Sintered microcrystalline ceramic material.
Abstract
(-- A summary 57) the (correction -- an owner) purpose -- it is especially suitable for abrasives and aims at offering the ceramic material which has high hardness with high viscosity especially based on special chemical constitution. Composition Ceramic material consists of nature ceramics of sintering micro crystallite which consist of 0.01 15% of the weight from the whisker of an alpha*AlO base which has an additive of 0.1 to 3% of the weight of a chromium compound preferably.
Term
No projected expiry on record.
- Priority and filed
- Granted
- Today
18 claims: 18 independent, 0 dependent
- 1CLAIMS PATENTANSPRÜCHE 1. Sintered microcrystalline ceramic material based on a-Al2O3consisting of a microcrystalline matrix and 0.1 to 30 vol.%, Preferably 1 to 25 vol.% And particularly preferably 1 to 15 vol.%, embedded in the matrix Whiskerähnlicher needles or Platelets, wherein the ceramic material contains an addition of 0.01 to 2 wt.%, Preferably 0.01 to 0.5 wt.% Of a cerium compound which is present substantially in the Whiskem, characterized in that the ceramic material an addition of 0.01 to 15 wt.%, Preferably 0.1 to 3 wt.% Of a chromium compound. 1. Gesintertes mikrokristallines keramisches Material auf der Basis von a-Al2O3, bestehend aus einer mikrokristallinen Matrix und 0,1 bis 30 Vol.%, vorzugsweise 1 bis 25 Vol.% und besonders vorzugsweise 1 bis 15 Vol.%, in der Matrix eingelagerter whiskerähnlicher Nadeln bzw. Plättchen, wobei das keramische Material einen Zusatz von 0,01 bis 2 Gew.%, vorzugsweise 0,01 bis 0,5 Gew.% einer Cer-Verbindung enthält, welche im wesentlichen in den Whiskem vorliegt, dadurch gekennzeichnet, daß das keramische Material einen Zusatz von 0,01 bis 15 Gew.%, vorzugsweise 0,1 bis 3 Gew.% einer Chrom-Verbindung aufweist.
- 2Keramisches Material nach Anspruch 1, dadurch gekennzeichnet, daß die whiskerähnlichen Nadeln auch Calcium und/oder Magnesium enthalten. Second Ceramic material according to claim 1, characterized in that the whisker-like needles also contain calcium and / or magnesium. -8AT394 850B -8AT394 850B
- 5Keramisches Material nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß der Anteil der CerVerbindung in den Whiskem bis zu 20 Gew.%, vorzugsweise bis zu 10 Gew.% beträgt 5th Ceramic material according to one of claims 1 to 4, characterized in that the proportion of cerium compound in the whiskem is up to 20% by weight, preferably up to 10% by weight
- 6Keramisches Material nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, daß die Kristallitengröße im wesentlichen unter 1 pm, vorzugsweise unter 0,5 pm beträgt. 6th Ceramic material according to one of claims 1 to 5, characterized in that the crystallite size is substantially less than 1 pm, preferably less than 0.5 pm.
- 7Verfahren zur Herstellung eines keramischen Materials durch Einrühren eines hochdispersen a-Aluminiumoxidhydrats in eine verdünnte Säurelösung, Zugabe einer Cerverbindung im Ausmaß 0,01 bis 2 Gew.-%, vorzugsweise 0,01 bis 0,5 Gew.-% (gerechnet als CeO2) bezogen auf den Aluminiumoxidgehalt, Entlüftung, Desagglomerierung, Trocknung und Zerkleinerung, sowie Durchführung eines mehrstufigen, teilweise unter Gasdruck stattfindenden Sintervorganges, dadurch gekennzeichnet, daß zur Suspension eine Chromverbindung im Ausmaß von 0,01 bis 15 Gew.%, vorzugsweise 0,1 bis 3 Gew.%, bezogen auf das A12O3, zugegeben wird. 7th A method for producing a ceramic material by stirring a highly dispersed a-alumina hydrate in a dilute acid solution, adding a cerium compound in the amount of 0.01 to 2 wt .-%, preferably 0.01 to 0.5 wt .-% (calculated as CeO2) Based on the alumina content, deaeration, deagglomeration, drying and crushing, and carrying out a multi-stage, sometimes taking place under gas pressure sintering process, characterized in that the suspension is a chromium compound in the amount of 0.01 to 15 wt.%, Preferably 0.1 to 3% by weight, based on the A12O3, is added.
- 8Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß zur α-Aluminiumoxidhydratsuspension neben dem Cerzusatz noch bis zu 5 Gew.%, vorzugsweise bis zu 2 Gew.%, bezogen auf das A12O3, feinste Partikel eines Keimbildners oder einer Vorstufe davon zugegeben werden. 8th. A method according to claim 7, characterized in that the α-alumina hydrate suspension in addition to the Cerzusatz still up to 5 wt.%, Preferably up to 2 wt.%, Based on the A12O3, Finest particles of a nucleating agent or a precursor thereof may be added.
- 9Verfahren nach Anspruch 8, dadurch gekennzeichnet, daß als Keimbildner ein Al2O3-Cr2O3-Mischkristall eingesetzt wird. 9th A method according to claim 8, characterized in that as nucleating an Al2O3cr2O3Mixed crystal is used.
- 10Verfahren nach Anspruch 8, dadurch gekennzeichnet, daß der Al2O3-Cr2O3-Mischkristall bis zu 99 Gew.% Cr2O3 enthält. 10th Process according to Claim 8, characterized in that the Al2O3cr2O3Mixed crystal up to 99% by weight Cr2O3 contains.
- 11Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß die zugesetzte Chromverbindung ganz oder teilweise aus A^Oß-C^O-j-Mischkristallen besteht. 11th A method according to claim 7, characterized in that the added chromium compound wholly or partly consists of A ^ Oß-C ^ Oj mixed crystals.
- 12Verfahren nach einem der Ansprüche 7 bis 11, dadurch gekennzeichnet, daß der Sinterungsprozeß mehrstufig bei Temperaturen zwischen 500 °C und 1400 °C durchgeführt wird. 12th Method according to one of claims 7 to 11, characterized in that the sintering process is carried out in several stages at temperatures between 500 ° C and 1400 ° C.
- 13Verfahren nach Anspruch 12, dadurch gekennzeichnet, daß die Sinterung in Stufe zwei und vier und bei einem Gasdruck von 1 bis 1000 bar, vorzugsweise 50 bis 100 bar während fünf Minuten bis maximal drei Stunden erfolgt, wobei die Temperatur in der ersten Stufe zwischen 800 °C und 1150 °C und in der vierten Stufe zwischen 1250 °C und 1400 °C eingestellt wird. 13th A method according to claim 12, characterized in that the sintering in stage two and four and at a gas pressure of 1 to 1000 bar, preferably 50 to 100 bar for five minutes to a maximum of three hours, wherein the temperature in the first stage between 800 ° C and 1150 ° C and in the fourth stage between 1250 ° C and 1400 ° C is set.
- 14Verfahren nach Anspruch 12, dadurch gekennzeichnet, daß der Trocknungs- und Sinterungsprozeß durch Mikrowellen erfolgt. 14th A method according to claim 12, characterized in that the drying and sintering process is carried out by microwaves.
- 15Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß das calcinierte Produkt auf bis zu 1650 °C erhitzt, danach mit einer Abkühlungsgeschwindigkeit von mindestens 100 °C/min rasch abgekühlt und dann bei 1100 bis 1400 °C fertiggesintert wird. 15th Process according to claim 7, characterized in that the calcined product is heated up to 1650 ° C, then rapidly cooled at a cooling rate of at least 100 ° C / min and then finish sintered at 1100 to 1400 ° C.
- 17Verfahren nach einem der Ansprüche 7 bis 14, dadurch gekennzeichnet, daß der Feststoffgehalt der Suspension zwischen fünf und 40 Gew.%, vorzugsweise zwischen 15 und 25 Gew.% liegt. 17th Process according to one of Claims 7 to 14, characterized in that the solids content of the suspension is between 5 and 40% by weight, preferably between 15 and 25% by weight.
- 18Verwendung eines gesinterten, mikrokristallinen, keramischen Materials nach einem der Ansprüche 1 bis 6 als Schleifmaterial, Schneidkeramik und für andere Einsatzzwecke von a-Aluminiumoxidkeramik. 18th Use of a sintered, microcrystalline, ceramic material according to any one of claims 1 to 6 as an abrasive material, cutting ceramic and for other uses of a-alumina ceramics.
Independent claims18
138 paragraphs in 9 sections, as filed
(42) Date of commencement of the patent: 15.12.1991 (45) Date of issue: 25. 6.1992
<td>(56) Documents:</td><td>(73) Patent owner:</td>
<td>EP-Al-395091 EP-A2-248788</td><td>TREIBACHER CHEMICAL WORKS AG A-9330 TREIBACH, CARINTHIA (AT).</td>
<td></td><td>(72) Inventor:</td>
<td></td><td>WINTER HERWIG DR. KLAGENFURT, CARINTHIA (AT). JANZ PETER DR. KLAGENFURT, CARINTHIA (AT). GOTTSCHAMEL GEORG DR. TREIBACH, CARINTHIA (AT).</td>
(54) SINTERED MICROCRYSTALLINE CERAMIC MATERIAL (57) An abrasive material having a particularly high grinding performance is achieved by treating the ceramic material consisting of alpha alumina, 0.1 to 30 vol. X whisker-like needles and 0.01 to 0.5 wt .-% of a cerium compound, nor an addition of 0.01 to 15 wt .-%, preferably 0.1 to 3 wt .-% of a chromium compound.
CQ
AT 394 850
KR 0070313
AT394 850 B
The present invention relates to a sintered, microcrystalline, ceramic material based on a-Al<sub>2</sub>O<sub>3</sub> with an addition of 0.01 to 2% by weight, preferably 0.01 to 0.5% by weight of a cerium compound and 0.01 to 15% by weight, preferably 0.1 to 5% by weight of a chromium compound.
The basic publications for the production of ceramic material from a-Al<sub>2</sub>O<sub>3</sub> The SolGel process has already been mentioned in EP-Al-368 837.
U.S. Patent 4,744,802 suggests the possibility of having a-Fe seed particles<sub>2</sub>O<sub>3</sub> additionally mixed sol with a chromium-containing compound. It is known from the literature that chromium (IH) oxide at high temperatures mixed crystals with a-Al<sub>2</sub>O<sub>3</sub> forms
EP-A2-395 091 describes the addition of chromium oxide as a nucleating agent as an alternative to a-Al<sub>2</sub>O<sub>3</sub> or a-Fe<sub>2</sub>OSS. That in the literature different opinions on the effect of chromium compounds on the conversion of transitional aluminas to a-Al<sub>2</sub>O<sub>3</sub> are believed to be due to the redox behavior of chromium oxide. GC Bye describes Influence of Cr and Fe on Formation of a-Al<sub>2</sub>O<sub>3 </sub>from gamma-Al<sub>2</sub>O<sub>3</sub> (J.Amer.Cer.Soc 57 (1974) pp. 367-371) in addition to the accelerating effect of Fe<sub>2</sub>O<sub>3 </sub>the retarding effect of Cr (VI) on the formation of a-Al<sub>2</sub>O<sub>3</sub>, At the same time, however, he points out the possibility that the hexagonal Cr (III) oxide crystals found by him between 800 and 900 ° C may have a germinative effect on the formation of the grain mixed crystal.
EP-A-368 837 describes a ceramic material which, in addition to a-Al<sub>2</sub>O<sub>3</sub> Whisker-like Needle Crystals The needles contain cerium.
The object of the invention is to provide a ceramic material which is suitable, inter alia, as an abrasive and due to its special chemical composition and structure has a particularly high toughness at the same time existing higher hardness.
This object is achieved in that the ceramic material consists of a crystalline matrix with 0.1 to 30 vol%, preferably 1 to 25 vol% whisker-like particles The particles have diameters between 0.2 and 1 pm, their length is 1-20 pm. The matrix consists of a solid solution of 0.01 to 15 wt% Cr<sub>2</sub>O<sub>3</sub> in α-Α1<sub>2</sub>Ο<sub>3</sub>· The hardness of this mixed crystal is higher than that of pure a-Al<sub>2</sub>O<sub>3</sub>, The matrix has a preferably crystallite size of less than 0.5 pm and a very uniform structure.
Transmission electron microscopic investigations showed that the embedded particles are in the form of acicular whiskers partly or wholly as platelets may be formed. The respective quantities certainly depend on the conditions of origin. For the sake of simplicity, the particles are referred to as whiskers and should also include monocrystalline platelets therein. The thickness of the platelets corresponds to the whisker diameter, the dimensions perpendicular to the Whiskerlänge.
The whiskers, according to TEM investigations, consist of a Ce-Al oxide compound of the type β-corundum. Part of the Al ions is replaced by Cr, further Ca and other alkaline earth or Alkaline ions incorporated in different amounts in the crystal lattice. Upon formation, the matrix Ca or removes other alkaline earth and alkali ions, thereby increasing the strength, as the amount of grain boundary contaminants decreasing in strength as both a crystalline and a glass phase decreases. The Ca- Alkaline earth and alkali content can be up to 1% without loss of strength. Possibly, a low Ca content is even necessary for whisker formation. The Ca content in the particles is greatly increased compared to the matrix, so that a considerable cleaning effect with respect to the matrix occurs
The incorporation of Cr into the lattice of the whiskers causes an increase in the hardness of the Ce aluminate; ß-KorundStrukturen have a much lower hardness than a-Al<sub>2</sub>O<sub>3</sub>,
The strength of the inventive ceramic shaped body or abrasive body, the z. As can be tested as usual in diamond grinding Komkom as compressive strength is thereby increased (see also examples). The higher hardness and strength of the whiskers through the incorporation of Cr enhances the pull-out effect and the crack deflecting mechanisms.
In addition, the grinding performance is probably increased by a self-sharpening effect. The crack deflection on the needles can contribute to the formation of new, sharp break edges. The size of the broken fragments is probably determined mainly by the distance of the needles from each other. For certain applications, the wear behavior could thus be adapted and optimized by varying the needle concentration (number / volume unit).
Preferably nucleating agents are added to the α-alumina hydrate suspension in addition to the cerium and chromium addition.
Nucleating agents are finest particles that are made from a-Al<sub>2</sub>O<sub>3</sub>, Diaspor, A1F<sub>3</sub>, a-Fe<sub>2</sub>O<sub>3</sub>, V<sub>2</sub>O<sub>3</sub>, Co<sub>2</sub>O<sub>3</sub>, Nb<sub>2</sub>O<sub>3</sub>, C ^ Oß, gamma-Al<sub>2</sub>O<sub>3</sub>, Ga<sub>2</sub>O<sub>3</sub>, GaOOH, FeOOH, Ti<sub>2</sub>O<sub>3</sub>, Cr<sub>2</sub>O<sub>3</sub> consist. It is also possible to add soluble or insoluble precursors, which are compounds which form on heating the dried material in the
-2AT394 850B convert the above oxides before normal nucleation of the aA ^ Oß begins (ie at lower temperatures). It is also possible to use mixtures or combinations of the abovementioned oxides or precursors, as well as preformed mixed crystals.
The nucleating agent is added in an amount of up to 5% by weight, referred to as oxide on the final product. It has been found that a material thus produced has improved properties. The reason for this is presumably due to the increased ratio of length to diameter of the whisker-like needles, the diameter of the needles is smaller with the same length, at the same time the number of needles per volume unit increases.
Increasing the addition of nucleating agent above 5% by weight did not improve the properties. The nucleating agent can be added to the boehmite suspension in the form of a suspension of very fine particles. Such a nucleant suspension is prepared from commercial powder by milling and sedimentation or any other method which yields a submicron powder. Of course, the nucleating agent may also be added in solid form before or after deagglomeration.
For the formation of the microcrystalline structure, it is advantageous to add magnesium nitrate or another Mg-containing compound to the α-alumina hydrate suspension
Furthermore, the invention relates to a method for producing a ceramic material by stirring a fumed aA ^ Oß hydrate into a dilute acid solution, adding a cerium compound in the amount of 0.01 to 2 wt%, preferably 0.01 to 0.5 wt%, calculated as oxide, based on the AI2O3, adding one
Chromium compound in the amount of 0.01 to 15% by weight, preferably 0.1 to 5% by weight, based on oxide on alumina and optionally addition of Ca and / or magnesium compounds to 1% by weight as oxide, based on Al2O3, drying, comminution and sintering. This process is characterized in that the suspension is deaerated and deagglomerated before drying and that the sintering process is carried out in several stages and preferably under gas pressure. In this case, the sintering process is performed so that form next to a microcrystalline matrix needle-shaped crystals.
The addition of chromium and cerium can take place in the form of inorganic or organic salts, but also in any other compound which can be dispersed or dissolved, such as oxides or hydroxides. The addition of ready C ^ OyA ^ Oß mixed crystal is advantageous. At the same time it results in a higher fineness and homogeneity of the chemical composition of the matrix and the whiskers at higher density (lower porosity) of the material.
The deagglomeration can be carried out in a dispersing device according to the rotor-stator principle. However, it is also possible to use other dispersing devices, such as stirred ball mills, although a greater grinding media abrasion or metal abrasion is detrimental to the quality of the product.
As finely divided α-alumina hydrates, the commercially available pseudoboehmites (Pural, Disperal, Versal) having a purity of over 99% and a specific surface area between 150 and 290 m2g can be used. The solids content of the suspension was between 5 and 40% by weight, preferably between 15 and 25% by weight. As Peptisatorsäure nitric acid, hydrochloric acid, formic acid or acetic acid can be used.
The drying is carried out in a thin-film evaporator with attached belt dryer. However, it can be used any other drying apparatus that allows mixing of the material in the drying phase, so that no segregation is possible. This is necessary to achieve the desired homogeneous distribution of the needles in the final product. The resulting pore structure of the dried material appears to be conducive to the formation of the needles, since substantially fewer needles are created when drying dormantly.
Preferably, the drying is carried out in a microwave-heated belt dryer. The resulting heating of the material from the inside causes a very good homogeneity of the dried products, which pore structure and chemical composition. Whisker formation and sintering activity are promoted thereby improving the properties of the finished product.
The dried material is crushed and sieved The obtained grain can either be sintered directly to Schleifkom or pressed wild in correspondingly fine form as a powder with organic binders to form parts. These are all known pressing methods such. B. die pressing, extrusion or roller presses.
The sintering times depend on the temperature and lie between a few minutes and several hours per stage. The multi-stage sintering process can be carried out in principle in a suitable furnace, but it has proved to be advantageous when the first stage, in particular because of the attack of acidic exhaust gases in a specially lined furnace is performed.
As a further variant of the process, the sintering can be carried out under non-oxidizing or reducing conditions, whereby the intermediate formation of C1O3 at about 300 to 500 ° C is prevented. However, the conditions must not lead to a reduction of the Cr below the 3-valued form.
As a further variant of the process, the precalcined material can be impregnated with solutions or suspensions, this process is known from the patent application 394 213. All abovementioned additives and
-3AT394 850 B
Precursors of the nucleating agents can be added in this way.
The material according to the invention is outstandingly suitable for loop awakening, but can also be used for all known purposes of alumina ceramics. For use in grinding wheels, comminution of the material before sintering proved to be advantageous, for use in belts and flexible disks comminution after sintering is cheaper.
The invention will now be explained in more detail by way of examples.
Example 1: (suspension production)
In a solution of 39.5 kg of water and 440 g conc. Nitric acid was continuously stirred into 10 kg of Disperal (R) alumina hydrate. The suspension was then deaerated in a laboratory vacuum deaerator at 100 mbar and then pumped through a disperser with two feed ports. The flow rate was 3 1 / h, the rotor speed was 15,000 rpm. A solution of 4.5 g / 1 cerium (III) nitrate hexahydrate and 14 g / l chromium (III) nitrate nonahydrate was pumped in at 300 ml per hour to the second inflow opening of the disperser. The deagglomerated suspension was then further processed in Examples 2-6 sintered final product contained 0.1% by weight of CeO<sub>2</sub> and 0.3% by weight of C 2 O 3.
Example 2:
The suspension from Example 1 was evaporated with stirring and dried after coagulation in polypropylene cups in a hot air dryer at 80 ° C for 36 hours to brittle plates. The dried slabs were crushed into granules in a hammer mill and classified in a sieving machine (fineness rate <0.1 mm - see Example 5). Subsequently, the grains were calcined for one hour in a muffle furnace at 600 ° C. Subsequently, the material was heated to 900 ° C. in a gas pressure sintering furnace. The gas atmosphere used was nitrogen. 100 bar, the temperature was increased within one hour to 1100 ° C then the pressure was lowered to 1 bar and the temperature further increased to 1300 ° C. After a further 1.5 h at 1300 ° C was sintered for 15 min at 100 bar. The material had 3 vol% porosity and contained approx. 15 Vol% Whisker with diameters of 0.2 - 0.5 ym and a length between 3 and 5 μτη.
The chemical composition of the matrix and the needles was determined by transmission electron microscopy - energy dispersive analysis (TEM - EDX). The matrix in the vicinity of the whiskers contained, apart from A 2 O 3 and about 0.3% Cr<sub>2</sub>No impurities. The whiskers themselves contained about 1% by weight CaO, 5% by weight CeO<sub>2</sub> and about 0.5% Cr<sub>2</sub>OSS.
Example 3:
The suspension of Example 1 was dried in a microwave dryer. The dried plates were further processed as in Example 2. The material had 2% by volume porosity and contained 18% by volume whisker.
Example 4:
The dried material of Example 3 was only roughly comminuted and sintered as in Example 2. After sintering, final comminution and sieving were carried out.
Example 5:
Dried fine grain (<0.1 mm, from Example 2 was about 25 wt% H<sub>2</sub>O mixed and pressed into cylinders (30 mm 0.5 mm in length) Pressing was uniaxial in a die at 400 MPa. The cylinders were sintered as in Example 2. The sintered material had 2% by volume porosity and exhibited virtually the same microstructure with needles as the material of Example 2. The sintered cylinders were chopped into grain and sieved
Example fc
The cylinders pressed as in Example 3 were crushed and sieved before sintering. The screened grain was sintered as in Example 2
Example 7:
The α-alumina hydrate suspension was prepared as in Example 1. The dosed solution contained 17.9 g / l citrate hexahydrate, 5.6 g / l magnesium nitrate hexahydrate and 14 g / l chromium nitrate nonahydrate so that 0.4% by weight of CeO in the end product<sub>2</sub>, 0.3% Cr<sub>2</sub>Oss and 0.05% MgO were included. The deagglomerated suspension was further processed as in Example 3. The sintered product contained 2% by volume of pores and 20% by volume of whiskers.
Example &
In a solution of 39.5 kg of water, 440 g conc. Nitric acid, 78 g of citrate hexahydrate, 205 g of chromium nitrate nonahydrate and 25 g of magnesium nitrate hexahydrate were stirred into 10 kg of Disperal (R) and deaerated (as described in US Pat
-4AT394 850 B
Example 1). The suspension was deagglomerated in an agitating ball mill, with the Mahlköiperabrieb (85% alumina balls) less than 02% by weight, based on the final product was. The suspension was processed further as in Example 3. The sintered product contained 0.4% CeO<sub>2</sub>, 1% Cr<sub>2</sub>Oxygen and 0.05% MgO. Analysis of the matrix in the vicinity of the whiskers - with TEM-EDX - showed next to Al<sub>2</sub>Oss only about 0.9% Cr<sub>2</sub>Oss, no Ca, Ce, K, Na and Mg. The whiskers contained besides Al<sub>2</sub>About 3 wt% CaO, 11 wt% CeO<sub>2</sub> and about 1% C ^ O ^.
Example.?;
In a solution of 39.5 kg of water, 440 g conc. Nitric acid, 78 g of citrate hexahydrate, 61 g of chromium nitrate nonahydrate and 25 g of magnesium nitrate hexahydrate were stirred into 10 kg of Disperal (R). The suspension was deaerated as in Example 1 and deagglomerated in the stirred ball mill. After drying in the microwave dryer, the material was comminuted and sieved. The sieved grain was precalcined in a muffle furnace at 800 ° C. for four hours, then heated in a continuous rotary kiln to 1650 ° C. (residence time in the hot zone approx. 10 min.), cooled rapidly and sintered in a muffle furnace at 1300 ° C for four hours. The sintered material contained 0.4% CeO<sub>2</sub>, 0.3% Cr<sub>2</sub>Oxygen and 0.05% MgO. The whisker content was about 20% by volume.
Production of the germ image:
A suspension of 6.5 kg of water and 3.5 kg of Bayer alumina with 105 g conc. Nitric acid was milled in a stirred ball mill until the median grain size distribution was 0.6 pm (determined by Sedigraph). The suspension was diluted (35 wt% A1<sub>2</sub>0j to 20% by weight) and freed by sedimentation of all particles> 0.2 pm. The resulting fine suspension contained 2% by weight of α-Al<sub>2</sub>Oss and was used as a nucleating additive
Alternatively, 4 kg of a pure Cr<sub>2</sub>Oxygen pigment in 6 kg of water and 50 g conc. Nitric acid stirred and ground in a stirred ball mill. As with the clay, the sedimentation freed the suspension of the coarse fraction above 0.2 .mu.m. The resulting suspension contained about 1.5% by weight of Cr<sub>2</sub>Oβ and was used in Example 12 as a nucleating additive.
A suspension of 10 kg of Disperal (R) was conc. With a solution of 500 g. Nitric acid and 10 kg of chromium nitrate nonahydrate in 39.5 kg of water kneaded in a laboratory kneader to a homogeneous mass (gel). Subsequently, the gel in the muffle furnace at approx. 1200 Annealed The annealed material was crushed and processed as the clay into a fine suspension which was used as the nucleating additive in Example 13. The suspension contained approx. 0.5% solids. This had the crystal structure of the a-Al<sub>2</sub>0SS-Cr<sub>2</sub>0ß mixed crystal and had a CrOß content of about 25% by weight.
As another example of a nucleating agent, commercially available diaspore such as alumina was made into a fine suspension. The suspension had about 5% by weight Al<sub>2</sub>O ^ content and was used as a nucleating additive in Examples 18-21
Beispkl IQ;
In 10 kg of alumina nucleants suspension 29.5 kg of water, 500 g conc. Nitric acid and 10 kg Disperal (R) stirred. The suspension was deaerated and deagglomerated as in Example 1. The pumped solution contained 17.9 g / l citrate hexahydrate and 14 g / l chromium nitrate nonahydrate. The deagglomerated suspension was further processed as in Example 3. The sintered material contained 0.4% by weight of CeO<sub>2</sub> and 0.3% by weight Cr<sub>2</sub>OSS. The whisker content was about 30% by volume, the whiskers had diameters of about 0.2-0.5 μm and lengths of 4-10 μm. The porosity was 1% by volume.
Example 11:
The sintered, screened material of Example 10 was precalcined at 900 ° C and sintered in the muffle furnace at 1300 ° C for four hours. The sintered material contained about 25 vol% whisker (diameter 0.2-0.5 pm, length 3-8 pm).
Example 12:
In 13 kg of Cr<sub>2</sub>Oss-containing suspension was 26.5 kg of water, 500 g conc. Nitric acid and 10 kg Disperal (R) stirred. The suspension was deaerated and deagglomerated as in Example 1. The pumped solution contained 4.5 g / l citrate hexahydrate, 14 g / l chromium nitrate nonahydrate, and 5.6 g / l magnesium nitrate hexahydrate. The suspension was processed further as in Example 3. The sintered product contained 0.1% by weight of CeO<sub>2</sub>, about 3% by weight Cr<sub>2</sub>O 3 and 0.05% by weight of MgO. The whiskers contained next to Al<sub>2</sub>About 3% by weight of CaO, 5% by weight of CeO<sub>2 </sub>and 2% by weight Cr<sub>2</sub>OSS.
-5AT394 850 B
Example 13:
In 40 kg of the fine mixed crystal suspension 500 g conc. Nitric acid and 10 kg Disperal stirred. The suspension was deaerated and deagglomerated as in Example 1. The added solution contained 4.5 g / l citrate hexahydrate. The suspension was dried in the microwave dryer, crushed and sieved. The sieved grain was precalcined at 900 ° C and sintered in the muffle furnace at 1300 ° C for four hours. The sintered product contained 0.1% by weight of CeO<sub>2</sub> and 0.65 wt% Cr<sub>2</sub>O<sub>3</sub>,
Example 14:
In a solution of 39.5 kg of water, 440 g conc. Nitric acid, 196 g of cerium nitrate hexahydrate and 20.3 g of chromium nitrate nonahydrate were stirred into 10 kg of Disperal (R). The suspension was deagglomerated in a stirred ball mill. The deagglomerated suspension was further processed as in Example 13. The sintered material contained about 1% CeO<sub>2</sub> and 0.1% by weight Cr<sub>2</sub>O<sub>3</sub>, In addition to 20 vol% Whiskem it still contained CeC ^ excretions.
Example 15: (without Cr)
The suspension was prepared analogously to Example 10. However, the dosed solution contained no chromium. The further processing likewise corresponded to Example 10. The sintered product contained about 0.4% by weight of CeO<sub>2</sub>,
Example 16: (without Cr)
The material was prepared analogously to Example 15, but the comminution and sieving was carried out after sintering.
Example 17:
In 5 kg of alumina nucleant suspension 34.5 kg of water, 500 g conc. Nitric acid and 10 kg Disperal stirred. The suspension was deaerated and deagglomerated as in Example 1. The pumped solution contained 17.9 g / l citrate hexahydrate, 245 g / l chromium nitrate nonahydrate and 5.6 g / l magnesium nitrate hexahydrate. The deagglomerated suspension was further processed as in Example 13. The sintered product contained 0.4% by weight of CeO<sub>2</sub> and 5% by weight Cr<sub>2</sub>OSS.
Example 18:
In 4 kg derdiasporhältigen nucleating suspension 35.4 kg of water, 500 g conc. Nitric acid and 10 kg Disperal (R) stirred. The suspension was deaerated and deagglomerated as in Example 1. The pumped solution contained 17.9 g / l citrate hexahydrate, 14 g / l chromium nitrate nonahydrate and 5.6 g / l magnesium nitrate hexahydrate. The deagglomerated suspension was further processed analogously to Example 17.
Example 19:
The suspension was prepared as in Example 18, deaerated and deagglomerated. The pumped solution contained 0.9 g / l citrate hexahydrate and 52 g / l calcium nitrate. Further processing was as in Example 3. The sintered material contained 0.02% CeO<sub>2</sub> and 1% CaO. The whiskers contained about 2% CeO<sub>2</sub> and 10% CaO.
Example 20:
The preparation was carried out analogously to Example 19, except that the pumped solution contained 17.9 g / l citrate hexahydrate, 47 g / l chromium nitrate nonahydrate and 52 g calcium nitrate. The sintered material contained 0.4% CeO<sub>2</sub>, 1% Cr<sub>2</sub>O<sub>3</sub> and 1% CaO. The whiskers contained about 7% CeO<sub>2</sub>, 10% CaO and 2% Cr<sub>2</sub>O<sub>3</sub>,
Example 21:
The preparation was analogous to Example 19, but the comminution and sieving was carried out after sintering.
Example 22:
The dried material prepared according to Example 15 was crushed, sieved and annealed at 1200 ° C in a muffle furnace for four hours. The eb-cooled grain was evacuated and covered with a solution of 100 g / 1 chromium nitrate nonahydrate. After aerating, the grain was filtered from the residual solution and The sintering took place according to example 20. The sintered material contained 0.4% CeO<sub>2</sub> and 0.4% Cr<sub>2</sub>O<sub>3</sub>,
-6AT394 850B
Example 23:
The dried material prepared according to Example 15 was crushed, sieved and annealed at 1000 ° C in a muffle furnace for eight hours. The cooled material was evacuated and overcoated with the deagglomerated suspension from Example 17. After aeration, the grain was separated from the suspension and dried. The grain was then sintered in a muffle furnace at 1300 ° C for four hours. The sintered material contained about 1% Cr<sub>2</sub>O<sub>3</sub> and 0.4% CeO<sub>2</sub>,
Example 24;
Analogously to Example 10, but was comminuted after sintering
Example 25:
The dried, screened material of Example 7 became 1600 <sup>0</sup> C annealed in a rotary kiln (residence time approx. 15 min.). It was then rapidly cooled and finish sintered at 1250 ° C for four hours in a muffle furnace
Example 26:
The dried, screened material of Example 7 was precalcined at 800 ° C for four hours and then sintered in the muffle furnace at 1300 ° C for four hours. During sintering, a mixture of 90% nitrogen by volume with 10% hydrogen by volume flowed through the furnace.
The materials described in the examples were tested for porosity, whisker content and compressive strength. Porosity was measured with the mercury pycnometer. The compressive strength of the abrasive grains was tested as follows: The grains were sieved to the fraction 0.5-0.6 mm, the sieved fraction was freed of all elongated grains on a vibrating table and the remainder (cubic shape) in a special diamond pressing tool crushed, each grain is crushed by itself and the necessary force is measured. The table shows the median values of the measured force-number distribution
Metallographic sections were used to produce images in a scanning electron microscope. At these the whisker content and its dimensions was measured. In this case, an average value over 20 grains was formed. Due to the segregation during drying, the whisker content is subject to fluctuations, but the vast majority of the grains contain the amount of whisker indicated in the tables.
The materials produced by the methods described in the examples were processed into grinding wheels, fiber discs and abrasive belts. The grinding tests described below are only examples to show the superior grinding performance. Of course, the material according to the invention can also be used successfully in many other applications.
Ceramic-bonded grinding wheels with the material according to the invention were used in dry grinding for tool grinding. The workpiece consisted of steel with a Rockwell hardness of HRC 65.
The delivery was kept constant and the sweeper of the power consumption was used as a measure of goodness. This value, based on the comparison material without Cr additive (Example 15), is given as a percentage.
Further, the materials of Example 4, 5, 16 and 21 were made into fiber discs (diameter 178 mm) and used for flat grinding of normal steel. The total amount of removal in g after 90 cycles was used as a measure of goodness. The workpiece had a diameter of 25 mm. The comparative material used was a commercially available sol-gel corundum and a semi-precious corundum. The values obtained are listed in the tables and clearly show the excellent grinding performance of the materials produced according to the invention.
table
Properties and grinding tests in grinding wheels
<td>example No.</td><td>Gehaltan CeO<sub>2</sub>(Wt%)</td><td>Cr<sub>2</sub>°<sub>3</sub></td><td>porosity (Vol%)</td><td>whisker (Vol%)</td><td>compressive ness (N)</td><td>grinding power (%)</td>
<td>2</td><td>0.1</td><td>0.3</td><td>3</td><td>15</td><td>69</td><td>120</td>
<td>3</td><td>0.1</td><td>0.3</td><td>2</td><td>18</td><td>72</td><td>130</td>
<td>6</td><td>0.1</td><td>0.3</td><td>2</td><td>17</td><td>74</td><td>135</td>
-7AT 394 850 B
Table (continued!
Properties and grinding tests in grinding wheels
<td>example No.</td><td>Gehaltan CeO<sub>2</sub>(Wt%)</td><td>ϋ<sup>Γ</sup>2θ3</td><td>porosity (Vol%)</td><td>whisker (Vol%)</td><td>compressive ness (N)</td><td>grinding power (%)</td>
<td>7</td><td>0.4</td><td>0.3</td><td>2</td><td>20</td><td>70</td><td>130</td>
<td>8th</td><td>0.4</td><td>1.0</td><td>1</td><td>22</td><td>78</td><td>135</td>
<td>9</td><td>0.4</td><td>0.3</td><td>2</td><td>20</td><td>77</td><td>135</td>
<td>10</td><td>0.4</td><td>0.3</td><td>1</td><td>30</td><td>80</td><td>140</td>
<td>11</td><td>0.4</td><td>0.3</td><td>2</td><td>25</td><td>69</td><td>130</td>
<td>12</td><td>0.1</td><td>3</td><td>1</td><td>20</td><td>75</td><td>135</td>
<td>13</td><td>0.1</td><td>0.65</td><td>2</td><td>18</td><td>65</td><td>115</td>
<td>14</td><td>1</td><td>0.1</td><td>2</td><td>20</td><td>60</td><td>105</td>
<td>15</td><td>0.4</td><td>-</td><td>1</td><td>30</td><td>60</td><td>100</td>
<td>17</td><td>0.4</td><td>5</td><td>1</td><td>28</td><td>80</td><td>135</td>
<td>18</td><td>0.4</td><td>0.3</td><td>2</td><td>25</td><td>78</td><td>140</td>
<td>19</td><td>0.02</td><td>-</td><td>1</td><td>5</td><td>55</td><td>95</td>
<td>20</td><td>0.4</td><td>1.0</td><td>1</td><td>30</td><td>81</td><td>140</td>
<td>22</td><td>0.4</td><td>0.4</td><td>2</td><td>30</td><td>81.</td><td>138</td>
<td>23</td><td>0.4</td><td>1.0</td><td>2</td><td>30</td><td>79</td><td>142</td>
<td>25</td><td>0.4</td><td>0.3</td><td>1</td><td>25</td><td>78</td><td>140</td>
<td>26</td><td>0.4</td><td>0.3</td><td>1</td><td>23</td><td>79</td><td>140</td>
table
Properties and grinding tests in fiber discs
<td>4</td><td>0.1</td><td>0.3</td><td>2</td><td>18</td><td>79</td><td>250</td><td>(G)</td>
<td>5</td><td>0.1</td><td>0.3</td><td>2</td><td>17</td><td>81</td><td>260</td><td>tt</td>
<td>16</td><td>0.4</td><td>-</td><td>1</td><td>30</td><td>60</td><td>200</td><td>11</td>
<td>21</td><td>0.4</td><td>1.0</td><td>2</td><td>30</td><td>79</td><td>280</td><td>tt</td>
<td>24</td><td>0.4</td><td>0.3</td><td>1</td><td>30</td><td>79</td><td>270</td><td>tt</td>
<td></td><td colspan="2">Commercially available sol-gel corundum</td><td></td><td></td><td>50</td><td>160</td><td>tt</td>
<td></td><td>semi-friable</td><td></td><td></td><td></td><td>40</td><td>130</td><td>tt</td>
Contents9
Every citation, both ways
| Document | Relation | Office | Cited during |
|---|---|---|---|
| US5551963A | Cited by | United States of America | Search report |
| US5489318A | Cited by | United States of America | Search report |
| US5498269A | Cited by | United States of America | Search report |
| US5611829A | Cited by | United States of America | Search report |
| US5690707A | Cited by | United States of America | Search report |
| US5871555A | Cited by | United States of America | Search report |
| US5645619A | Cited by | United States of America | Search report |
| US5429647A | Cited by | United States of America | Search report |
| EP0248788A2 | Cites | European Patent Office (EPO) | Search report |
| EP0395091A2 | Cites | European Patent Office (EPO) | Search report |
3 priority claims, no other members on record
Priority claims3
| Document | Office | Kind | Date |
|---|---|---|---|
| 52091 | Austria | A | |
| 0052091 | – | – | – |
| AT19910000520 | – | – | – |
Numbers
- Publication, DOCDB
- 394850
- Publication, EPODOC
- AT394850B
- Application
- 52091
- Application, DOCDB
- 52091
- Application, EPODOC
- AT19910000520
Titles2
- German
- GESINTERTES, MIKROKRISTALLINES KERAMISCHES MATERIAL
- English
- SINTERED, MICROCRYSTALLINE CERAMIC MATERIAL
Classification
- CPC, 3
- C09K3/14
- C04B35/1115
- C04B35/803
- IPC, 6
- C04B35 10
- C04B35 111
- C04B35 80
- C04B35 81
- C09K3 14
- C30B29 62