Yttria stabilized zirconia and polymer composition

Abstract

A composition includes yttria and zirconia. The composition can include one or more additional metal oxides and / or metals. The composition can include one or more polymers, such as a polyester and / or an aromatic polyester. The composition can be a powder. The composition can be used for thermal spray coating, for example by plasma spraying, a substrate.

Description

CGT-382 / 8931-0022 YTTRIA STABILIZED ZIRCONIA AND POLYMER COMPOSITION

[0001] This application claims the benefit of U.S. Provisional Application No.63 / 643,212, filed May 6, 2024, the specification and any additional aspects of which are hereby incorporated by reference in their entireties. TECHNICAL FIELD

[0002] Compositions, for example for thermal spraying onto a surface, are presented. SUMMARY

[0003] An aspect of the embodiments includes a composition, comprising yttria (Y2O3) in a weight percentage being in a range from about 0.2 wt% to about 50 wt%; hafnia (HfO2) in a minimum weight percentage of about 0.0001 wt%; and zirconia (ZrO2).

[0004] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0005] In the description of the embodiments, specification, and claims, the term “about” as an adjective or qualitative term for a value or series of values is associated with the first quantitative value(s). Moreover, in the description of the embodiments, specification, and claims, the term “about” as an adjective or qualitative term for the first quantitative value or series of values is also to be associated with the remainder of the quantitative values for all subsequent compositional quantitative values in that composition.

[0006] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising yttria (Y2O3) in a weight percentage being in a range from about 0.2, 0.5, 1, 2, 3, 4, 5, 5.5, 6, 6.5, 7, 7.2, 7.4, 7.5, 7.6, 7.8, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 18, 20, 25, 30, 35, 40, or 45 wt% to about 0.5, 1, 2, 3, 4, 5, 5.5, 6, 6.5, 7, 7.2, 7.4, 7.5, 7.6, 7.8, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 18, 20, 25, 30, 35, 40, 45, or 50 wt%.

[0007] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising hafnia (HfO2) in a weight percentage being in a rangeCGT-382 / 8931-0022 from about 0.001, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 1.2, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 15, 20, or 25 wt% to about 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 1.2, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 15, 20, 25, or 30 wt% .

[0008] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising alumina (Al2O3) in a weight percentage being in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25 wt%, or 30 wt%.

[0009] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising calcium oxide (CaO) in a weight percentage being in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25, or 30 wt%.

[0010] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising magnesia (MgO) in a weight percentage being in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25, or 30 wt%.

[0011] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising silica (SiO2) in a weight percentage being in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 0.7, 1, 1.5, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 0.7, 1, 1.5, 2, 5, or 10 wt%.

[0012] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising titania (TiO2) in a weight percentage being in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4, 0.5, 0.8, 1, 1.5, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4, 0.5, 0.8, 1, 1.5, 2, 5, or 10 wt%.

[0013] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising ferric oxide (Fe2O3) in a weight percentage being in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, or 10 wt% ferric oxide (Fe2O3).CGT-382 / 8931-0022

[0014] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising thorium (Th) in a weight percentage being in a range from about 0.001, 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, or 0.5 wt% to about 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, or 1 wt%.

[0015] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising uranium (U) in a weight percentage being in a range from about 0.001, 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, or 0.5 wt% to about 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, or 1 wt%.

[0016] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising hafnia (HfO2) in a maximum weight percentage about 5, 4, 3, 2.5, 2, 1.5, 1.2, 1, 0.5, 0.2, 0.1, 0.05, 0.02, 0.01, or 0.005 wt% .

[0017] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising alumina (Al2O3) in a maximum weight percentage about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0018] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising calcium oxide (CaO) in a maximum weight percentage about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0019] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising magnesia (MgO) in a maximum weight percentage about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0020] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising silica (SiO2) in a maximum weight percentage about 1.5, 1, 0.7, 0.5, 0.2, 0.1, or 0.05 wt%.CGT-382 / 8931-0022

[0021] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising titania (TiO2) in a maximum weight percentage about 0.8, 0.4, 0.2, 0.1, 0.05, or 0.02 wt%.

[0022] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising ferric oxide (Fe2O3) in a maximum weight percentage about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0023] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising combined thorium (Th) and uranium (U) in a maximum weight percentage about 5, 2, 1, 0.5, or 0.2 wt%.

[0024] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising combined thorium (Th) and uranium (U) in a maximum weight percentage about 0.1, 0.07, 0.05, 0.02, 0.01, or 0.005 wt%.

[0025] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: yttria (Y2O3) comprising a weight percentage in a range from about 1 wt% to about 20 wt%; hafnia (HfO2) comprising a weight percentage from about 0.5 wt% to about 5 wt%; and zirconia (ZrO2).

[0026] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0027] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: yttria (Y2O3) comprising a weight percentage in a range from about 4 wt% to about 12 wt%; hafnia (HfO2) comprising a weight percentage in a range from about 1 wt% to about 3 wt%; and zirconia (ZrO2).CGT-382 / 8931-0022

[0028] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0029] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: yttria (Y2O3) comprising a weight percentage in a range from about 6 wt% to about 8 wt%; hafnia (HfO2) comprising a weight percentage in a range from about 2 wt% to about 3 wt%; and zirconia (ZrO2).

[0030] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0031] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: yttria (Y2O3) comprising a weight percentage in a range from about 7 wt% to about 8 wt%; hafnia (HfO2) in a maximum weight percentage about 2.5 wt%; and zirconia (ZrO2).

[0032] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0033] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, comprising: yttria (Y2O3) comprising a weight percentage in a range from about 6 wt% to about 9 wt% ; hafnia (HfO2) comprising a weight percentage in a range from about 1 wt% to about 3 wt%; zirconia (ZrO2); alumina (Al2O3) in a maximum weight percentage about 0.25 wt%;CGT-382 / 8931-0022 calcium oxide (CaO) in a maximum weight percentage about 0.25 wt%; magnesia (MgO) in a maximum weight percentage about 0.25 wt%; silica (SiO2) in a maximum weight percentage about 0.8 wt%; titania (TiO2) in a maximum weight percentage about 0.5 wt%; ferric oxide (Fe2O3) in a maximum weight percentage about 0.25 wt%; and combined thorium (Th) and uranium (U) in a maximum weight percentage about 0.08 wt%.

[0034] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0035] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: yttria (Y2O3) comprising a weight percentage in a range from about 6 wt% to about 8 wt%; hafnia (HfO2) in a maximum weight percentage about 2.5 wt%; zirconia (ZrO2); alumina (Al2O3) in a maximum weight percentage about 0.2 wt%; calcium oxide (CaO) in a maximum weight percentage about 0.2 wt%; magnesia (MgO) in a maximum weight percentage about 0.2 wt%; silica (SiO2) in a maximum weight percentage about 0.7 wt%; titania (TiO2) in a maximum weight percentage about 0.4 wt%; ferric oxide (Fe2O3) in a maximum weight percentage about 0.2 wt%; and combined thorium (Th) and uranium (U) in a maximum weight percentage about 0.05 wt%.

[0036] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0037] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: yttria (Y2O3) comprising a weight percentage in a range from about 7 wt% to about 8 wt%;CGT-382 / 8931-0022 hafnia (HfO2) in a maximum weight percentage about 2.5 wt%; zirconia (ZrO2); alumina (Al2O3) in a maximum weight percentage about 0.2 wt%; calcium oxide (CaO) in a maximum weight percentage about 0.2 wt%; magnesia (MgO) in a maximum weight percentage about 0.2 wt%; silica (SiO2) in a maximum weight percentage about 0.7 wt%; titania (TiO2) in a maximum weight percentage about 0.4 wt%; ferric oxide (Fe2O3) in a maximum weight percentage about 0.2 wt%; and combined thorium (Th) and uranium (U) in a maximum weight percentage about 0.05 wt%.

[0038] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0039] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein the composition comprises a powder.

[0040] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein particles of the composition have a size in a range from about 8 μm to about 200 μm.

[0041] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein particles of the composition have a size in a range from about 8 μm to about 180 μm.

[0042] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein particles of the composition have a size in a range from about 20 μm to about 125 μm.

[0043] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition further comprising a polymer.CGT-382 / 8931-0022

[0044] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein the polymer comprises a weight percentage in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.15, 1.2, 1.25, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.5, 3, 3.5, 4, 5, 7, 10, 12, 15, or 20 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.15, 1.2, 1.25, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.5, 3, 3.5, 4, 5, 7, 10, 12, 15, 20, or 25 wt% of the composition.

[0045] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein the polymer comprises a weight percentage in a range from about 0.5 wt% to about 2.5 wt% of the composition.

[0046] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein the polymer comprises a weight percentage in a range from about 1 wt% to about 1.5 wt% of the composition.

[0047] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition, wherein the polymer comprises a weight percentage in a range from about 1.15 wt% to about 1.25 wt% of the composition.

[0048] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein the polymer comprises a polyester.

[0049] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein the polymer comprises an aromatic polyester.

[0050] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein the polymer comprises poly(p-oxybenzoate).

[0051] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein the polymer comprises polyethylene terephthalate or polytrimethylene terephthalate.CGT-382 / 8931-0022

[0052] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein the polymer comprises a compound selected from the group consisting of a polycarbonate, a polysulfone, polyethersulfone, polyphenylene sulfone, polyphenylene sulfide, a polyetherketone, polyetheretherketone, polyaryletherketone, polyetherimide, a polyimide, a polyamide, a polyphthalamide, and combinations.

[0053] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein the polymer has a powder form.

[0054] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein particles of the polymer have a size in a range from about 20 μm to about 180 μm.

[0055] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein particles of the polymer have a size in a range from about 45 μm to about 180 μm.

[0056] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein particles of the polymer have a size in a range from about 20 μm to about 125 μm.

[0057] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition wherein particles of the polymer have a size in a range from about 45 μm to about 125 μm.

[0058] A further aspect of the embodiments in accordance with any one or more preceding aspect includes the composition comprising: a metal oxide powder comprising yttria (Y2O3) comprising a weight percentage in a range from about 7 wt% to about 8 wt%; hafnia (HfO2) in a maximum weight percentage about 2.5 wt%; zirconia (ZrO2); alumina (Al2O3) in a maximum weight percentage about 0.2 wt%;CGT-382 / 8931-0022 calcium oxide (CaO) in a maximum weight percentage about 0.2 wt%; magnesia (MgO) in a maximum weight percentage about 0.2 wt%; silica (SiO2) in a maximum weight percentage about 0.7 wt%; titania (TiO2) in a maximum weight percentage about 0.4 wt%; ferric oxide (Fe2O3) in a maximum weight percentage about 0.2 wt%; and combined thorium (Th) and uranium (U) in a maximum weight percentage about 0.05 wt%; and a poly(p-oxybenzoate) powder, wherein particles of the metal oxide powder have a size in a range from about 8 μm to about 180 μm, wherein particles of the poly(p-oxybenzoate) powder have a size in a range from about 45 μm to about 180 μm, and wherein the composition comprises poly(p-oxybenzoate) powder in a weight percentage being in a range from about 1.15 wt% to about 1.25 wt%.

[0059] If additional components of the composition are not present, then the metal oxide powder may be the balance of the composition; if additional components of the composition are present, then, along with those additional components, the metal oxide powder may be the balance of the composition.

[0060] If additional components of the metal oxide powder are not present, then zirconia (ZrO2) may be the balance of the metal oxide powder; if additional components of the metal oxide powder are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the metal oxide powder. DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0061] Embodiments are discussed in detail below. In describing embodiments, specific terminology is employed for the sake of clarity. However, the embodiments are not intended to be limited to the specific terminology so selected. A person skilled in the relevant art will recognize that other equivalent parts can be employed and other methods developed without parting from the spirit and scope of the embodiments. All documents cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated. Any sections are used in this Detailed Description solely in order to orient the reader as to the general subject matter of each section; the description of a feature may span multiple sections; and headings should not be read as affecting the meaning of the description included in any section.CGT-382 / 8931-0022

[0062] In the description of the embodiments, specification, and claims, the term “about” as an adjective or qualitative term for a value is associated with the first quantitative value. Moreover, in the description of the embodiments, specification, and claims, the term “about” as an adjective or qualitative term for the first quantitative value is also to be associated with the remainder of the quantitative values for all subsequent compositional quantitative values in that composition.

[0063] Compositions, as embodied by the disclosure, that can be applied by thermal spraying onto a surface are presented.

[0064] An embodiment includes a composition of metal oxides, which can be ceramics. The composition can include yttria (Y2O3) (a Group 3, Period 5 transition metal oxide) and zirconia (ZrO2) (a Group 4, Period 5 transition metal oxide). The yttria (Y2O3) may stabilize the zirconia (ZrO2). For example, and without being bound by theory, the yttria (Y2O3) may act to reduce the change in density from that of a pure zirconia composition over a large temperature range; that is, the change in density of an yttria and zirconia composition may be less than the change in density of a pure zirconia composition over a temperature range. For example, the yttria (Y2O3) may reduce or eliminate phenomena such as cracking and spalling associated with a change in density in an yttria and zirconia coating from that of a pure zirconia coating when temperature changes, for example, in repeated thermal cycling over large temperature ranges, such as in a coating applied to a turbine component in a gas turbine engine, such as a jet engine. A composition in which yttria stabilizes zirconia can be termed an yttria stabilized zirconia composition.

[0065] For example, an yttria stabilized zirconia composition can be applied as a coating onto a substrate, such as applied as a coating onto a stationary turbine component, including but not limited to a shroud in the interior of a gas turbine engine. For example, the yttria stabilized zirconia composition, for example, as a powder, can be thermally sprayed, for example and not limiting of the disclosure, by plasma spraying, such as atmospheric (air) plasma spraying onto the substrate to form the coating. The yttria stabilized zirconia composition can melt during the thermal spraying, for example during the air plasma spraying.

[0066] The yttria stabilized zirconia coating on a shroud / substrate can be the surface of an abradable seal system. That is, the tips of rotating turbine component blades in the engine can cut (abrade) a groove into the yttria stabilized zirconia coating of the abradable seal system. ForCGT-382 / 8931-0022 example, the yttria stabilized zirconia abradable coating of the abradable seal system can be abraded and / or sacrificially rubbed (off) against and / or by a hard, abrasive tip, such as a tip including cubic boron nitride (cBN), of a blade. The close proximity of the tips of the rotating turbine component blades to the yttria stabilized zirconia coating on the shroud / substrate can provide a seal to prevent or reduce air and / or other gases from leaking past the blade tip, which can decrease the efficiency of the engine. To provide a close (tight) seal, an yttria stabilized zirconia coating should be sufficiently abradable for the rotating turbine component blade tips to cut the groove into the yttria stabilized zirconia coating; while the yttria stabilized zirconia coating should be resistant to erosion by abrasive particles that might be ingested into a gas turbine engine.

[0067] In accordance with aspects of the embodiments of the disclosure, values, ranges, amounts, and other numerical quantifications are approximate. Moreover, in the description of the embodiments, specification, and claims, the term “about” as an adjective or qualitative term for a value or values is associated with the first quantitative value. Moreover, in the description of the embodiments, specification, and claims, the term “about” as an adjective or qualitative term for the first quantitative value(s) is also to be associated with the remainder of the quantitative values for all subsequent compositional quantitative value(s) in that composition.

[0068] In an embodiment, the yttria stabilized zirconia coating has a porosity, which allows control over the mechanical characteristics and properties of the yttria stabilized zirconia coating. Thus, the coating can be sufficiently abradable to allow for formation of the seal with the rotating blade tips and can be sufficiently resistant to erosion. For example, a porosity in a range from about 2, 3, 5, 7, 10, 15, 20, or 25 % to about 3, 5, 7, 10, 15, 20, 25, or 30 % may be desirable. For example, a porosity in a range from about 5 to about 15%, in a range from about 8 to about 15%, or in a range from about 11 to about 14%, such as about 12.5%, can be desirable.

[0069] In an embodiment, to have, increase, and / or control porosity in the yttria stabilized zirconia coating, a fugitive material or fugitive can be included in (mixed with) the yttria stabilized zirconia composition, where the composition can be thermally sprayed, for example plasma sprayed, such as by atmospheric (air) plasma spraying, onto the substrate. The inclusion of the fugitive material can increase and / or control porosity in the yttria stabilized zirconia coating. For example, the fugitive material or fugitive can be a polymer. For example, the fugitive material or fugitive can be a polyester, an aromatic polyester, or poly(p-oxybenzoate). The fugitive material or fugitive can be vaporized, volatized, decomposed, and / or burned during the thermal spraying,CGT-382 / 8931-0022 once the yttria stabilized zirconia coating has been deposited onto the substrate, and / or by heating the substrate onto which the yttria stabilized zirconia coating has been deposited, for example, by heating to a temperature of 704 °C (1300 °F) or greater. For example, the fugitive material or fugitive can be burned off during air plasma spraying, after coating, and / or during one or more burnouts after coating with the yttria stabilized zirconia composition. The vaporization, volatilization, decomposition, burning, burning off, and / or burnouts of the fugitive can increase the porosity of the coating, for example, can increase the porosity of the coating in a controlled manner, for example, so that the coating is abradable and / or to control the abradability of the coating.

[0070] In an embodiment, the yttria stabilized zirconia composition includes yttria (Y2O3) in a range from about 0.2, 0.5, 1, 2, 3, 4, 5, 5.5, 6, 6.5, 7, 7.2, 7.4, 7.5, 7.6, 7.8, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14 15, 16, 18, 20, 25, 30, 35, 40, or 45 wt% to about 0.5, 1, 2, 3, 4, 5, 5.5, 6, 6.5, 7, 7.2, 7.4, 7.5, 7.6, 7.8, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 18, 20, 25, 30, 35, 40, 45, or 50 wt%.

[0071] In an embodiment, the yttria stabilized zirconia composition includes at least one metal oxide, for example, at least one transition metal oxide, in addition to yttria and zirconia. For example, the yttria stabilized zirconia composition can include the Group 4, Period 6 transition metal oxide hafnia (HfO2). The hafnia can be a desired component that enhances properties of the yttria stabilized zirconia composition, can be an impurity that is a tolerated component that has minimal effect on the properties of the yttria stabilized zirconia composition, or can be an impurity that can be reduced in the yttria stabilized zirconia composition. For example, hafnia (HfO2) can be in commercial-grade zirconia (ZrO2) as a result of hafnium (Hf) co-occurring with zirconium (Zr) in ore from which zirconia (ZrO2) is derived. Alternatively, the hafnia (HfO2) percentage can be less than that in commercial-grade zirconia (ZrO2), for example, because a portion or all of the zirconia (ZrO2) is derived from hafnium-depleted zirconium metal, such as nuclear-grade zirconium metal. Alternatively, the percentage of hafnia (HfO2) can be greater than that in commercial-grade zirconia (ZrO2), for example, because commercially-available hafnia (HfO2), for example, oxidized hafnium (Hf) metal, is added to the yttria stabilized zirconia composition. For example, the yttria stabilized zirconia composition can include hafnia (HfO2) in a range from about 0.001, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 1.2, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 15, 20, or 25 wt% to about 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 1.21.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 15, 20, 25, or 30 wt%. For example, the yttria stabilized zirconia composition can include hafnia (HfO2) at maximum about 5, 4, 3, 2.5, 2, 1.5, 1.2, 1, 0.5, 0.2, 0.1, 0.05, 0.02, 0.01, or 0.005 wt%.CGT-382 / 8931-0022

[0072] For example, the yttria stabilized zirconia composition can include the Group 4, Period 4 transition metal oxide titania (TiO2) and / or the Group 8, Period 4 transition metal oxide ferric oxide (Fe2O3). Titania (TiO2) and / or ferric oxide (Fe2O3) can be co-occurring with the provided zirconia (ZrO2), yttria (Y2O3), or another metal oxide in or can be added to the yttria stabilized zirconia composition. The titania (TiO2) and / or the ferric oxide (Fe2O3) can be a desired component that enhances properties of the yttria stabilized zirconia composition, can be an impurity that is a tolerated component that has minimal effect on the properties of the yttria stabilized zirconia composition, or can be an impurity that can be reduced in the yttria stabilized zirconia composition. For example, the yttria stabilized zirconia composition can include titania (TiO2) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4, 0.5, 0.8, 1, 1.5, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4, 0.5, 0.8, 1, 1.5, 2, 5, or 10 wt%. For example, the yttria stabilized zirconia composition can include titania (TiO2) at maximum about 0.8, 0.4, 0.2, 0.1, 0.05, or 0.02 wt%. For example, the yttria stabilized zirconia composition can include ferric oxide (Fe2O3) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, or 10 wt%. For example, the yttria stabilized zirconia composition can include ferric oxide (Fe2O3) at maximum about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0073] For example, the yttria stabilized zirconia composition can include at least one alkaline earth metal oxide, such as the Group 2, Period 3 alkaline earth metal oxide magnesia (MgO) and / or the Group 2, Period 4 alkaline earth metal oxide calcium oxide (CaO) (also termed calcia). Magnesia (MgO) and / or calcium oxide (CaO) can be co-occurring with the provided zirconia (ZrO2), yttria (Y2O3), or another metal oxide in or can be added to the yttria stabilized zirconia composition. The magnesia (MgO) and / or calcium oxide (CaO) can be a desired component that enhances properties of the yttria stabilized zirconia composition, can be an impurity that is a tolerated component that has minimal effect on the properties of the yttria stabilized zirconia composition, or can be an impurity that can be reduced in the yttria stabilized zirconia composition. For example, the yttria stabilized zirconia composition can include magnesia (MgO) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25, or 30 wt%. For example, the yttria stabilized zirconia composition can include magnesia (MgO) at maximum about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%. For example, the yttria stabilized zirconia composition can include calcium oxide (CaO) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3,CGT-382 / 8931-0022 0.5, 1, 2, 5, 10, 15, 20, 25 wt%, or 30 wt%. For example, the yttria stabilized zirconia composition can include calcium oxide (CaO) at maximum about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0074] For example, the yttria stabilized zirconia composition can include at least one boron group metalloid or metal oxide, such as the Group 13, Period 3 metal oxide alumina (Al2O3). Alumina can be co-occurring with the provided zirconia (ZrO2), yttria (Y2O3), or another metal oxide in or can be added to the yttria stabilized zirconia composition. The alumina (Al2O3) can be a desired component that enhances properties of the yttria stabilized zirconia composition, can be an impurity that is a tolerated component that has minimal effect on the properties of the yttria stabilized zirconia composition, or can be an impurity that can be reduced in the yttria stabilized zirconia composition. For example, the yttria stabilized zirconia composition can include alumina (Al2O3) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25, or 30 wt%. For example, the yttria stabilized zirconia composition can include alumina (Al2O3) at maximum about 0.4, 0.3, 0.2, 0.15, 0.1, 0.05, or 0.02 wt%.

[0075] For example, the yttria stabilized zirconia composition can include at least one carbon group oxide, such as the Group 14, Period 3 metalloid oxide silica (SiO2). Silica can be naturally occurring with the provided zirconia (ZrO2), yttria (Y2O3), or another metal oxide in or can be added to the yttria stabilized zirconia composition. The silica (SiO2) can be a desired component that enhances properties of the yttria stabilized zirconia composition, can be an impurity that is a tolerated component that has minimal effect on the properties of the yttria stabilized zirconia composition, or can be an impurity that can be reduced in the yttria stabilized zirconia composition. For example, the yttria stabilized zirconia composition can include silica (SiO2) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 0.7, 1, 1.5, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 0.7, 1, 1.5, 2, 5, or 10 wt%. For example, the yttria stabilized zirconia composition can include silica (SiO2) at maximum about 1.5, 1, 0.7, 0.5, 0.2, 0.1, or 0.05 wt%.

[0076] For example, the yttria stabilized zirconia composition can include at least one actinide in Period 7, such as the actinide thorium (Th) and / or the actinide uranium (U). The actinide can be in a compound, for example, in an oxide, such as in thoria (ThO2), urania (UO2), or triuranium octoxide (U3O8). The actinide can be co-occurring with the provided zirconia (ZrO2), yttria (Y2O3), or another metal oxide in or can be added to the yttria stabilized zirconia composition. The actinide can be a desired component that enhances properties of the yttria stabilized zirconia composition, can be an impurity that is a tolerated component that has minimalCGT-382 / 8931-0022 effect on the properties of the yttria stabilized zirconia composition, or can be an impurity that can be reduced in the yttria stabilized zirconia composition. For example, the percentage of an actinide in the yttria stabilized zirconia composition can be reduced to reduce the overall radioactivity of the yttria stabilized zirconia composition. For example, the yttria stabilized zirconia composition can include thorium (Th) in a range from about 0.001, 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, or 0.5 wt% to about 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, or 1 wt%. For example, the yttria stabilized zirconia composition can include uranium (U) in a range from about 0.001, 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, or 0.5 wt% to about 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, or 1 wt%. For example, the yttria stabilized zirconia composition can include combined thorium (Th) and uranium (U) at maximum about 5, 2, 1, 0.5, or 0.2 wt%. For example, the yttria stabilized zirconia composition can include combined thorium (Th) and uranium (U) at maximum about 0.1, 0.07, 0.05, 0.02, 0.01, or 0.005 wt%.

[0077] For example, the yttria stabilized zirconia composition can include as the balance (remainder), after yttria (Y2O3) and any other components, zirconia (ZrO2). For example, the yttria stabilized zirconia composition can include zirconia (ZrO2) in a range from about 5, 10, 20, 30, 40, 50, 55, 60, 62, 65, 70, 75, 80, 82, 85, 87, 87.6, 88, 88.6, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 wt% to about 10, 20, 30, 40, 50, 55, 60, 62, 65, 70, 75, 80, 82, 85, 87, 87.6, 88, 88.6, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.5, or 99.8 wt%.

[0078] For example, the yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 1 wt% to about 20 wt%, hafnia (HfO2) in a range from about 0.5 wt% to about 5 wt%, and zirconia (ZrO2). For example, the balance of the yttria stabilized zirconia composition can be zirconia (ZrO2) or, with one or more additional components, the balance of the yttria stabilized zirconia composition can be zirconia (ZrO2). In this example, the yttria stabilized zirconia composition can include zirconia (ZrO2) in a range from about 98.5 wt% to about 75 wt%.

[0079] For example, the yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 4 wt% to about 12 wt%, hafnia (HfO2) in a range from about 1 wt% to about 3 wt%, and zirconia (ZrO2).

[0080] For example, the yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 6 wt% to about 8 wt%, hafnia (HfO2) in a range from about 2 wt% to about 3 wt%, and zirconia (ZrO2).

[0081] For example, the yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 7 wt% to about 8 wt%, hafnia (HfO2) at about 2.5 wt%, and zirconia (ZrO2).CGT-382 / 8931-0022

[0082] If additional components are not present, then zirconia (ZrO2) may be the balance of the composition; if additional components are present, then, along with those additional components, zirconia (ZrO2) may be the balance of the composition.

[0083] For example, the yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 6 wt% to about 9 wt%, hafnia (HfO2) in a range from about 1 wt% to about 3 wt%, alumina (Al2O3) at maximum (i.e., at most, i.e., less than or equal to) about 0.25 wt%, calcium oxide (CaO) at maximum about 0.25 wt%, magnesia (MgO) at maximum about 0.25 wt%, silica (SiO2) at maximum about 0.8 wt%, titania (TiO2) at maximum about 0.5 wt%, ferric oxide (Fe2O3) at maximum about 0.25 wt%, combined thorium (Th) and uranium (U) at maximum about 0.08 wt%, and zirconia (ZrO2).

[0084] For example, the yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 6 wt% to about 8 wt%, hafnia (HfO2) at maximum (i.e., at most, i.e., less than or equal to) about 2.5 wt%, alumina (Al2O3) at maximum about 0.2 wt%, calcium oxide (CaO) at maximum about 0.2 wt%, magnesia (MgO) at maximum about 0.2 wt%, silica (SiO2) at maximum about 0.7 wt%, titania (TiO2) at maximum about 0.4 wt%, ferric oxide (Fe2O3) at maximum about 0.2 wt%, combined thorium (Th) and uranium (U) at maximum about 0.05 wt%, and zirconia (ZrO2).

[0085] For example, an yttria stabilized zirconia composition can include yttria (Y2O3) in a range from about 7 wt% to about 8 wt%, hafnia (HfO2) at maximum (i.e., at most, i.e., less than or equal to) about 2.5 wt%, alumina (Al2O3) at maximum about 0.2 wt%, calcium oxide (CaO) at maximum about 0.2 wt%, magnesia (MgO) at maximum about 0.2 wt%, silica (SiO2) at maximum about 0.7 wt%, titania (TiO2) at maximum about 0.4 wt%, ferric oxide (Fe2O3) at maximum about 0.2 wt%, combined thorium (Th) and uranium (U) at maximum about 0.05 wt%, and zirconia (ZrO2).

[0086] In an exemplified embodiment, the composition can include zirconia (ZrO2), yttria (Y2O3), alumina (Al2O3), calcium oxide (CaO), ferric oxide (Fe2O3), hafnia (HfO2), magnesia (MgO), silica (SiO2), titania (TiO2), uranium (U), and thorium (Th). In certain embodiments, the composition can include one or more components in addition to zirconia (ZrO2), yttria (Y2O3), alumina (Al2O3), calcium oxide (CaO), ferric oxide (Fe2O3), hafnia (HfO2), magnesia (MgO), silica (SiO2), titania (TiO2), uranium (U), and thorium (Th). In other embodiments, the composition can omit one or more of alumina (Al2O3), calcium oxide (CaO), ferric oxide (Fe2O3),CGT-382 / 8931-0022 hafnia (HfO2), magnesia (MgO), silica (SiO2), titania (TiO2), uranium (U), and thorium (Th). In certain other embodiments, the composition can include zirconia (ZrO2) and yttria (Y2O3) and can omit one or more of, replace with another component one or more of, and / or include one or more components in addition to alumina (Al2O3), calcium oxide (CaO), ferric oxide (Fe2O3), hafnia (HfO2), magnesia (MgO), silica (SiO2), titania (TiO2), uranium (U), and thorium (Th).

[0087] An yttria stabilized zirconia composition can be a powder including particles. Alternatively, the yttria stabilized zirconia composition can be partially or entirely in another form. For example, the yttria stabilized zirconia composition can be granules, flakes, or elongated particles that are or appear similar to chopped fibers.

[0088] The yttria stabilized zirconia composition can have a particle size distribution (PSD). For example, the yttria stabilized zirconia composition can have a PSD, where particles have a size (for example, a diameter) in a range from about 8 μm to about 200 μm, in a range from about 8 μm to about 180 μm, or in a range from about 20 μm to about 125 μm.

[0089] For example, yttria stabilized zirconia, for example, in powder form, can be formed by spray drying yttria and zirconia components. Sintering can be applied.

[0090] In an exemplified embodiment, an yttria stabilized zirconia and polymer composition can include an yttria stabilized zirconia composition as discussed above and include a polymer. For example, the polymer can be in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.15, 1.2, 1.25, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.5, 3, 3.5, 4, 5, 7, 10, 12, 15, or 20 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.15, 1.2, 1.25, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.5, 3, 3.5, 4, 5, 7, 10, 12, 15, 20, or 25 wt% of the yttria stabilized zirconia and polymer composition. For example, the polymer can be in a range from about 0.5 wt% to about 2.5 wt%, in a range from about 1 wt% to about 1.5 wt%, or in a range from about 1.15 wt% to about 1.25 wt%, such as about 1.2 wt%, of the yttria stabilized zirconia and polymer composition.

[0091] In another example, the polymer can include a polyester, such as an aromatic polyester. For example, the polymer can be or include poly(p-oxybenzoate).

[0092] The polymer can include polyethylene terephthalate or polytrimethylene terephthalate. The polymer can include a polycarbonate, a polysulfone, polyethersulfone, polyphenylene sulfone, polyphenylene sulfide, a polyetherketone, polyetheretherketone,CGT-382 / 8931-0022 polyaryletherketone, polyetherimide, a polyimide, a polyamide, and / or a polyphthalamide or another suitable polymer now known or hereinafter developed.

[0093] The polymer can be a powder including particles. Alternatively, the polymer can be partially or entirely in another form. For example, the polymer can be granules, flakes, or elongated particles that are or appear similar to chopped fibers.

[0094] The polymer can have a particle size distribution (PSD). For example, the polymer can have a PSD such that the particles have a size (for example, a diameter) in a range from about 20 μm to about 180 μm, in a range from about 45 μm to about 180 μm, in a range from about 20 μm to about 125 μm, or in a range from about 45 μm to about 125 μm.

[0095] The polymer powder can be mixed with the yttria stabilized zirconia composition powder to form a blend, such as a uniform or nearly uniform blend of an yttria stabilized zirconia and polymer composition powder. Example 1

[0096] An yttria stabilized zirconia composition has the composition shown in Table 1.Table 1

[0097] In the yttria stabilized zirconia composition in Table 1, yttria (Y2O3) forms from about 7 to about 8 wt% of the composition. The alumina (Al2O3), calcium oxide (CaO), ferricCGT-382 / 8931-0022 oxide (Fe2O3), hafnia (HfO2), magnesia (MgO), silica (SiO2), titania (TiO2), and uranium and thorium (U + Th) are each in the composition at a percentage by weight (weight percentage, wt%) no greater than shown. The zirconia (ZrO2) forms the balance of the composition. For example, if the composition has the components each at the wt% shown in the right-most column, then the zirconia (ZrO2) is 100 – (8 + 0.20 + 0.20 + 0.20 + 2.50 + 0.20 +0.70 + 0.4 + 0.05) = 87.55 wt% of the composition.

[0098] The yttria stabilized zirconia composition of the composition shown in Table 1 can be a powder having a particle size distribution (PSD) as shown in Table 2.Table 2

[0099] For the yttria stabilized zirconia composition in Table 1, in a given row of Table 2, the minimum cumulative percentage of the powder having the particle size indicated in the left- most column and / or the maximum cumulative percentage of the powder having the particle size indicated in the left-most column is shown. For example, in the 1strow, 100% (all or nearly all) of the mass of the powder has particles of a size less than 176 μm. For example, in the 4throw, at least 43% of the mass of the powder has particles of a size less than 62 μm and at most 68.5% of the mass of the powder has particles of a size less than 62 μm. For example, in the 10th(last) row, 0% (none or almost none) of the mass of the powder has particles of a size less than 7.8 μm.CGT-382 / 8931-0022

[0100] The yttria stabilized zirconia powder is formed by agglomeration (spray drying) of yttria (Y2O3) and zirconia (ZrO2). Sintering is applied. The yttria stabilized zirconia powder is blended for more uniform or uniform particle size distribution (PSD). Example 2

[0101] An yttria stabilized zirconia and polymer composition that includes a polymer, for example the aromatic polyester poly(p-oxybenzoate), includes 100 parts by mass of the yttria stabilized zirconia powder of Example 1 and 1.2 parts by mass of poly(p-oxybenzoate).

[0102] The poly(p-oxybenzoate) is a powder having a particle size distribution (PSD) as shown in Table 3.Table 3

[0103] For the poly(p-oxybenzoate), in a given row of Table 3, the minimum cumulative percentage of poly(p-oxybenzoate) powder having the size indicated in the left-most column and / or the maximum cumulative percentage of powder having the size indicated in the left-most column is shown. For example, in the 1strow, at least 98% of the mass of the powder has particles of a size less than 176 μm. For example, in the 3rdrow, at least 65% of the mass of the powder has particles of a size less than 88 μm and at most 85% of the mass of the powder has particles of a size less than 88 μm. For example, in the 5th(last) row, at most 10% of the mass of the powder has particles of a size less than 44 μm.

[0104] The poly(p-oxybenzoate) powder is mixed with the yttria stabilized zirconia powder of Example 1 to form a blend, such as a uniform or a nearly uniform blend of the yttria stabilized zirconia and polymer powder.CGT-382 / 8931-0022

[0105] Although certain embodiments include features presented herein and may include additional features that are not specifically presented herein, other embodiments may completely or essentially omit elements that are presented herein or that are not presented herein.

[0106] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the embodiments. Nothing in this specification should be considered as limiting the scope of the embodiments. All examples presented are representative and non-limiting. All structural and functional equivalents to the elements of the above-described embodiments that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed.

[0107] Moreover, it is not necessary for a composition, device, or method to address each and every problem sought to be solved by the embodiments, for it to be encompassed by the embodiments. No embodiment, feature, element, component, or step in this specification (including the written description, claims, abstract, and any drawings) is intended to be dedicated to the public. In this specification (including the written description, claims, abstract, and any drawings), the terms "comprise" or "comprising" do not exclude other elements or steps, the terms "a", “an”, or "one" do not exclude a plural number, and the term "or" means either or both, unless this application indicates otherwise. As used herein, the terms "approximately" and "about", as applied to one or more values of interest, refer to a value that is similar to a stated reference value. In certain embodiments, the term "approximately" or "about" refers to a range of values that fall within 25%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less in either direction of (greater than or less than) the stated reference value unless otherwise stated or otherwise evident from the context. In certain embodiments, the term "substantially" refers to a quantity, status, or process that a person having ordinary skill in the art would consider to be complete.

[0108] The above-described embodiments may be modified or varied, without departing from the embodiments, as appreciated by those skilled in the art, in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the embodiments may be practiced otherwise than as specifically described.

Claims

CGT-382 / 8931-0022 CLAIMS 1. A composition, comprising: yttria (Y2O3) in a range from about 0.2, 0.5, 1, 2, 3, 4, 5, 5.5, 6, 6.5, 7, 7.2, 7.4, 7.5, 7.6, 7.8, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 18, 20, 25, 30, 35, 40, or 45 wt% to about 0.5, 1, 2, 3, 4, 5, 5.5, 6, 6.5, 7, 7.2, 7.4, 7.5, 7.6, 7.8, 8, 8.5, 9, 9.5, 10, 11, 12, 13, 14, 15, 16, 18, 20, 25, 30, 35, 40, 45, or 50 wt%; hafnia (HfO2) in a range from about 0.001, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 1.2, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 15, 20, or 25 wt% to about 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 1.2, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, 10, 12, 15, 20, 25 wt%, or 30 wt% ; and zirconia (ZrO2).

2. The composition of claim 1, further comprising alumina (Al2O3) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25 wt%, or 30 wt%.

3. The composition of claim 1, further comprising calcium oxide (CaO) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25 wt%, or 30 wt%.

4. The composition of claim 1, further comprising magnesia (MgO) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, or 25 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, 10, 15, 20, 25, or 30 wt%.

5. The composition of claim 1, further comprising silica (SiO2) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 0.7, 1, 1.5, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 0.7, 1, 1.5, 2, 5, or 10 wt%.

6. The composition of claim 1, further comprising titania (TiO2) in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4, 0.5, 0.8, 1, 1.5, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.4, 0.5, 0.8, 1, 1.5, 2, 5, or 10 wt%.CGT-382 / 8931-0022 7. The composition of claim 1, further comprising ferric oxide (Fe2O3) in a range from about 0.01, 0.02, 0.05,0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, or 5 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.5, 1, 2, 5, or 10 wt%.

8. The composition of claim 1, further comprising combined thorium (Th) and uranium (U) at maximum about 5, 2, 1, 0.5, or 0.2 wt%.

9. The composition of claim 1, further comprising combined thorium (Th) and uranium (U) at maximum about 0.1, 0.07, 0.05, 0.02, 0.01, or 0.005 wt%.

10. The composition of claim 1, comprising: yttria (Y2O3) in a range from about 1 wt% to about 20 wt%; hafnia (HfO2) in a range from about 0.5 wt% to about 5 wt%; and zirconia (ZrO2).

11. The composition of claim 1, comprising: yttria (Y2O3) in a range from about 7 wt% to about 8 wt%; hafnia (HfO2) at maximum about 2.5 wt%; zirconia (ZrO2); alumina (Al2O3) at maximum about 0.2 wt%; calcium oxide (CaO) at maximum about 0.2 wt%; magnesia (MgO) at maximum about 0.2 wt%; silica (SiO2) at maximum about 0.7 wt%; titania (TiO2) at maximum about 0.4 wt%; ferric oxide (Fe2O3) at maximum about 0.2 wt%; and combined thorium (Th) and uranium (U) at maximum about 0.05 wt%.

12. The composition of claim 1, wherein the composition comprises a powder.

13. The composition of claim 1, wherein particles of the composition have a size in a range from about 8 μm to about 180 μm.

14. The composition of claim 1, further comprising a polymer.CGT-382 / 8931-0022 15. The composition of claim 14, wherein the composition comprises the polymer in a range from about 0.01, 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.15, 1.2, 1.25, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.5, 3, 3.5, 4, 5, 7, 10, 12, 15, or 20 wt% to about 0.02, 0.05, 0.1, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.15, 1.2, 1.25, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.2, 2.5, 3, 3.5, 4, 5, 7, 10, 12, 15, 20, or 25 wt%.

16. The composition of claim 14, wherein the composition comprises the polymer in a range from about 1 wt% to about 1.5 wt%.

17. The composition of claim 14, wherein the polymer comprises poly(p-oxybenzoate).

18. The composition of claim 14, wherein particles of the polymer have a size in a range from about 45 μm to about 180 μm.

19. The composition of claim 1, comprising: a metal oxide powder comprising yttria (Y2O3) in a range from about 7 wt% to about 8 wt%; hafnia (HfO2) at maximum about 2.5 wt%; zirconia (ZrO2); alumina (Al2O3) at maximum about 0.2 wt%; calcium oxide (CaO) at maximum about 0.2 wt%; magnesia (MgO) at maximum about 0.2 wt%; silica (SiO2) at maximum about 0.7 wt%; titania (TiO2) at maximum about 0.4 wt%; ferric oxide (Fe2O3) at maximum about 0.2 wt%; and combined thorium (Th) and uranium (U) at maximum about 0.05 wt%; and a poly(p-oxybenzoate) powder, wherein particles of the metal oxide powder have a size in a range from about 8 μm to about 180 μm, wherein particles of the poly(p-oxybenzoate) powder have a size in a range from about 45 μm to about 180 μm, andCGT-382 / 8931-0022 wherein the composition comprises poly(p-oxybenzoate) powder in a range from about 1.15 wt% to about 1.25 wt%.

Images