Zirconia Powder Composition for Tough Sintered Bodies Without HIP
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Solution Overview
Problem
Existing methods for producing zirconia sintered bodies are complicated and difficult to control particle diameters, and HIP sintering lacks versatility, hindering the production of zirconia sintered bodies with high toughness.
Innovation Solution
A zirconia powder with specific stabilizer content (CaO, Y2O3, Er2O3, or Yb2O3) and controlled pore distribution (10 nm to 200 nm) is used, allowing for low-temperature sintering and adjusting the monoclinic crystal phase ratio to 0.2% to 5%, thereby suppressing crack generation and enhancing toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If HIP sintering is used to obtain high toughness zirconia sintered body, then toughness is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The invention changes the stabilizer content parameter to a specific range (1.4-2.0 mol% for Y2O3, 1.4-1.8 mol% for Er2O3 or Yb2O3) and controls pore distribution parameters (peak top diameter 20-120 nm, pore volume 0.2-0.5 ml/g, pore distribution width 30-170 nm) to achieve the desired monoclinic crystal phase ratio (0.2-5%) and high toughness without HIP treatment
Solution Approach 2:
The invention extracts and eliminates the HIP sintering step from the manufacturing process by achieving high toughness through compositional control and conventional sintering alone, thereby simplifying the device and manufacturing complexity
2Strength
If two types of zirconia powders are mixed to achieve high toughness, then toughness is improved, but manufacturing precision and ease of manufacture deteriorate
Solution Approach 1:
The invention uses a single type of zirconia powder with locally optimized properties (specific stabilizer content and controlled pore distribution) rather than mixing different powders, achieving high toughness while simplifying manufacturing precision requirements
Solution Approach 2:
The invention achieves high toughness using a homogeneous single-type zirconia powder composition with controlled stabilizer content and pore distribution, eliminating the complexity of mixing and controlling multiple powder types with different particle diameters
3Reliability
If stabilizer content is increased to prevent cracking, then reliability is improved, but toughness deteriorates
Solution Approach 1:
The invention optimizes the stabilizer content parameter to a specific range (1.4-2.0 mol% for Y2O3, 1.4-1.8 mol% for Er2O3 or Yb2O3) and controls pore distribution parameters to achieve the desired balance between crack resistance and toughness through the monoclinic crystal phase ratio control
Solution Approach 2:
The invention uses the monoclinic crystal phase ratio (0.2-5%) as a feedback parameter to simultaneously indicate both adequate crack resistance (through sufficient stabilizer) and high toughness (through controlled phase transformation), achieving the optimal balance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of zirconia sintered bodies with high toughness and strength, avoiding the need for HIP sintering and two-powder mixing, while maintaining excellent sinterability and resistance to hydrothermal degradation.
Implementation Method 1
step Y of sintering the molded body under conditions at 1200° C. or higher and 1350° C. or lower and for 1 hour or more and 5 hours or less after the step X
Implementation Method 2
the monoclinic crystal phase ratio in a zirconia sintered body increases as the amount of s stabilizer decreases. Here, the fact that the monoclinic crystal phase ratio increases means that much transformation from tetragonal crystal phase to monoclinic crystal phase occurs
Data Source
AI summary
A zirconia powder in which when a stabilizer is Y2O3, a content thereof is 1.4 mol % or more and less than 2.0 mol %; when the stabilizer is Er2O3, a content thereof is 1.4 mol % or more and 1.8 mol % or less; when the stabilizer is Yb2O3, a content thereof is 1.4 mol % or more and 1.8 mol % or less; and when the stabilizer is CaO, a content thereof is 3.5 mol % or more and 4.5 mol % or less; and in a range of 10 nm or more and 200 nm or less in a pore distribution, a peak top diameter of a pore volume distribution is 20 nm or more and 120 nm or less, a pore volume is 0.2 ml/g or more and less than 0.5 ml/g, and a pore distribution width is 30 nm or more and 170 nm or less.