examples is approximated by the value of the resistance to fracture by indentation, according to the standard ISO 14627, on disks with a diameter equal to 32 mm and a thickness equal to 3 mm, the number of disks per product to be tested being equal to 3, the surface on which the indentation is performed being polished so that it has a roughness Ra<0.1 μm, the measurements being taken at room temperature, with the application of a force equal to 98 N for a time equal to 15 seconds, five indentations being made per disc, the value of the modulus of elasticity being equal to 205 GPa.
The color parameters (L, a* and b*) are measured according to the standard NF ISO 7724 on polished parts, the last step of polishing having been performed with a Mecaprex LD32-E 1 μm diamond preparation sold by the company PRESI, using a CM-2500d machine, manufactured by the company Konica-Minolta, with illuminant D65 (natural light), observer at 10°, and specular reflection excluded.
Manufacturing Protocol
Sintered products were prepared using:
These powders were mixed and then wet co-milled until a particle mixture was obtained with a median particle size of less than 0.5 μm. Polyvinyl alcohol was then added in an amount equal to 2% on the basis of the dry matter of the particle mixture. The starting feedstock obtained was then atomized in a spray dryer in the form of a powder of granules with a median size equal to 60 μm, a relative density of between 30% and 60% and a sphericity index of greater than 0.85, the relative density of a granule powder being the ratio equal to the real density divided by the absolute density, expressed as a percentage, the absolute density of a granule powder being the ratio equal to the dry matter mass of said powder after grinding to a fineness such that substantially no closed pores remain, divided by the volume of that mass after grinding, measured by helium pycnometry, and the real density of a granule powder being the average of the bulk densities of each granule of the powder, the bulk density of a granule being the ratio equal to the mass of said granule divided by the volume occupied by said granule.
In step b), each granule powder was then pressed on a uniaxial press at a pressure equal to 100 MPa.
In step c), the preforms obtained were then transferred into a sintering furnace where they were heated, at a rate of 100° C./hour, to 1400° C. The temperature of 1400° C. was maintained for 2 hours. The temperature decrease was performed by natural cooling.
Tables 1, 2 and 3 below summarize the composition of the particle mixtures used in step a), their features and the features of the sintered products obtained, respectively.
The particle mixtures of Examples 1-5 and the sintered products obtained from said particle mixtures consist substantially entirely of oxides.
In the particle mixtures of Examples 3-5, as in the sintered products obtained from said particle mixtures, substantially all of the cerium is present in the CeO2 form.
Examples 1 and 2 are representative of the prior art.
Example 5, outside the invention, is given to serve as a basis for comparison with the examples according to the invention.
When the toughness is greater than or equal to 12 MPa·m1/2, preferably greater than 13 MPa·m1/2, and when the monoclinic zirconia fraction after the aging test as described is less than or equal to 25%, preferably less than or equal to 20%, the product is considered satisfactory.
Examples 1 and 2, which are representative of the prior art, are thus unsatisfactory: Example 1 has a low toughness equal to 5.5 MPa·m1/2, and Example 2 has a low resistance to hydrothermal aging (monoclinic zirconia fraction after the aging test equal to 52%).
Example 5, outside of the invention, shows that a CeO2 content equal to 1%, as a molar percentage on the basis of ZrO2+HfO2+Y2O3+CeO2, does not achieve the objective in terms of toughness: the toughness obtained is in fact equal to 11 MPa·m1/2.
Examples 3 and 4 illustrate the invention. Example 3 is the example that is preferred among all.
As is now clearly seen, the inventors have discovered that the simultaneous presence of a low yttrium oxide content, a low cerium oxide content, and an oxide pigment, in a particle mixture according to the invention, advantageously makes it possible to obtain a sintered colored zirconia product having a toughness of greater than or equal to 12 MPa·m1/2 and a monoclinic zirconia fraction after the aging test as described of less than or equal to 25%.
Needless to say, the invention is not limited to the examples and embodiments described above.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003343 | Apr 2020 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2021/058814 | 4/2/2021 | WO |
