Sintered ceramic component and a process of forming the same

Patent metadata

Field	Value
Publication number	US-10081575-B2
Application number	US-201715466321-A
Country	US
Kind code	B2
Filing date	Mar 22, 2017
Priority date	Nov 10, 2014
Publication date	Sep 25, 2018
Grant date	Sep 25, 2018

Abstract

A sintered ceramic component can have a final composition including at least 50 wt. % MgO and at least one desired dopant, wherein each dopant of the at least one desired dopant has a desired dopant content of at least 0.1 wt. %. All impurities (not including the desired dopant(s)) are present at a combined impurity content of less than 0.7 wt. %. A remainder can include Al 2 O 3 . The selection of dopants can allow for better control over the visual appearance of the sintered ceramic component, reduces the presence of undesired impurities that may adversely affect another part of an apparatus, or both. The addition of the dopant(s) can help to improve the sintering characteristics and density as compared to a sintered ceramic component that includes the material with no dopant and a relatively low impurity content.

First claim

What is claimed is:

1. A sintered ceramic component, comprising:
at least 50 wt. % MgO;
at least one dopant including CaO, TiO 2 , or a combination thereof, wherein each dopant of the at least one dopant has a dopant content of at least 0.1 wt. %, and
all impurities are present at a combined impurity content of less than 0.7 wt. %,
wherein the sintered ceramic component comprises MgAl 2 O 4 and has a density that is at least 90% of theoretical density; and
wherein when the sintered ceramic component comprises SiO 2 , the SiO 2 is one of the impurities.

2. The sintered ceramic component of claim 1 , wherein the density is at least 94% of the theoretical density.

3. The sintered ceramic component of claim 1 , wherein MgO is in a content from 50 wt. % to 80 wt. %.

4. The sintered ceramic component of claim 1 , wherein the dopant content is in a range of 0.2 wt. % to 5 wt. %.

5. The sintered ceramic component of claim 1 , wherein the at least one dopant includes CaO.

6. The sintered ceramic component of claim 5 , wherein CaO is in a content of at least 0.2 wt. %.

7. The sintered ceramic component of claim 1 , wherein the at least one dopant includes TiO 2 .

8. The sintered ceramic component of claim 7 , wherein TiO 2 is in a content of no greater than 3 wt. %.

9. The sintered ceramic component of claim 1 , wherein the at least one dopant consists essentially of CaO, TiO 2 , or a combination thereof.

10. A sintered ceramic gas manifold, comprising;
at least 50 wt. % MgO;
at least one dopant including CaO, TiO 2 , or a combination thereof, wherein each dopant of the at least one dopant has a dopant content of at least 0.1 wt. %, and
all impurities are present at a combined impurity content of less than 0.7 wt. %,
wherein the sintered ceramic component comprises MgAl 2 O 4 and has a density that is at least 90% of theoretical density.

11. The sintered ceramic component of claim 1 , wherein the sintered ceramic component is a component of a gas-to-liquid membrane system.

12. The sintered ceramic component of claim 1 , wherein the sintered ceramic component has a coefficient of thermal expansion from 25° C. to 1200° C. in a range of 9.0 ppm/° C. to 13.0 ppm/° C.

13. A process of forming a sintered ceramic component including MgAl 2 O 4 comprising:
combining a binder and at least one powder to form a green mixture, wherein the at least one powder includes:
at least 50 wt. % MgO;
at least one dopant material including CaO, CaCO 3 , TiO 2 , or a combination thereof, wherein each dopant material of the at least one desired dopant material has a desired content of at least 0.1 wt. %; and
all impurities are present at a combined impurity content of less than 0.7 wt. %;

shaping the green mixture to form an object having a shape corresponding to the sintered ceramic component; and
sintering the object to form the sintered ceramic component including MgAl 2 O 4 and having a density of at least 90% of theoretical density, wherein when the sintered ceramic component comprises SiO 2 , the SiO 2 is one of the impurities.

14. The process of claim 13 , wherein the at least one powder includes a material including MgAl 2 O 4 .

15. The process of claim 13 , wherein the at least one powder includes MgO and spinel.

16. The process of claim 13 , wherein the at least one powder includes Al 2 O 3 .

17. The process of claim 13 , wherein the at least one dopant material includes CaO, CaCO 3 , or a combination thereof.

18. The process of claim 13 , wherein the at least one dopant material includes Y 2 O 3 .

19. The process of claim 13 , wherein the at least one dopant material consists essentially of CaO, CaCO 3 , TiO 2 or a combination thereof.

20. The process of claim 13 , wherein sintering is performed at a temperature less than 1600° C.

Assignees

• Saint Gobain Ceramics
• Saint Gobain Ct Recherches
• Saint Gobain Ct Recherches

Inventors

• Lin Guangyong
• Narendar Yeshwanth
• Lacourse Brian C
• Robbins Wesley R
• Urffer Daniel René

Classifications

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B2235/72

  Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics · CPC title

• H01M8/1246

  the electrolyte consisting of oxides · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title

• C04B35/053 Primary

  Fine ceramics · CPC title