COMPOSITE ARTICLES AND METHODS OF MAKING THE SAME

• US 20070155293A1
• Filed: 12/30/2005
• Published: 07/05/2007
• Est. Priority Date: 12/30/2005
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Anderson, Thomas, Rosenflanz, Anatoly, Endres, Berkan
• Granted Patent: US 7,281,970 B2
• Time in Patent Office: Days
• US Class Current: 451/56
• CPC Class Codes: B24D 3/18 for porous or cellular structure
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C03C 10/00 Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
• CPC Class Codes: C03C 3/125 containing aluminium as glass former
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/3227 Lanthanum oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/36 Glass starting materials for making ceramics, e.g. silica glass
• CPC Class Codes: C04B 2235/5427 millimeter or submillimeter sized, i.e. larger than 0,1 mm
• CPC Class Codes: C04B 2235/77 Density
• CPC Class Codes: C04B 2235/781 Nanograined materials, i.e. having grain sizes below 100 nm
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 35/119 with zirconium oxide
• CPC Class Codes: C04B 35/44 based on aluminates
• CPC Class Codes: C04B 35/62665 Flame, plasma or melting treatment
• CPC Class Codes: C04B 35/645 Pressure sintering

Abstract

Composite articles (e.g., abrasive articles (e.g., abrasive wheels and honing sticks), cutting tools, and cutting tool inserts) comprising a glass-ceramic distributed in a ceramic matrix.

Claims

1. A composite article comprising a glass-ceramic of a first composition distributed in a ceramic matrix comprising a glass of a second composition, wherein the first and second compositions each comprise a mixture of metal oxides, wherein the amount of any particular metal oxide by weight in the first composition is at least 90 percent of its weight percent in the second composition, and the combined amount of metal oxides that are different between the first and second compositions do not exceed 10% of the total weight of all first and second compositions metal oxides, wherein the first and second compositions each comprise at least 35 percent by weight Al₂O₃, based on the total weight of the first and second compositions, respectively, and wherein the glass-ceramic of the first composition has a density at least 90 percent of theoretical density.

2. The composite article according to claim 1, wherein the composite article is an abrasive article.

3. The composite article according to claim 1, wherein the composite article is an abrasive wheel.

4. The composite article according to claim 3, wherein the abrasive article has a porosity in the range from 35 to 65 percent by volume.

5. The composite article according to claim 1, wherein the composite article is a honing stick.

6. The composite article according to claim 1, wherein the composite article is a one of a cutting tool or a cutting tool insert.

7. The composite article according to claim 6, wherein the cutting tool or the cutting tool insert has a porosity in the range from 0 to 5 percent by volume.

8. The composite article according to claim 6, wherein the cutting tool or the cutting tool insert has a porosity in the range from 0 to 2 percent by volume.

9. The composite article according to claim 1, wherein the glass-ceramic of the first composition comprises crystallites having average size no greater than 200 nanometers.

10. The composite article according to claim 1, wherein the first and second compositions each contain not more than 10 percent by weight collectively As₂O₃, Bi₂O₃, B₂O₃, GeO₂, P₂O₅, SiO₂, TeO₂, V₂O₅, alkaline oxides, and alkaline earth oxides, based on the total weight of the first and second compositions, respectively.

11. The composite article according to claim 1 comprising a volume fraction of the ceramic matrix in a range from 30 to 90, and a volume fraction of the glass-ceramic of the first composition in a range from 10 to 70, based on the total volume of the composite article.

12. A method for making a composite article according to claim 1, the method comprising:

providing a mixture of glass-ceramic particles having the first composition and ceramic particles comprising glass having the second composition; and

consolidating glass of the ceramic particles to provide the composite article.

13. The method according to claim 12, wherein the consolidation of glass is conducted at a temperature in a range from 800°

C. to 1 200°

C.

14. The method according to claim 13, wherein the consolidation of glass is conducted at a pressure 100 MPa.

15. A composite article comprising a glass-ceramic of a first composition distributed in a ceramic matrix comprising a glass-ceramic of a second composition, wherein the first and second compositions each comprise a mixture of metal oxides, wherein the amount of any particular metal oxide by weight in the first composition is at least 90 percent of its weight percent in the second composition, and the combined amount of metal oxides that are different between the first and second compositions do not exceed 10% of the total weight of all first and second compositions metal oxides, wherein the first and second compositions each comprise at least 35 percent by weight Al₂O₃, based on the total weight of the first and second compositions, respectively, and wherein the glass-ceramic of the of a first composition has a density at least 90 percent of theoretical density.

16. The composite article according to claim 15 wherein the composite article is an abrasive article.

17. The composite article according to claim 15, wherein the composite article is an abrasive wheel.

18. The composite article according to claim 17, wherein the abrasive article has a porosity in the range from 35 to 65 percent by volume.

19. The composite article according to claim 15, wherein the composite article is a honing stick.

20. The composite article according to claim 15, wherein the composite article is at least one of a cutting tool or cutting tool insert.

21. The composite article according to claim 20, wherein the cutting tool or the cutting tool insert has a porosity in the range from 0 to 5 percent by volume.

22. The composite article according to claim 20, wherein the cutting tool or cutting tool insert has a porosity in the range from 0 to 2 percent by volume.

23. The composite article according to claim 15, wherein the glass-ceramic of the first composition comprises crystallites having average size no greater than 200 nanometers.

24. The composite article according to claim 15, wherein the first and second compositions each contain not more than 10 percent by weight collectively As₂O₃, Bi₂O₃, B₂O₃, GeO₂, P₂O₅, SiO₂, TeO₂, V₂O₅, alkaline oxides, and alkaline earth oxides, based on the total weight of the first and second compositions, respectively.

25. The composite article according to claim 15 comprising a volume fraction of the ceramic matrix in a range from 30 to 90, and a volume fraction of the glass-ceramic of the first composition in a range from 10 to 70, based on the total volume of the composite article.

26. A method for making a composite article according to claim 15, the method comprising:

providing a mixture of glass-ceramic particles having the first composition and ceramic particles comprising glass having the second composition;

consolidating glass of the ceramic particles; and

heat-treating the consolidated glass to convert at least a portion of the glass to crystalline ceramic and provide glass-ceramic to provide the composite article.

27. The method according to claim 26, wherein the consolidation of glass is conducted at a temperature in a range from 800°

C. to 1200°

C.

28. The method according to claim 27, wherein the consolidation of glass is conducted at a pressure 100 MPa.