Stabilized ZrO₂ (Custom Composition)

Stabilised Zirconium Dioxide platform is a custom-manufacturing capability, not a single fixed product: customers specify the stabilising oxide – yttria (Y2O3), calcia (CaO), or magnesia (MgO) – and the doping level, and Infinita formulates zirconia powder to match, from partially-stabilised tetragonal compositions through fully cubic-stabilised grades. This flexibility lets fuel cell developers, thermal barrier coating manufacturers, and structural ceramics engineers source a single supplier for compositions ranging from premium yttria-stabilised electrolyte powders to cost-optimised calcia- or magnesia-stabilised structural and refractory grades. Every batch is formulated to the customer’s target mol% stabiliser, particle size distribution, and purity, with full documentation for qualification. For programs that need a proven, off-the-shelf composition rather than a custom build, Infinita’s catalogue also lists fixed-composition 3YSZ electrolyte powder and alumina-doped scandia-stabilised zirconia (ScSZ-Al2O3) as ready-made examples of what this platform can produce.

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Description

Introduction to Stabilised Zirconium Dioxide Powder

Stabilised zirconia powders are engineered ZrO₂ ceramics in which Y₂O₃, CaO, or MgO stabilisers suppress the disruptive tetragonal-to-monoclinic transformation that occurs in pure zirconia during cooling. Stabiliser concentration controls the resulting phase, from partially stabilised tetragonal zirconia with transformation-toughening capability to fully stabilised cubic zirconia with greater phase stability and, particularly for yttria-stabilised grades, high oxygen-ion conductivity. YSZ is widely used for SOFC electrolytes, while calcia- and magnesia-stabilised zirconia are attractive for structural ceramics, refractories, thermal-barrier coatings, and wear-resistant components. Supplied as fine, free-flowing powders, these materials are engineered with controlled stabiliser content, particle size, and surface area for tape casting, screen printing, plasma spraying, pressing, and extrusion.

FAQs

Question: What is stabilized zirconium dioxide?

Answer: Stabilized zirconium dioxide (ZrO2) is simply a modification of zirconium oxide, with additions such as Y3+, CaO, and MgO added to stabilize temperatures with improved ionic conductivity to a compound tailored to fuel cell applications.

Question: How does stabilized zirconium dioxide improve fuel cell performance?

Answer: The stabilized ZrO2 improves fuel cells' general efficiency, durability, and performance by offering a stable electrolyte and enhancing electrode compatibility. Its resistance to phase transformation and thermal shock contributes to longer operational life.

Question: Can stabilized zirconium dioxide be used in other applications beyond fuel cells?

Answer: Yes, it is used in gas sensors, thermal barrier coatings, electrolytic hydrogen production, and other advanced ceramics applications, giving solid-stabilized zirconium dioxide more versatile usage in various industries.

Question: What doping level determines partial versus full stabilization?

Answer: This varies by stabilizer: yttria-zirconia is typically partially stabilized (tetragonal) around 2-4 mol% and fully stabilized (cubic) around 8 mol% and above, while calcia and magnesia systems use different mol% thresholds. Infinita works with customers to select the doping level that achieves their target crystal structure and property balance.

Introduction to Stabilised Zirconium Dioxide Powder

Property	Value	Significance
Stabilizer Type	Y2O3, CaO, or MgO (customer-specified)	Determines whether the product prioritises ionic conductivity (Y2O3) or low-cost structural/thermal stability (CaO, MgO)
Doping Level	Customer-specified, typically 3-8 mol% (Y2O3) or higher for CaO/MgO systems	Governs partial vs. full stabilization and the resulting balance of toughness versus phase-purity/conductivity
Crystal Structure	Tetragonal (partially stabilised) or cubic fluorite (fully stabilised), depending on stabiliser and level	Tetragonal grades favour fracture toughness; cubic grades favour dimensional/thermal stability and (with Y2O3) ionic conductivity
Density	~5.9-6.1 g/cm3 typical for stabilised cubic/tetragonal zirconia (varies with stabiliser)	Sets target green and sintered densities for the customer’s forming process; see dataNotes on the source page’s unstabilized-ZrO2 value
Melting Point	~2650-2715 degC (comparable for pure and stabilised ZrO2)	Defines the high-temperature processing and service-temperature ceiling regardless of stabiliser chosen
Thermal Conductivity	~1.3-2.5 W/m*K depending on stabilizer, doping level, and porosity	Low thermal conductivity is favourable for thermal barrier coatings; higher-density electrolyte grades trend toward the upper end of this range
Ionic Conductivity	Significant only in Y2O3-stabilized grades; negligible in CaO/MgO-stabilized grades	Determines suitability for SOFC electrolyte use versus purely structural/thermal-barrier use
CAS Number	Stabilizer-specific (e.g., distinct registry numbers exist for Y2O3-, CaO-, and MgO-stabilized ZrO2)	No single CAS number correctly describes every stabilizer/doping combination this platform can produce – final CAS is confirmed once composition is fixed.

Property

Value

Significance

Stabilizer Type

Y2O3, CaO, or MgO (customer-specified)

Determines whether the product prioritises ionic conductivity (Y2O3) or low-cost structural/thermal stability (CaO, MgO)

Doping Level

Customer-specified, typically 3-8 mol% (Y2O3) or higher for CaO/MgO systems

Governs partial vs. full stabilization and the resulting balance of toughness versus phase-purity/conductivity

Crystal Structure

Tetragonal (partially stabilised) or cubic fluorite (fully stabilised), depending on stabiliser and level

Tetragonal grades favour fracture toughness; cubic grades favour dimensional/thermal stability and (with Y2O3) ionic conductivity

Density

~5.9-6.1 g/cm3 typical for stabilised cubic/tetragonal zirconia (varies with stabiliser)

Sets target green and sintered densities for the customer’s forming process; see dataNotes on the source page’s unstabilized-ZrO2 value

Melting Point

~2650-2715 degC (comparable for pure and stabilised ZrO2)

Defines the high-temperature processing and service-temperature ceiling regardless of stabiliser chosen

Thermal Conductivity

~1.3-2.5 W/m*K depending on stabilizer, doping level, and porosity

Low thermal conductivity is favourable for thermal barrier coatings; higher-density electrolyte grades trend toward the upper end of this range

Ionic Conductivity

Significant only in Y2O3-stabilized grades; negligible in CaO/MgO-stabilized grades

Determines suitability for SOFC electrolyte use versus purely structural/thermal-barrier use

CAS Number

Stabilizer-specific (e.g., distinct registry numbers exist for Y2O3-, CaO-, and MgO-stabilized ZrO2)

No single CAS number correctly describes every stabilizer/doping combination this platform can produce – final CAS is confirmed once composition is fixed.

Grade / Form	Typical Purity	Key Features / Uses
Y2O3-stabilized (electrolyte grade)	99.5% – 99.9%, submicron D50	Optimized for oxygen-ion conductivity; matches Infinita’s fixed-composition 3YSZ electrolyte powder at 3 mol% Y2O3
CaO-stabilized (calcia-stabilised zirconia)	99% – 99.5%	Lower raw-material cost stabiliser for structural ceramics, refractories, and general high-temperature components
MgO-stabilized (magnesia partially-stabilised zirconia, Mg-PSZ)	99% – 99.5%	Cost-effective, tetragonal-precipitate microstructure valued for wear resistance and fracture toughness in structural parts
Partially- vs. fully-stabilised grades	Customer-specified doping level	Partially-stabilised (lower mol% dopant) retains transformation toughening; fully-stabilised (higher mol% dopant) maximises phase purity and thermal-cycling stability
Nano-grade powder	99.9%+, D50 well under 100 nm	Enhanced sinterability and lower firing temperature for thin-film, coating, and advanced ceramic applications across any stabiliser chemistry

Grade / Form

Typical Purity

Key Features / Uses

Y2O3-stabilized (electrolyte grade)

99.5% – 99.9%, submicron D50

Optimized for oxygen-ion conductivity; matches Infinita’s fixed-composition 3YSZ electrolyte powder at 3 mol% Y2O3

CaO-stabilized (calcia-stabilised zirconia)

99% – 99.5%

Lower raw-material cost stabiliser for structural ceramics, refractories, and general high-temperature components

MgO-stabilized (magnesia partially-stabilised zirconia, Mg-PSZ)

99% – 99.5%

Cost-effective, tetragonal-precipitate microstructure valued for wear resistance and fracture toughness in structural parts

Partially- vs. fully-stabilised grades

Customer-specified doping level

Partially-stabilised (lower mol% dopant) retains transformation toughening; fully-stabilised (higher mol% dopant) maximises phase purity and thermal-cycling stability

Nano-grade powder

99.9%+, D50 well under 100 nm

Enhanced sinterability and lower firing temperature for thin-film, coating, and advanced ceramic applications across any stabiliser chemistry

Industry	Application	Function
Automotive & Stationary Fuel Cells	SOFC electrolyte membrane (Y2O3-stabilized formulations only)	Fluorite lattice oxygen vacancies conduct O2- ions from cathode to anode while blocking electronic current
Automotive & Stationary Fuel Cells	Electrode support structure	Stabilised zirconia scaffold provides mechanical support and thermal-expansion matching for electrode layers.
Aerospace & Power Generation	Thermal barrier coatings (typically Y2O3- or MgO-stabilized)	Low thermal conductivity and high melting point insulate metal substrates from combustion-level temperatures
Industrial & Structural Ceramics	High-temperature durability components (CaO- or MgO-stabilized)	Suppressed phase transformation delivers dimensional stability through repeated thermal cycling at lower material cost
Automotive Emissions Control	Oxygen (lambda) sensors (Y2O3-stabilized formulations)	Stabilised zirconia solid electrolyte generates a Nernst potential proportional to exhaust oxygen partial pressure
Refractories & Wear Components	Kiln furniture, extrusion dies, wear-resistant liners (CaO/MgO-stabilized)	Transformation-toughened, phase-stable ceramic resists thermal shock and abrasive wear in industrial service

Industry

Application

Function

Automotive & Stationary Fuel Cells

SOFC electrolyte membrane (Y2O3-stabilized formulations only)

Fluorite lattice oxygen vacancies conduct O2- ions from cathode to anode while blocking electronic current

Automotive & Stationary Fuel Cells

Electrode support structure

Stabilised zirconia scaffold provides mechanical support and thermal-expansion matching for electrode layers.

Aerospace & Power Generation

Thermal barrier coatings (typically Y2O3- or MgO-stabilized)

Low thermal conductivity and high melting point insulate metal substrates from combustion-level temperatures