CA1207153A - Alumina-zirconia abrasive - Google Patents

Alumina-zirconia abrasive

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Publication number
CA1207153A
CA1207153A CA000453779A CA453779A CA1207153A CA 1207153 A CA1207153 A CA 1207153A CA 000453779 A CA000453779 A CA 000453779A CA 453779 A CA453779 A CA 453779A CA 1207153 A CA1207153 A CA 1207153A
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Canada
Prior art keywords
abrasive
alumina
zirconia
product
fused
Prior art date
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Expired
Application number
CA000453779A
Other languages
French (fr)
Inventor
Simon Poon
Ronald W. Trischuk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Abrasives Inc
Original Assignee
Norton Co
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Publication date
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Publication of CA1207153A publication Critical patent/CA1207153A/en
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Abstract

ABSTRACT
Abrasive properties of co-fused alumina zirconia are improved by the addition of from 0.1 to 2% of Y2O3 to the fusion mix and quenching the fused product. Y2O3 ores containing mostly Y2O3 with lesser amounts of rare earth oxides can be substituted for high purity Y2O3.

Description

~2~7~3 Docket A-1887 ALUMINA-ZIRCOMIA ABRASIVE

FIELD OF THE I~VENTION
This invention relates to co-fused alumina zirconia abrasives.
BACKGROUND OF THE I~VENTIO~
U.S. Patent 3,891,408 discloses co-fu~ed alumina zirconia abrasives of eutectic and near eutectic composition (35-50~ zirconia), particularly suitable for low and moderate pressure grinding for which the previously known alumina-ziconia abrasives were not most useful.
The present invention is an improvement over the abrasive disclosed in U~S. Patent 3,891,408, which improvement has been found particularly useful in improving the performance of coated abrasive products.
SUMMARY OF THE lNV~NlION
The invention consists in an alumina-æirconia abrasive product of eutectic or near eutectic composition, as disclosed in U.S. Patent 3,891,408, but difering from such abrasive in the inclusion o from 0.1 to 2.0 weight percent of yttrium oxide, calculated as Y2O3. The 20 abrasive is made by fusing alumina, zirconia, and Y2O3 or a precursor thereo in an arc urnace as, for example, taught in U.S. Patent 3,891,408.
The usion is preferably conducted, at least at the time the fused product to be poured into molds to 25 rapidly chill it, under slightly reducing conditions so that some reduction products such as suboxides, carbides, nitrides, carbonitrides, oxynitrides, or even some elemental metal, are presen~ in small bu~ discernable amounts. The ~2~7~3
2 --product thus has a black appearance, with sometimes visible gold metallic areas, rather than having a light colored or whitish appearance. m e presence of ~uch partially reduced material can also be demonstrated by the presence of a few 5 tenths of a percent by weight of nitrogen and carbon, and by a weight gain upon forced o~idation of 3% or less.
It is essential that the product be rapidly chilled from the molten state so that a fine crystal structure is produced, as described in prior patent 10 3,891,408, whereby the average rod spacing at the center of eutectic colonies is less than 4000 Angstroms.
To ensure reducing conditions readily oxidizeable material such as carbon or aluminum or zirconium metal may be added just before the pouring of the melt into the 15 chilling molds.
After cooling, the product is crushed, for example, by a roll crusher, and screened and separated into useable size porlions of abrasive grits. The grits may then be applied to prepared flexible backings to produce coated 20 abrasive products in any conventional manner well known in the art.
The effect of the addition of Y2O3 to the fusion is believed to be to lower the content of monoclinic zirconia thus minimizing cracking due to the phase 25 tran~formation (tetragonal to monoclinic). This results in high hardness.
EXAMPLE I
A 3,430 pound batch containing the following materials was prepared:
Q5A10 Zirconia 34 Alumina 35~
Scrap alumina-zirconia (fused) 15%
Over~ize " " 15%
Coal 1%

7~i3 Typical analysis of the Q5A10 zirconia i~ as follows:
Si~2 5.22 Fe23 0.12 5 Tio2 0.51 A123 10.98 Zr2 ~2.97 CaO 0.09 MgO 0.02 The mixture was fused in the electric arc furnace in the conventional manner. After staxt-up feed of the mix was completed in 15 minu~es, fusion was continued for 20 minutes at which time Y2O3 was added, over a 5 minute interval, in an amount to result in 0.5% Y2O3 in the 15 final product; then aluminum metal (4% of mix) was added and~ after the elapse of 15 more minutes ~for a total time from feed to tap of 55 minutes). m e molten product was cast between steel plates spaced 3/16" of an inch apart (using a mold such as disclosed in U.S. Patent 3,993,119).
The chemical analysis of the fused, ~olidified product in weight %, designated HPD-02~ was:
sio2 0.13 Fa23 0.32 Tio2 0.07 25 Zr2 39 99 A123 58.69 (by difference) CaO 0.06 MgO 0.02 Hf 0.70 Y2O3 0.50 This example (A2047) was carried out in a small (200 pound capacity) arc furnace. The mix consisted of:
Oversized fused alumina-zirconia lumps 86%
Q5A10 9%
Al ingot (added separately 15 minutes before tap) 4 ~2~53 In this run, the feed was completed after 25 minutes from start up, after 5 more minutes of fusion, yttria was added to give 0.42~ in the product; the addition was completed after 5 minutes at which time the aluminum 5 metal was added, and 15 minutes from the beginning of the aluminum addition the furnace was tapped, using the same mold as in Example 1.
EX~MPLE 3 This was identical to Example 2, except that 10 instead of high purity Y203, a low cost Y203 source was used which contained 63% Y203, with the balance made up of rare earth oxides. ~o significant difference in properties was found as compared with a product made from 99.9~ pure Y203.
15 The analysis of two sources of impure Y203 ound useful were:
Oxide Source ASource B

La203 .5 1.3 CeO2 1 5.2 Pr6ll 5 .6 Nd23 1 1.7 Sm203 2 1.4 EV23 5 .1 Cd203 5 3 3 Tb407 1.7 .5 DY23 11 ~.8 Ho203 2.7 2.2 Er23 6.4 4.5 Tm23 1 .9 Yb203 4.7 g.7 L203 1 ___ Of these materials, La203 - Sm203 are expected to be less desirable, due to their l~wer solubility 35 in ZrO2 at high temperatures. The oxides Tb407 -Lu203 are expected to mimic closely the behavior of Y203 (by inspection of phase diagrams published as "Phase Diagrams for Ceramists" - American Ceramic Society) and are hence thought to be good.

- ~2~7~;3 The abrasive of Ex~nple 1 was crushed to produce an elongated shaped abrasive and compared to a similarly crushed abrasive of the same general composition but without yttria. The abrasive, in the 36 grit size, showed an 5 average overall quality improvement of about 25% in a variety of coated abrasive belt grinding tests, in grinding steels. The 50 grit product showed an average improvement of only over 5% in the 50 grit size.
In resin bonded cut-off wheels, for cutting steel, 10 there was a 26~ improvement over the standard, and in steel grinding with resin bonded disc wheels, the improvement was 23%. In the case of ~he wheel tests the crushing procedure was altered to produce a blocky shape of grit.
Physical hardness and fracture toughness testing 15 indica~es an improvement in such properties having an optimum between O.5 and 1~ Y203, with significant property improvements over the same abrasive, but without Y203 from 0.1% to 2% Y203.

Claims (4)

WHAT IS CLAIMED IS:
1. Fused alumina/zirconia near eutectic abrasive grits with 0.1 to 2.0% by weight of yttrium oxide calculated as Y2O3, and having a maximum spacing of zirconia rods of 4,000 Angstroms, as measured at the eutectic cell centers.
2. An abrasive material as in Claim 1 in which the yttrium oxide content is from 0.4 to 0.7%.
3. A coated abrasive sheet material having the abrasive grits of claim 1 bonded to at least one side thereof.
4. A grinding wheel having the abrasive grits of claim 1 bonded thereon by an organic resin matrix.
CA000453779A 1983-09-29 1984-05-08 Alumina-zirconia abrasive Expired CA1207153A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US537,214 1983-09-29
US06/537,214 US4457767A (en) 1983-09-29 1983-09-29 Alumina-zirconia abrasive

Publications (1)

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CA1207153A true CA1207153A (en) 1986-07-08

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US (1) US4457767A (en)
EP (1) EP0140164B1 (en)
JP (1) JPS6099567A (en)
AT (1) ATE26855T1 (en)
AU (1) AU573625B2 (en)
BR (1) BR8404844A (en)
CA (1) CA1207153A (en)
DE (1) DE3463393D1 (en)
ES (1) ES536206A0 (en)
IN (1) IN162220B (en)
ZA (1) ZA847230B (en)

Families Citing this family (105)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4988370A (en) * 1984-05-31 1991-01-29 Minnesota Mining And Manufacturing Company Alumina bonded abrasive for cast iron
US4741743A (en) * 1985-08-19 1988-05-03 Norton Company Grinding wheel with combination of fused and sintered abrasive grits
US4770671A (en) * 1985-12-30 1988-09-13 Minnesota Mining And Manufacturing Company Abrasive grits formed of ceramic containing oxides of aluminum and yttrium, method of making and using the same and products made therewith
US4960441A (en) * 1987-05-11 1990-10-02 Norton Company Sintered alumina-zirconia ceramic bodies
US5053369A (en) * 1988-11-02 1991-10-01 Treibacher Chemische Werke Aktiengesellschaft Sintered microcrystalline ceramic material
WO1990008744A1 (en) * 1989-02-01 1990-08-09 Showa Denko Kabushiki Kaisha Alumina ceramic, abrasive material, and production thereof
JPH06104817B2 (en) * 1990-10-09 1994-12-21 日本研磨材工業株式会社 Alumina-zirconia lap abrasive, method for producing the same, and polishing composition
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