CA1241027A - PROCESS FOR PRODUCING .beta.-SILICON ALUMINUM OXYNITRIDE (.beta.'-SIALON) USING DISCRETE PARTICLES - Google Patents

Abstract

Abstract A process for producing a refractory material comprising essentially beta'-SiAlON wherein the initial reactants include discrete particles of an SiO2 source and discrete particles of an A12O3 source.

Description

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This invention relates to a process for making a silicon aluminum oxynitride refractory material and, more particularly, a process which includes the use of A12O3 and SiO2 in a discrete particle form as initial reactants.
Silicon aluminum oxynitride refractory materials, and more particularly materials in the Si3N4-AlN-A12O3-SiO2 system, are of ever-increasing interest for refractory applications.
For ease of identification, compositions within this system are referred to as SiAlON, and a number of different phases of SiAlON have been produced and identified. For example, Jack et al U.S. Patent No. 3,991,166 describes one phase and methods of making it, the phase having the general formula Si6 zAlzOzN8 z where z is greater than zero and less than or equal to five.
Various compositions within the bounds of the general formula taught by Jack et al may be produced and each has a crystalline structure similar to beta-Si3N4 and is consequently identified as beta'-SiAlON. Beta'-SiAlON can be defined as a solid solution of A12O3 within a matrix of Si3N4. The compositional limits of reactants, referred to as effective reactants, to produce beta'-SiAlON may be seen by referring to Fig. 2. The compositional amounts of Si3N4, AlN and A12O3 for any beta'-SiAlON formulation may be determined by referring to line AB which is a plot of the compositions of the aforesaid compounds to produce a beta'-SiAlON having the general formula Si6 zAlzOzN8 z where z is greater than zero and less than or equal to five.
Another phase, known as y-phase SiAlON represented by the formula SiA14O2N4, is described in an article entitled "Review: SiAlONs and Related Nitrogen Ceramics", published in ~ s .

~ 0~ 7 Journal of Material Sciences, 11, (1976) at pages 1135-1158.
Compcsitions of SiAlON within a given phase and from phase to phase demonstrate varying characteristics, for example, variances in density, which effect their preferential use in a given application.
Thus far, of all the SiAlON materials, the beta'-SiAlONs have generated the greatest interest because their refractory properties and corrosion resistance characteristics are similar to other nitride refractories such as silicon nitride and silicon oxynitride. Beta'-SiAlON
compositions offer a distinct advantage over silicon nitride and silicon oxynitride for making a refractory, however, because beta'-SiAlON material can be used to produce a refractory by conventional sintering techniques, whereas a refractory produced from silicon nitride or silicon oxynitride requires the use of a pressure sintering technique.
A number of processes for making silicon aluminum oxynitride refractories and refractory materials have been suggested. Weaver U.S. Patent No. 3,837,871 describes a method for producing a product having a substantial amount of what the patentee believes to be the quaternary compound silicon aluminum oxynitride which has a structure similar to that of beta Si3N4 but with an expanded lattice structure. Weaver's method of making the described product is by hot pressing Si20N2 (silicon oxynitride) in the presence of varying amounts of aluminum.
Kamigaito et al U.S. Patent No. 3,903,230 describes a method of making a silicon aluminum oxynitride ceramic by 12~02~7 sintering or hot pressing a mixture of finely divided powders of silicon nitride, alumina and aluminum nitride.
Cutler U.S. Patent No. 3,960,581 describes a process for producing SiAlON by reacting silicon and aluminum compounds in the presence of carbon and nitrogen. Cutler teaches and stresses the importance of using a reactant material having the silicon and aLuminum compounds intimately combined prior to nitriding in order that aluminum oxide is intimately dispersed throughout silicon nitride in the final product. Suggested reactant materials are clay, rice hulls having a solution containing a dissolved aluminum salt absorbed therein, and a precipitate of aluminum and silicon salts. In each case Cutler emphasizes that the silicon and aluminum compound reactants are intimately combined prior to nitriding to produce SiAlON.
Jack et al U.S. Patent No. 3,991,166 describes a beta'-SiAlON product produced by sintering a mixture of alumina or a compound which decomposes to produce alumina and silicon nitride. Another method of producing beta'-SiAlON as described by Jack et al is nitriding silicon powder in the presence of alumina powder.
It may be noted that several of the foregoing processes employ silicon nitride or silicon oxynitride as reactants. Neither of these compounds is found in nature and they are relatively expensive to produce. Cutler's process provides for the use of reactants found in nature but also requires that the reactants be intimately combined before being converted to SiAlON.

It would be advantageous, therefore, to provide a process whereby readily available and relatively inexpensive react:ant materials are nitrided to make silicon aluminum oxynitride materials.
Discrete particles of silica, alumina and carbon may be used as initial reactants in producing essentially beta'-SiAlON. For purposes of this invention, a material that is described as essentially beta'-SiAlON is intended to mean a material having a beta'-SiAlON content greater than approximately 80%. Alternatively, compounds which yield silica or alumina under the temperatures employed in the practice of this invention may be used as sources of silica or alumina.
Such sources include silicates such as quartz, cristabolite, tridymite and amorphous silica as silica sources, for example, and aluminum carbonate, aluminum nitrate, aluminum hydroxide or gibbsite (aluminum trihydrate), for example, as alumina sources. References hereinafter to silica (SiO2) and alumina (A1203) are intended to include, but are not limited to, the foregoing materials cited as examples. The discrete particles of silica, alumina and carbon are mixed to uniformly distribute the particles throughout the mixture which is then combined with enough water to plasticize the mixture for forming into shapes. Forming may be by extruding or other molding methods familiar to those skilled in the art to shape the mixture into pellets. The pellets are then heated in a nitrogen atmosphere to convert the reactants to a beta'-SiAlON material.
It is an object of the invention to provide a method of producing beta'-SiAlON from economical, readily available reactants.

0~'7 This and other objects and advantages will be more fully understood and appreciated with reference to the following description and associated drawings.
Fig. 1 is a graph showing the compositional limits of theinitial reactants to produce beta'-SiAlCN by a process of this invention.
Fig. 2 is a graph showing the compositional limits of transitional or effective reactants to produce beta'-SiAlON by a process of this invention.
As has been noted previously, beta'-SiAlON may be defined as a solid solution of A12O3 within an Si3N4 matrix and is represented by the general formula Si6 zAlzOzN8 z where z is greater than zero and less than or equal to five. To produce beta'-SiAlON by a process of this invention, initial reactants A12O3, SiO2 and C are provided in compositional ratios as indicated by the line AB in Fig. 1. To produce a beta'-SiAlON
when z = 2 with a formula of Si2AlON3, for example, would require 23% by weight A12O3, 24% by weight C and 53% by weight SiO2. Although not essential, it is advantageous to add iron in a form such as Fe2O3 as a catalyst in promoting the formation of beta'-SiAlON. It is believed that oxides of other transitional metals such as nickel, chrome or manganese, for example, may also be used as catalysts in the practice of this invention. Only a small percentagae of catalyst, such as 2%
for example, is added.
The SiO2, A12O3 and C initial reactants are mechanically mixed by any suitable mixing method to uniformly blend the particles. The particles are then combined with enough water by mixing either during blending or subsequent lZ ~ ~ Z 7 thereto, preferably subsequent thereto, to render the mixture plastic for extruding or other molding methods familiar to one skilled in the art to produce a pellet suitable for nitriding.
The particle size and particle distribution of the reactants may vary, but generally, the finer the particles, the more complete is the reaction when fired, as will be discussed later.
It has been observed in the practice of a process of this invention using fumed silica, petrole~m carbon and A12O3 as reactants that approximately 70% of the A12O3 reactant goes into solution within an Si3N4 matrix with a distribution of A12O3 particles as follows: 90% less than 136 microns, 50%
less than 77 microns, 30% less than 62 microns, and 10% less than 42 microns. If the particle size distribution of A1203 is changed to 90% less than 7 microns, 70% less than 4.4 microns, 50% less than 3.3 microns, 30% less than 2.3 microns, and 10%
less than 1.3 microns, the amount of Al2O3 which goes into solution within the Si3N4 matrix increases to 81%. With yet a further reduction in particle size and distribution of 90% less than 1.1 microns, 70% less than 0.52 micron, 50% less than 0.37 micron, 30% less than 0.29 micron, and 10% less than 0.20 micron, the percentage of Al2O3 in solid solution within the Si3N4 matrix increased to more than 95%.
To determine a preferred median particle size and part~cle distribution for SiO2, tests were performed in practicing a process of this invention using petroleum carbon, A12O3 having a median particle size of 0.37 micron, and SiO2 having a particle size distribution of 90% less than 88 microns, 70% less than 44 microns, 50% less than 27.6 microns, ~24~0Z7 30% l.ess than 11 microns, and 10~ less than 3.9 microns. With the foregoing SiO2 particle distribution, 92.3~ of the SiO2 was nitrided and 86% of the A12O3 went into solid solution within an Si3N4 matrix. With a change in SiO2 particle distribution to 90% less than 24.7 microns, 70% less than 11 microns, 50%
less than 5.7 microns, 30% less than 3.9 microns, and 10% less than 2.3 microns, 100% of the SiO2 was nitrided and 86% of the A12O3 went into solid solution within an Si3N4 matrix.
On the basis of the above observations, a preferred median particle size for A12O3 in the practice of a process of this invention is less than 3.5 microns, and a more preferred median particle size of A12O3 is less than 0.37 micron. A
preferred median particle size for SiO2 is less than 27.6 microns and a more preerred median particle size is less than 5.7 microns.
After mixing and molding the initial reactants into pellets, the pellets are dried at a low temperature, such as 110~C, for example, to drive off any excess moisture.
Conversion of the reactants into beta'-SiAlON is accomplished by heating the pellets in a nitrogen atmosphere.
A preferred method of conversion as hereinafter described is the subject of an improved method for producing SiAlON in an application for a U.S. patent by Phelps et al filed concurrently herewith. To convert the reactants to beta'-SiAlON by the referenced preferred method, the pellets are charged into a reactor adapted to maintain the pellets in a nitrogen atmosphere. Nitrogen may be provided as a gas or a compound, such as ammonia, for example, that will reduce to nitrogen gas at the reaction temperature. It is preferred that the nitrogen 1~41027 be provided continuously under a positive pressure to insure that the nitrogen will uniformly contact all of the reactants during the reaction cycle. A suitable reactor to accomplish the above purposes is a fluid bed reactor or packed bed reactor provided with a nitrogen gas dispersing means near the bottom of the reactor and a nitrogen and off-gas outlet near the top.
After charging the pellets into the reactor to form a suitable bed, nitrogen is dispersed through the bed under a positive pressure to purge the reactor of its normal atmosphere.
After establishing a nitrogen atmosphere within the reactor, temperature of the reactants is elevated by a suitable heating means to a temperature of at least 1200C, preferably at least 1400C. It is believed that by maintaining the reactants at a given temperature of at least 1200C for a sufficient period of time, a portion of the initial reactants are reduced to a portion of the effective reactants necessary for producing beta'-SiAlON. The period of time required to accomplish this initial reaction will vary with the temperature employed. It has been discovered that heating at a temperature of 1400C for 1-1/2 hours, for example, is sufficient to accomplish the initial reaction in the process.
It is believed that the above-described initial nitriding step yields Si3N4, AlN and CO as off-gas and may be represented by the equations:

ta) SiO2 + C ~2 Si3N4 + CO

(b) A12O3 + C ~2 AlN + CO.

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It may be noted that in addition to Si3N~ and AlN, A12O,3 is also required as an effective reactant in producing beta^-SiAlON, and A12O3 is provided in a quantity in excess of the amount needed for production of the necessary AlN so that a portion of the A12O3 remains as an effective reactant after the initial reaction.
Following the above-described initial nitriding step.
the reactant temperature is increased to a maximum of 1650C, preferably within a range of 1550 to 1600C, and maintained within that temperature range for a time sufficient to convert the effective reactants to beta'-SiAlON. It is believed that some conversion of the effective reactants begins to occur at temperatures as low as 1200C, but it has been discovered that if the temperature is increased, less time is required to effect an essentially complete conversion of the effective reactants to beta'-SiAlON. Within the range of 1550 to 1600C, a time of heating of approximately 1-1/2 hours is sufficient to yield an essentially single phase beta'-SiAlON.
Although raising the temperature after the initial heating step to produce effective reactants is advantageous in effecting a conversion of the transitional or effective reactants into an essentially single phase beta'-SiAlON, raising the temperature above approximately 1650C promotes the formation of other SiAlON phases which is detrimental to the purposes of the invention.
During the final heating step after nitriding, a nitrogen atmosphere is maintained in the reactor to preserve a stoichiometric balance as expressed in the equation:
Si3N4 + A12O3 + AlN ~ beta'-SiAlON.

4~027 In the foregoing description the two-step nitriding and h,eating cycle of the reactants was accomplished successively and continuously in a reactor. If desired, the process may be interrupted after the initial nitriding step in making the effective reactants, and the effective reactants can then be transferred to an alternate reactor to make the ultimate conversion to beta'-SiAlON.
The following example is offered to illustrate the production of beta'-SiAlON by a preferred process of this invention.
Example 500 g of beta'-SiAlON having a formula Si2AlON3 were prepared from discrete particles of A12O3, fumed SiO2, petroleum carbon and an Fe2O3 catalyst.
The above-mentioned initial reaction particles of A12O3, fumed silica and Fe2O3 were provided having median particle sizes as follows: A12O3 - approximately 1 micron, SiO2 - 0.1 micron, and Fe2O3 - 2.5 microns. By reference to Fig, 1, the portions of reaction materials required to produce 500 g of Si2AlON3 were determined to be: 115 g A12O3, 265 g SiO2 and 120 g of carbon.
The reaction materials in the above-stated portions plus 2~ or 10 g of Fe2O3 catalyst material were charged into a 4.9 liter ceramic ball mill where the materials were uniformly mixed. The resultant mixture was then mixed with enough water to render the mixture plastic, and pellets having dimensions of approximately 3.1 mm in diameter x 18.75 mm long were produced by extruding.

124~02~7 The pellets were then dried to drive off excess water and were charged into an enclosed reactor vessel provided with an inlet below the pellet bed to permit uniform circulation of gaseous nitrogen through the pellets and an outlet near the top of the vessel to permit discharge of nitrogen and reaction gas products.
The vessel having the pellets therein was enclosed in a heating chamber and nitrogen was charged into the vessel at a pressure sufficient to maintain a flow of nitrogen through the vessel throughout the subsequent heating cycles.
When it was determined that the reaction vessel had been purged of air, temperature within the heating chamber was increased an amount necessary to raise the temperature of the pellets to 1400C and that pellet temperature was maintained for 1-1/2 hours.
The pellet temperature was then increased to 1600C
and maintained thereat for 1-1/2 hours. The pellets were then cooled to room temperature and analyzed for composition. It was determined by X-ray diffraction that the processed material was comprised of beta'-Si2AlON3 in excess of 90% and 3A12O3 ' 2SiO2 (mullite), alpha-Fe, SiC and other unidentified phases making up the balance.
Various modifications may be made in the invention without departing from the spirit thereof, or the scope of the claims, and therefore, the exact form shown is to be taken as illustrative only and not in a limiting sense, and it is desired that only such.limitations shall be placed thereon as are :imposed by the prior art, or are specifically set forth in the appended claims.

Claims (11)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A process for producing an essentially beta'-SiAlON
refractory material, comprising mixing initial reactants of SiO2, Al2O3 and C with each of such reactants in discrete particle form and heating the mixture to convert the initial reactants to beta'-SiAlON.

2. The process according to claim 1 wherein said SiO2 initial reactant is selected from a group of materials consisting of quartz, cristabolite, tridymite and amorphous silica.

3. The process according to claim 1 wherein said Al2O3 initial reactant is selected from a group of materials consisting of aluminum carbonate, aluminum nitrate, aluminum hydroxide and gibbsite.

4. The process according to claim 1 wherein the initial reactants are provided in a uniform mixture, said mixture is nitrided in a reactor at temperatures between 1200° and 1450°C
for a time sufficient to convert at least a portion of said initial reactants to at least a portion of effective reactants, and heating said effective reactants in the presence of nitrogen at temperatures from 1400° to 1650°C for a time sufficient to convert said effective reactants to an essentially beta'-SiAlON
refractory material.

5. The process according to claim 4 wherein heating said effective reactants in the presence of nitrogen is at temperatures from 1550° to 1600°C.

6. The process according to claim 1 wherein the median particle size of the Al2O3 initial reactant is less than 3.5 microns.

7. The process according to claim 1 wherein the median particle size of the Al2O3 initial reactant is less than 0.5 micron.

8. The process according to claim 4 wherein effective reactants are Si3N4, AlN and Al2O3.

9. The process according to claim 1 which further includes providing a catalyst selected from the group consisting of iron oxide, nickel oxide, chrome oxide, manganese oxide, cobalt oxide, vanadium oxide, and any other transitional metal oxides.

10. The process according to claim 1 which further includes providing iron oxide as a catalyst.

11. The process according to claim 1 wherein the initial reactants are provided within the following ranges by weight percent: SiO2 from approximately 17% to approximately 63%, Al2O3 from approximately 10% to approximately 70%, and C
from approximately 15% to approximately 27%.