Hot pressing of silicon nitride using beryllium additive

Claim 1

A method of producing a hot-pressed polycrystalline silicon nitride body having a density of at least 80% of the theoretical density of silicon nitride which consists essentially of providing a significantly homogeneous powder dispersion having an average particle size which is submicron of silicon nitride and a beryllium additive, and based on the total composition of the starting silicon nitride powder said silicon nitride powder containing up to about 0.1% by weight of metallic impurities which react with SiO 2 or Si and O 2 to form low melting intergranular silicate glassy phase, up to about 3% by weight of oxygen, up to about 4% by weight of elemental silicon, and up to about 1% by weight of halogen, said beryllium additive being selected from the group consisting of beryllium, beryllium nitride, beryllium fluoride, beryllium silicon nitride and mixtures thereof, said beryllium additive being used in an amount wherein the beryllium component is equivalent to about 0.1% by weight to about 2% by weight of elemental beryllium based on the amount of silicon nitride, and hot-pressing said dispersion in an atmosphere of nitrogen at a temperature ranging from about 1600° C. to about 1850° C. under a pressure of at least about 2000 psi, said nitrogen being free of oxygen or substantially free of oxygen so that there is no significant oxygen pickup by said hot-pressed body, said body being at least substantially free of an intergranular silicate glassy phase at its grain boundaries and substantially retaining its room temperature mechanical properties at elevated temperatures ranging up to about 1400° C. in air.

Claim 2

A method of producing a hot-pressed polycrystalline silicon nitride body having a density of at least 80% of the theoretical density of silicon nitride which consists essentially of providing a significantly homogeneous powder dispersion having an average particle size which is submicron of silicon nitride and a beryllium additive, and based on the total composition of the starting silicon nitride powder said silicon nitride powder containing up to about 0.1% by weight of metallic impurities which react with SiO 2 or Si and O 2 to form low melting intergranular silicate glassy phase, up to about 3% by weight of oxygen, up to about 4% by weight of elemental silicon, and up to about 1% by weight of halogen, said beryllium additive being selected from the group consisting of beryllium, beryllium nitride, beryllium fluoride, beryllium silicon nitride and mixtures thereof, said beryllium additive being used in an amount wherein the beryllium component is equivalent to about 0.1% by weight to about 2% by weight of elemental beryllium based on the amount of silicon nitride, and hot-pressing said dispersion in an atmosphere of nitrogen at a temperature ranging from about 1600° C. to about 1850° C. under a pressure of at least about 2000 psi, said nitrogen being free of oxygen or substantially free of oxygen so that there is no significant oxygen pickup by said hot-pressed body, said body being at least substantially free of an intergranular silicate glassy phase at its grain boundaries and substantially retaining its room temperature mechanical properties at elevated temperatures ranging up to about 1400° C. in air.