Self-reinforced silicon nitride ceramic of high fracture toughness and a method of preparing the same

Claim 2

A process for preparing a silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 and containing predominantly β-silicon nitride whiskers having a high average aspect ratio, the process comprising: subjecting a powder mixture comprising (a) silicon nitride in an amount sufficient to provide a ceramic body; (b) a densification aid, said densification aid being a non-oxide derivative of magnesium or a source of an element selected from the group consisting of beryllium, calcium, strontium, barium, radium, lithium, sodium, potassium, rubidium, cesium, silicon, hafnium, tantalum, indium, galium, zinc, titanium and francium, said source being present in an amount sufficient to promote densification of the powder; (c) a conversion aid, said conversion aid being a non-oxide derivative of yttrium or a source of an element selected from the group consisting of scandium, actinium, lanthanum, lithium, sodium, potassium, rubidium, cesium and francium, said source being present in an amount sufficient to promote the essentially complete conversion of the starting silicon nitride to β-silicon nitride; (d) at least one whisker growth enhancing compound in an amount sufficient to promote the formation of β-silicon nitride whiskers, said compound being a non-oxide derivative of calcium, or a derivative of an element selected from the group consisting of sodium, potassium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, strontium, zirconium, niobium, barium, lanthanum, and mixtures thereof, or an oxide of an element selected from the group consisting of gallium, indium, hafnium, tantalum and boron; and (e) a Palmqvist toughness enhancing amount of at least one preformed reinforcing material selected from the group consisting of β-silicon nitride in whisker or fiber form, and silicon carbide, titanium carbide, boron carbide, titanium diboride, aluminum oxide or zirconium oxide in whisker, fiber, particle or platelet form; (b), (c) and (d) being derived from three different elements; to conditions of temperature and pressure sufficient to provide for densification and in situ formation of β-silicon nitride whiskers having an average aspect ratio of at least about 2.5 occur and such that the silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 is formed.

Claim 3

The process of claim 1 wherein the β-silicon nitride whiskers have an aspect ratio of between about 2 and about 16 and are present in an amount of at least about 20 volume percent, as measured by viewing one plane of the silicon nitride ceramic body by scanning electron microscopy.

Claim 4

The process of claim 1 wherein the starting silicon nitride contains no greater than about 10 weight percent β-silicon nitride.

Claim 5

The process of claim 1 wherein the densification aid is present in an amount within a range of from about 0.04 weight percent to about 27.0 weight percent based on the total weight of the powder mixture.

Claim 6

The process of claim 4 wherein the densification aid is selected from the group consisting of oxides of strontium, calcium and sodium.

Claim 7

The process of claim 1 wherein the conversion aid is present in an amount within a range of from about 0.2 weight percent to about 29.5 weight percent based on the total weight of the powder mixture.

Claim 8

The process of claim 1 wherein the densification aid and the conversion aid are present in amounts sufficient to provide a weight ratio of densification aid to conversion aid of from about 0.25 to about 8.

Claim 9

The process of claim 7 wherein the weight ratio is from about 1:1 to about 1.8:1.

Claim 10

The process of claim 1 wherein the whisker growth enhancing compound is present in an amount of from about 0.01 to about five weight percent based upon total weight of the powder mixture.

Claim 11

The process of claim 1 wherein the whisker growth enhancing compound is a non-oxide derivative of calcium.

Claim 12

The process of claim 1 wherein the whisker growth enhancing compound is an oxide of an element selected from the group consisting of gallium, indium, hafnium, tantalum and boron.

Claim 13

The process of claim 1 wherein the powder mixture further comprises silica in an amount of from about 2.3 to about 6 weight percent based upon total weight of the powder mixture.

Claim 14

The process of claim 1 wherein the powder mixture further comprises aluminum nitride or boron nitride in an amount of from about 0.01 to about 5 weight percent based upon total weight of the powder mixture.

Claim 15

The process of claim 1 wherein a total of the amount of silicon nitride plus the amount of preformed reinforcing material is in a range of from about 65 to about 99.75 weight percent based on the total weight of the powder mixture.

Claim 16

The process of claim 14 wherein the total amount is from about 80 to about 97 weight percent based upon total weight of the powder mixture.

Claim 17

The process of claim 1 wherein the temperature is in the range from about 1750° C. to about 1870° C.

Claim 18

The process of claim 1 wherein the pressure is in the range from about 3000 psig to about 6000 psig.

Claim 19

The process of claim 1 wherein the density of the silicon nitride ceramic is greater than about 95 percent of the theoretical value.

Claim 20

A process for preparing a silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 and containing predominantly β-silicon nitride whiskers having a high average aspect ratio, the process comprising: subjecting a powder mixture comprising (a) silicon nitride in an amount sufficient to provide a ceramic body; (b) a densification aid, said densification aid being a non-oxide derivative of magnesium or a source of an element selected from the group consisting of silicon, hafnium, tantalum, indium, galium, zinc and titanium, said source being present in an amount sufficient to promote densification of the powder; (c) a conversion aid, said conversion aid being a non-oxide derivative of yttrium or a source of an element selected from the group consisting of scandium, actanium, lanthanum, lithium, sodium, potassium, rubidium, cesium and francium, said source being present in an amount sufficient to promote the essentially complete conversion of the starting silicon nitride to β-silicon nitride; and (d) at least one whisker growth enhancing compound in an amount sufficient to promote the formation of β-silicon nitride whiskers, said compound being a non-oxide derivative of calcium, or a derivative of an element selected from the group consisting of sodium, potassium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, strontium, zirconium, niobium, barium, lanthanum, and mixtures thereof, or an oxide of an element selected from the group consisting of gallium, indium, hafnium, tantalum and boron; (b), (c) and (d) being derived from three different elements; to conditions of temperature and pressure sufficient to provide for densification and in situ formation of β-silicon nitride whiskers having an average aspect ratio of at least about 2.5 occur and such that the silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 is formed.

Claim 21

A process for preparing a silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 and containing predominantly β-silicon nitride whiskers having a high average aspect ratio, the process comprising: subjecting a powder mixture comprising (a) silicon nitride in an amount sufficient to provide a ceramic body; (b) a densification aid, said densification aid being a non-oxide derivative of magnesium or a source of an element selected from the group consisting of silicon, hafnium, tantalum, indium, galium, zinc and titanium, said source being present in an amount sufficient to promote densification of the powder; (c) a conversion aid, said conversion aid being a non-oxide derivative of yttrium or a source of an element selected from the group consisting of scandium, actanium, lanthanum, lithium, sodium, potassium, rubidium, cesium and francium, said source being present in an amount sufficient to promote the essentially complete conversion of the starting silicon nitride to β-silicon nitride; and (d) at least one whisker growth enhancing compound in an amount sufficient to promote the formation of β-silicon nitride whiskers, said compound being a non-oxide derivative of calcium, or a derivative of an element selected from the group consisting of sodium, potassium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, strontium, zirconium, niobium, barium, lanthanum, and mixtures thereof, or an oxide of an element selected from the group consisting of gallium, indium, hafnium, tantalum and boron; (b), (c) and (d) being derived from three different elements; to conditions of temperature and pressure sufficient to provide for densification and in situ formation of β-silicon nitride whiskers having an average aspect ratio of at least about 2.5 occur and such that the silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 is formed.

Claim 22

A process for preparing a silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 and containing predominantly β-silicon nitride whiskers having a high average aspect ratio, the process comprising: subjecting a powder mixture comprising (a) silicon nitride in an amount sufficient to provide a ceramic body; (b) a densification aid, said densification aid being a non-oxide derivative of magnesium or a source of an element selected from the group consisting of beryllium, calcium, strontium, barium, radium, lithium, sodium, potassium, rubidium, cesium, silicon, hafnium, tantalum, indium, galium, zinc, titanium and francium, said source being present in an amount sufficient to promote densification of the powder; (c) a conversion aid, said conversion aid being a non-oxide derivative of yttrium or a source of an element selected from the group consisting of scandium, actinium, lanthanum, lithium, sodium, potassium, rubidium, cesium and francium, said source being present in an amount sufficient to promote the essentially complete conversion of the starting silicon nitride to β-silicon nitride; (d) at least one whisker growth enhancing compound in an amount sufficient to promote the formation of β-silicon nitride whiskers, said compound being a non-oxide derivative of calcium, or a derivative of an element selected from the group consisting of sodium, potassium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, strontium, zirconium, niobium, barium, lanthanum, and mixtures thereof, or an oxide of an element selected from the group consisting of gallium, indium, hafnium, tantalum and boron; and (e) a Palmqvist toughness enhancing amount of at least one preferred, coated reinforcing material in whisker, fiber or platelet form, the reinforcing material selected from the group consisting of magnesium oxide, aluminum nitride and mullite, the coating selected from the group consisting of silicon carbide, titanium carbide, boron carbide, titanium diboride, aluminum oxide and zirconium oxide; (b), (c) and (d) being derived from three different elements; to conditions of temperature and pressure sufficient to provide for densification and in situ formation of β-silicon nitride whiskers having an average aspect ratio of at least about 2.5 occur and such that the silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 is formed.

Claim 23

A process for preparing a silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 and containing predominantly β-silicon nitride whiskers having a high average aspect ratio, the process comprising: subjecting a powder mixture comprising (a) silicon nitride in an amount sufficient to provide a ceramic body; (b) a densification aid, said densification aid being a non-oxide derivative of magnesium or a source of an element selected from the group consisting of beryllium, calcium, strontium, barium, radium, lithium, sodium, potassium, rubidium, cesium, silicon, hafnium, tantalum, indium, galium, zinc, titanium and francium, said source being present in an amount sufficient to promote densification of the powder; (c) a conversion aid, said conversion aid being a non-oxide derivative of yttrium or a source of an element selected from the group consisting of scandium, actinium, lanthanum, lithium, sodium, potassium, rubidium, cesium and francium, said source being present in an amount sufficient to promote the essentially complete conversion of the starting silicon nitride to β-silicon nitride; (d) at least one whisker growth enhancing compound in an amount sufficient to promote the formation of β-silicon nitride whiskers, said compound being a non-oxide derivative of calcium, or a derivative of an element selected from the group consisting of sodium, potassium, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, strontium, zirconium, niobium, barium, lanthanum, and mixtures thereof, or an oxide of an element selected from the group consisting of gallium, indium, hafnium, tantalum and boron; and (e) a Palmqvist toughness enhancing amount of at least one preferred, coated reinforcing material in whisker, fiber or platelet form, the reinforcing material selected from the group consisting of magnesium oxide, aluminum nitride and mullite, the coating selected from the group consisting of silicon carbide, titanium carbide, boron carbide, titanium diboride, aluminum oxide and zirconium oxide; (b), (c) and (d) being derived from three different elements; to conditions of temperature and pressure sufficient to provide for densification and in situ formation of β-silicon nitride whiskers having an average aspect ratio of at least about 2.5 occur and such that the silicon nitride ceramic body having a fracture toughness greater than about 6 MPa (m) 1/2 is formed.

Claim 24

The process of claim 20 wherein a total of the amount of silicon nitride plus the amount of preformed, coated reinforcing material is in a range of from about 65 to about 99.75 weight percent based on the total weight of the powder mixture.