Chemical vapor deposition process for producing metal carbide or nitride whiskers

Claim 2

A process for producing metal carbide, nitride, or carbonitride whiskers comprising the steps of: A. flushing a reaction chamber sealed from the ambient atmosphere with flowing hydrogen gas, wherein the reaction chamber includes one or more substrate surfaces formed from one or more substrate materials suitable for providing catalyzing and supporting substrates for nucleation and growth of the whiskers, and wherein the substrate surfaces are maintained at an operating temperature of about 1025°-1125° C.; and B. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising one or more metal halide gas selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more gases selected from the group consisting of nitrogen, ammonia, and aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon, in an atomic ratio of carbon plus nitrogen to metal of about 5:1 to 16:1 and a volume ratio of hydrocarbon, plus nitrogen, plus ammonia to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a suitable linear velocity for a time sufficient to nucleate and grow the metal carbide, nitride, or carbonitride whiskers on the substrate material surfaces.

Claim 3

A process according to claim 1 wherein the linear velocity of the flowing gas mixture is maintained at about 120-140 cm/sec.

Claim 4

A process according to claim 1 wherein the reaction chamber is arranged generally vertically above and open to a collecting chamber, the collecting chamber being sealed from the ambient atmosphere and being maintained at a temperature sufficiently below the operating temperature to preclude significant reaction of the reactants therein; and further comprising the step of, at least once during the growth of the whiskers, and after time intervals sufficient to permit whisker growth, detaching at least some of the whiskers from the substrate surfaces to fall downward into the collecting chamber to permit additional whiskers to nucleate and grow on the substrate surfaces.

Claim 5

A process according to claim 3 wherein the whisker growth time intervals and the operating temperature are selected to produce whiskers having an aspect ratio of diameter to length of about 1:20 to 1:400.

Claim 6

A process according to claim 3 wherein the collecting chamber is reversibly sealable from the reaction chamber and further comprising the steps of, intermittently during the whisker growth step, sealing the collecting chamber from the reaction chamber; removing the collected whiskers from the reactor; and reopening the collecting chamber to the reaction chamber for collection of additional whiskers.

Claim 7

A process for producing metal carbide whiskers comprising the steps of: A. flushing a reaction chamber sealed from the ambient atmosphere with flowing hydrogen gas, wherein the reaction chamber includes one or more substrate surfaces formed from one or more substrate materials suitable for providing catalyzing and supporting substrates for nucleation and growth of the whiskers, and wherein the substrate surfaces are maintained at an operating temperature of about 1025°-1125° C.; and B. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising a metal halide gas selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon, in an atomic ratio of carbon to metal of about 5:1 to 16:1 and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a suitable linear velocity for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 8

A process for producing metal carbide whiskers comprising the steps of: A. flushing a reaction chamber sealed from the ambient atmosphere with flowing hydrogen gas, wherein the reaction chamber includes one or more substrate surfaces formed from one or more substrate materials suitable for providing catalyzing and supporting substrates for nucleation and growth of the whiskers, and wherein the substrate surfaces are maintained at an operating temperature of about 1025°-1125° C.; and B. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising a metal halide gas selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon, in an atomic ratio of carbon to metal of about 5:1 to 16:1 and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a suitable linear velocity for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 9

A process according to claim 6 wherein the operating temperature is about 1075°-1100° C.

Claim 10

A process according to claim 6 wherein the atomic ratio of carbon to metal is about 8:1 to 12:1.

Claim 11

A process according to claim 6 wherein the linear velocity of the flowing gas mixture is maintained at about 120-140 cm/sec.

Claim 12

A process according to claim 6 wherein the reaction time and operating temperature are selected to produce metal carbide whiskers having an aspect ratio of diameter to length of about 1:20 to 1:400.

Claim 13

A process according to claim 6 wherein the metal halide gas is selected from the group consisting of chlorides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten; and the hydrocarbon gases are selected from the group consisting of compounds of the formulas C n H 2n+2 , C n H 2n , and C n H 2n-2 , where n is a positive integer of 1-4.

Claim 14

A process according to claim 11 wherein the hydrocarbon gases are selected from the group consisting of methane, propane, and acetylene.

Claim 15

A process for producing metal carbide whiskers comprising the steps of: A. heating a reaction chamber sealed from the ambient atmosphere to an operating temperature of about 1025°-1125° C. in an inert atmosphere, the reaction chamber including one or more substrate surfaces formed from one or more substrate materials selected from the group consisting of nickel and an alloy containing at least 50% by weight nickel each coated with a titanium carbide or nitride layer about 20-30 microns thick, and graphite impregnated with about 0.1-1.0 mole % nickel; B. flushing the heated reaction chamber with flowing hydrogen gas; C. where the one or more substrate materials include titanium carbide or nitride coated nickel or nickel alloy, mixing with the hydrogen flowing through the flushed reaction chamber, an aliphatic hydrocarbon gas pyrolyzable at the operating temperature to form free carbon, in a molar ratio, at a flow rate and for a time sufficient to form a thin film of pyrolytic carbon on the substrate material surfaces; and D. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising one or more metal halide gases selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon and which may be the same or different from the hydrocarbon of step C, in an atomic ratio of carbon to metal of about 5:1 to 16:1, and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a linear velocity of about 120-140 cm/sec, for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 16

A process for producing metal carbide whiskers comprising the steps of: A. heating a reaction chamber sealed from the ambient atmosphere to an operating temperature of about 1025°-1125° C. in an inert atmosphere, the reaction chamber including one or more substrate surfaces formed from one or more substrate materials selected from the group consisting of nickel and an alloy containing at least 50% by weight nickel each coated with a titanium carbide or nitride layer about 20-30 microns thick, and graphite impregnated with about 0.1-1.0 mole % nickel; B. flushing the heated reaction chamber with flowing hydrogen gas; C. where the one or more substrate materials include titanium carbide or nitride coated nickel or nickel alloy, mixing with the hydrogen flowing through the flushed reaction chamber, an aliphatic hydrocarbon gas pyrolyzable at the operating temperature to form free carbon, in a molar ratio, at a flow rate and for a time sufficient to form a thin film of pyrolytic carbon on the substrate material surfaces; and D. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising one or more metal halide gases selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon and which may be the same or different from the hydrocarbon of step C, in an atomic ratio of carbon to metal of about 5:1 to 16:1, and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a linear velocity of about 120-140 cm/sec, for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 17

A process according to claim 13 wherein the operating temperature is about 1075°-1100° C.

Claim 18

A process according to claim 13 wherein the atomic ratio of carbon to metal is about 8:1 to 12:1.

Claim 19

A process according to claim 13 wherein the reaction time and operating temperature are selected to produce metal carbide whiskers having an aspect ratio of diameter to length of about 1:20 to 1:400.

Claim 20

A process according to claim 13 wherein the hydrocarbon reactant gases are selected from the group consisting of compounds of the formulas C n H 2n+2 , C n H 2n , and C n H 2n-2 , where n is a positive integer of 1-4.

Claim 21

A process according to claim 13 wherein the metal halide gas is TiCl 4 and the hydrocarbon reactant gases are selected from the group consisting of methane, propane, and acetylene.

Claim 22

A process for producing metal carbide, nitride, or carbonitride whiskers according to claim 1, comprising the steps of: A. flushing a reaction chamber sealed from the ambient atmosphere with flowing hydrogen gas, wherein the reaction chamber is defined by surfaces of which at least a major portion of the surface area is formed from one or more substrate materials suitable for providing catalyzing and supporting substrates for nucleation and growth of the whiskers, and wherein the substrate material surfaces are maintained at an operating temperature of about 1025°-1125° C.; and B. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising one or more metal halide gases selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more gases selected from the group consisting of nitrogen, ammonia, and aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon, in an atomic ratio of carbon plus nitrogen to metal of about 5:1 to 16:1 and a volume ratio of hydrocarbon, plus nitrogen, plus ammonia to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a suitable linear velocity for a time sufficient to nucleate and grow the metal carbide, nitride, or carbonitride whiskers on the substrate material surfaces.

Claim 23

A process according to claim 19 wherein the linear velocity of the flowing gas mixture is maintained at about 120-140 cm/sec.

Claim 24

A process according to claim 19 wherein: the one or more substrate materials are selected from the group consisting of nickel and an alloy containing at least 50% by weight nickel each coated with a titanium carbide or nitride layer about 20-30 microns thick, and graphite impregnated with about 0.1-1.0 mole % nickel.

Claim 25

A process for producing metal carbide whiskers comprising the steps of: A. flushing a reaction chamber sealed from the ambient atmosphere with flowing hydrogen gas, wherein the reaction chamber is defined by surfaces of which at least a major portion of the surface area is formed from one or more substrate materials suitable for providing catalyzing and supporting substrates for nucleation and growth of the whiskers, and wherein the substrate material surfaces are maintained at an operating temperature of about 1025°-1125° C.; and B. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising a metal halide gas selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon, in an atomic ratio of carbon to metal of about 5:1 to 16:1 and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a suitable linear velocity for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 26

A process for producing metal carbide whiskers comprising the steps of: A. flushing a reaction chamber sealed from the ambient atmosphere with flowing hydrogen gas, wherein the reaction chamber is defined by surfaces of which at least a major portion of the surface area is formed from one or more substrate materials suitable for providing catalyzing and supporting substrates for nucleation and growth of the whiskers, and wherein the substrate material surfaces are maintained at an operating temperature of about 1025°-1125° C.; and B. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising a metal halide gas selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon, in an atomic ratio of carbon to metal of about 5:1 to 16:1 and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a suitable linear velocity for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 27

A process according to claim 22 wherein the operating temperature is about 1075°-1100° C.

Claim 28

A process according to claim 22 wherein the atomic ratio of carbon to metal is about 8:1 to 12:1.

Claim 29

A process according to claim 22 wherein the linear velocity of the flowing gas mixture is maintained at about 120-140 cm/sec.

Claim 30

A process according to claim 22 wherein the reaction time and operating temperature are selected to produce metal carbide whiskers having an aspect ratio of diameter to length of about 1:20 to 1:400.

Claim 31

A process according to claim 22 wherein the metal halide gas is selected from the group consisting of chlorides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten; and the hydrocarbon gases are selected from the group consisting of compounds of the formulas C n H 2n+2 , C n H 2n , and C n H 2n-2 , where n is a positive integer of 1-4.

Claim 32

A process according to claim 27 wherein the hydrocarbon gases are selected from the group consisting of methane, propane, and acetylene.

Claim 33

A process for producing metal carbide whiskers comprising the steps of: A. heating a reaction chamber sealed from the ambient atmosphere to an operating temperature of about 1025°-1125° C. in an inert atmosphere, the reaction chamber being defined by surfaces of which at least a major portion of the surface area is formed from one or more substrate materials selected from the group consisting of nickel and an alloy containing at least 50% by weight nickel each coated with a titanium carbide or nitride layer about 20-30 microns thick, and graphite impregnated with about 0.1-1.0 mole % nickel; B. flushing the heated reaction chamber with flowing hydrogen gas; C. where the one or more substrate materials include titanium carbide or nitride coated nickel or nickel alloy, mixing with the hydrogen flowing through the flushed reaction chamber, an aliphatic hydrocarbon gas pyrolyzable at the operating temperature to form free carbon, in a molar ratio, at a flow rate and for a time sufficient to form a thin film of pyrolytic carbon on the substrate material surfaces; and D. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising one or more metal halide gases selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon and which may be the same or different from the hydrocarbon of step C, in an atomic ratio of carbon to metal of about 5:1 to 16:1, and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a linear velocity of about 120-140 cm/sec, for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 34

A process for producing metal carbide whiskers comprising the steps of: A. heating a reaction chamber sealed from the ambient atmosphere to an operating temperature of about 1025°-1125° C. in an inert atmosphere, the reaction chamber being defined by surfaces of which at least a major portion of the surface area is formed from one or more substrate materials selected from the group consisting of nickel and an alloy containing at least 50% by weight nickel each coated with a titanium carbide or nitride layer about 20-30 microns thick, and graphite impregnated with about 0.1-1.0 mole % nickel; B. flushing the heated reaction chamber with flowing hydrogen gas; C. where the one or more substrate materials include titanium carbide or nitride coated nickel or nickel alloy, mixing with the hydrogen flowing through the flushed reaction chamber, an aliphatic hydrocarbon gas pyrolyzable at the operating temperature to form free carbon, in a molar ratio, at a flow rate and for a time sufficient to form a thin film of pyrolytic carbon on the substrate material surfaces; and D. mixing with the hydrogen flowing through the reaction chamber, at about ambient pressure, reactants comprising one or more metal halide gases selected from the group consisting of halides of titanium, zirconium, hafnium, niobium, tantalum, and tungsten, and one or more aliphatic hydrocarbon gases pyrolyzable at the operating temperature to form free carbon and which may be the same or different from the hydrocarbon of step C, in an atomic ratio of carbon to metal of about 5:1 to 16:1, and a volume ratio of hydrocarbon to hydrogen of about 1:5 to 1:20, the flowing mixture of gases being maintained at a linear velocity of about 120-140 cm/sec, for a time sufficient to nucleate and grow metal carbide whiskers on the substrate material surfaces.

Claim 35

A process according to claim 29 wherein the operating temperature is about 1075°-1100° C.

Claim 36

A process according to claim 29 wherein the atomic ratio of carbon to metal is about 8:1 to 12:1.

Claim 37

A process according to claim 29 wherein the reaction time and operating temperature are selected to produce metal carbide whiskers having an aspect ratio of diameter to length of about 1:20 to 1:400.

Claim 38

A process according to claim 29 wherein the hydrocarbon reactant gases are selected from the group consisting of compounds of the formulas C n H 2n+2 , C n H 2n , and C n H 2n-2 , where n is a positive integer of 1-4.

Claim 39

A process according to claim 29 wherein the metal halide gas is TiCl 4 and the hydrocarbon reactant gases are selected from the group consisting of methane, propane, and acetylene.