JPH0547498B2 - - Google Patents
Info
- Publication number
- JPH0547498B2 JPH0547498B2 JP63188798A JP18879888A JPH0547498B2 JP H0547498 B2 JPH0547498 B2 JP H0547498B2 JP 63188798 A JP63188798 A JP 63188798A JP 18879888 A JP18879888 A JP 18879888A JP H0547498 B2 JPH0547498 B2 JP H0547498B2
- Authority
- JP
- Japan
- Prior art keywords
- solid solution
- sintered body
- solution phase
- heat
- composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000006104 solid solution Substances 0.000 claims description 60
- 239000000203 mixture Substances 0.000 claims description 54
- 239000000126 substance Substances 0.000 claims description 18
- 229910019142 PO4 Inorganic materials 0.000 claims description 16
- 150000001768 cations Chemical class 0.000 claims description 15
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 claims description 15
- 239000010452 phosphate Substances 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 11
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 8
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 7
- 229910006501 ZrSiO Inorganic materials 0.000 claims description 7
- 239000013078 crystal Substances 0.000 claims description 6
- 235000021317 phosphate Nutrition 0.000 description 15
- 238000010304 firing Methods 0.000 description 12
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 10
- 239000000919 ceramic Substances 0.000 description 10
- 150000001875 compounds Chemical class 0.000 description 10
- 230000004580 weight loss Effects 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 7
- 238000000465 moulding Methods 0.000 description 7
- 238000013001 point bending Methods 0.000 description 7
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 5
- 238000005452 bending Methods 0.000 description 5
- 239000011575 calcium Substances 0.000 description 5
- 150000002500 ions Chemical class 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 5
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 229910052788 barium Inorganic materials 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 229910052698 phosphorus Inorganic materials 0.000 description 4
- 239000011574 phosphorus Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 229910052712 strontium Inorganic materials 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 229910052845 zircon Inorganic materials 0.000 description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 244000309464 bull Species 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- 239000003779 heat-resistant material Substances 0.000 description 2
- 150000004679 hydroxides Chemical class 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000000634 powder X-ray diffraction Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 2
- 239000004254 Ammonium phosphate Substances 0.000 description 1
- 238000007088 Archimedes method Methods 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 229910006249 ZrSi Inorganic materials 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 229910000148 ammonium phosphate Inorganic materials 0.000 description 1
- 235000019289 ammonium phosphates Nutrition 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- AYJRCSIUFZENHW-DEQYMQKBSA-L barium(2+);oxomethanediolate Chemical compound [Ba+2].[O-][14C]([O-])=O AYJRCSIUFZENHW-DEQYMQKBSA-L 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000001506 calcium phosphate Substances 0.000 description 1
- 229910000389 calcium phosphate Inorganic materials 0.000 description 1
- 235000011010 calcium phosphates Nutrition 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000005338 heat storage Methods 0.000 description 1
- BDAGIHXWWSANSR-NJFSPNSNSA-N hydroxyformaldehyde Chemical compound O[14CH]=O BDAGIHXWWSANSR-NJFSPNSNSA-N 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 238000007582 slurry-cast process Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- YHKRPJOUGGFYNB-UHFFFAOYSA-K sodium;zirconium(4+);phosphate Chemical compound [Na+].[Zr+4].[O-]P([O-])([O-])=O YHKRPJOUGGFYNB-UHFFFAOYSA-K 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 229910000018 strontium carbonate Inorganic materials 0.000 description 1
- 229910001427 strontium ion Inorganic materials 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910000166 zirconium phosphate Inorganic materials 0.000 description 1
- LEHFSLREWWMLPU-UHFFFAOYSA-B zirconium(4+);tetraphosphate Chemical compound [Zr+4].[Zr+4].[Zr+4].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O LEHFSLREWWMLPU-UHFFFAOYSA-B 0.000 description 1
Landscapes
- Compositions Of Oxide Ceramics (AREA)
Description
[産業上の利用分野]
本発明は、Rが2〜3価の陽イオンとなり得る
元素から選ばれる一種以上の組み合わせからなる
RyZr4SixP6-xO24(xは0以上2以下の数値、yは
化学式の電気的中性条件を満たす2/3以上2以下
の数値を有する)組成の固溶相、該固溶相からな
る耐熱性焼結体、及びその製造方法に関し、更に
詳しくは、耐熱性、高温安定性に優れたRyZr4Six
P6-xO24組成の固溶相、該固溶相からなる低膨張
性と高温熱安定性に優れた耐熱性高強度焼結体及
びその製造方法に関する。
[従来の技術]
近年、工業技術の進歩に伴ない、耐熱性、低膨
張性に優れた材料の要請が高まつている。
このような要請の中、リン酸ジルコニル
〔(ZrO)2P2O7〕が耐熱性且つ低膨張性に優れた材
料として有望であることが分かつてきた。
また、最近、ナトリウム等アルカリ金属のリン
酸ジルコニウムが耐熱性を有し、且つ熱膨張係数
が低い物質として提案されている。(Mat.Res.
Bull.、Vol.19、pp.1451−1456(1984)、Journal
of Materials Science 16、1633−1642(1981)、
及び窯業協会誌95[5]、第531〜537頁(1987))
更には、特定組成のアルカリ土類金属のリン酸
塩化合物についても低膨張性を有するものとして
提案されている。(Mat.Res.Bull.、Vol.20、
pp.99−106、1985、及びJ.Am.Ceram.Soc.、70
[10]C−232〜C−236(1987))
又、米国特許第4675302号明細書には、Ca0.5
Ti2P3O12の基本組成を有するセラミツク材料が
低膨張性に優れたものとして提案されている。
[発明が解決しようとする課題]
しかしながら、上記のリン酸ジルコニル等のリ
ン酸塩化合物は、低膨張性に優れているという利
点を有するものの、1200℃以上の高温においては
熱分解を起こし、リン(P)分が蒸発することが挙げ
られている。例えば、1400℃で100時間熱処理し
た場合には、リン酸ジルコニルは19%、リン酸ジ
ルコニウムナトリウムは36%のもの重量減を示
す、という問題がある。
また、米国特許第4675302号明細書で提案され
ているセラミツク材料は、人工衛星用の温度変化
によつても変形等が生じない低膨張の光学反射器
の基板に主として用いるものであるが、その第2
図に示される如く、温度変化は高々500℃程度ま
でが意図され、例えば1200℃以上の高温における
安定性、耐熱性等についての考慮は何ら払われて
いない。
一方、CaZr4P6O24、SrZr4P6O24、BaZr4P6O24
等のリン酸塩化合物はリン酸ジルコニルに比べ
て、高温での安定性に優れ、1400℃で100時間熱
処理した時の重量減少が、10%以下と優れるが、
CaZr4P6O24は負の熱膨張係数を有するもので低
強度であり、SrZr4P6O24は高強度であるが熱膨
張係数が25×10-7/℃と比較的高熱膨張であり、
高強度で低膨張な特性を有する耐熱性セラミツク
スが望まれていた。
ところでリン酸塩化合物の製造法としては、
Na2CO3、ZrO2、ZrOCl2・8H2O、SiO2、
(NH4)2HPO4、H3PO4、Nb2O5、Y2O3、SrCO3、
K2CO3、CaCO3等の組合わせを用いる方法が知
られている。〔T.Oota and I.Yamai、Journal
of the American Ceramic Society、69、1、
(1986)〕
しかしながら、上記の製造法では、リン酸アン
モニウムあるいはH3PO4が分解する過程で、
P2O5成分が単独に生成して局所的にリン濃度の
高い部分を形成し、焼結中に低融点化合物を生じ
てしまうのである。このため、低融点化合物を中
心にして、焼結体中に巨大ポア(空隙)が生じ、
重大な欠陥が発生することになる。
[課題を解決するための手段]
そこで、本発明者は、上記従来技術の問題点を
解決するため、種々検討したところ、RがCa、
Sr、Ba、Y等2〜3価の陽イオンとなり得る元
素からなる場合に、結晶相の耐熱性や高温熱安定
性が優れ、さらにCaZr4P6O24、SrZr4P6O24、
BaZr4P6O24等の種々のRyZr4P6O24(2/3≦y≦1、
Rは2〜3価の陽イオンとなり得る元素の1種以
上の組み合わせ)化合物はそれぞれ全率固溶体を
形成すること、固溶によりRyZr4P6O24そのもの
の特性、例えば熱膨張挙動や熱的性質等が制御で
きることを見出し、耐熱性、高温熱安定性を維持
しつつ、高強度かつ低膨張である焼結体が得られ
ることがわかつた。加えて、(1)式のようにPイオ
ンの一部をSiイオンとRイオンで同時に置換した
固溶体が形成可能なこと、固溶によりRyZr4Six
P6-xO24そのものの特性、例えば熱膨張挙動や熱
的性質等が制御できることを見出し、耐熱性、強
度を維持しつつ、より高温熱安定性に優れた耐熱
性低膨張材料が得られることがわかり、本発明の
完成に至つたのである。
RyZr4P6O24+xSi4++1/nR′n+
−xP5+RyR′1/oZrSixP6-xO24 ……(1)
(nはRの価数)
即ち、本発明によれば、Rが2〜3価の陽イオ
ンとなり得る元素から選ばれる一種以上の組み合
わせからなるRyZr4SixP6-xO24(xは0以上2以下
の数値、yは化学式の電気的中性条件を満たす2/
3以上2以下の数値を有する)組成の固溶相、該
固溶相からなる耐熱性焼結体、およびZrP2O7、
(ZrO)2P2O7、ZrO2、Zr(OH)4、ZrSiO4、SiO2、
Rのリン酸塩、Rのケイ酸塩、およびRO(Rは
2〜3価の陽イオンとなり得る元素)から選ばれ
るバツチ混合物を成形し焼成することによりRy
Zr4SixP6-xO24を析出させることからなる、Ry
Zr4SixP6-xO24組成の固溶相からなる耐熱性焼結
体の製造方法、が提供される。
なお、本発明のRyZr4SixP6-xO24組成の固溶相
は、それ単味からなる焼結体として応用できるだ
けでなく、例えばジルコン、ジルコニア等耐熱性
化合物との複合体の構成化合物としても応用する
ことができる。
本発明のRyZr4SixP6-xO24組成の固溶相は、R
が2〜3価の陽イオンとなり得る元素から選ばれ
る一種以上の組み合わせからなり、さらにxは0
以上2以下の数値、yは2/3以上2以下の数値を
とることが必要である。Rに1価の陽イオンが含
まれると高温熱安定生に劣り、xが2を越える
と、耐熱性が低下する。
これらの条件を満たすことにより耐熱性、高温
安定生性優れた固溶相が得られる。
Rは2〜3価の陽イオンとなり得る一種以上の
元素の組み合わせであり、一般に周期律表のa
族に属する元素を示すが、バリウム(Ba)、スト
ロンチウム(Sr)、カルシウム(Ca)のうちの一
種以上から構成されることが好ましい。
更に本発明の焼結体によれば、その開気孔率が
50%以下の範囲において、1400℃で100時間熱処
理した後の、リン分蒸発による重量減少率を10%
以下という低い数値とすることができ、しかも曲
げ強度を100Kg/cm2以上とすることができる。す
なわち、開気孔率が50%を超えると曲げ強度が
100Kg/cm2未満となり、セラミツクスを実用材と
して用いる際の必須の強度を満足しなくなる。
又、この焼結体は1400℃にて5時間熱処理後の自
重軟化率は0.3%以下となり、耐熱材料としての
要件を満たすものである。
また、この焼結体は、寸法変化率も小さく、
1400℃にて100時間熱処理した場合、その寸法変
化率は1%以下であり、同じく耐熱材料としての
要件を満足している。さらにこの焼結体は、室温
から1400℃までの熱膨張係数は25×10-7/℃以下
という低さであり、耐熱衝撃性に優れるのであ
る。従つて、上記のような特性を有する本発明の
焼結体は、自動車排ガス浄化触媒担体等のセラミ
ツクハニカム構造体、回転蓄熱式セラミツク熱交
換体、伝熱式熱交換体、ターボチヤージヤーロー
ター用ハウジング及びエンジンマニホールド部断
熱材、デイーゼルパテイキユレートフイルターな
どの如き、耐熱性および高温における熱安定性を
要求される材料に好適に適用される。
次に、本発明に係る耐熱性焼結体の製造方法に
おいては、その原料をZrP2O7、(ZrO)2P2O7、
ZrO2、Zr(OH)4、ZrSiO4、SiO2、Rのリン酸塩、
Rのケイ酸塩、及びRO(Rは2〜3価の陽イオ
ンとなり得る元素)から選ばれる物質よりなる粉
末のバツチ混合物とした点が特徴である。即ち、
ZrP2O7、(ZrO)2P2O7、ZrO2、Zr(OH)4、
ZrSiO4、SiO2、Rのリン酸塩、Rのケイ酸塩、
及びROはそそれ安定な化合物であり、成形焼成
過程で不均一が生じ難く、高温で焼成可能であ
り、耐熱性に優れたセラミツクスを得ることがで
きるのである。
一方、P2O5源を従来用いられているリン酸に
求めた場合、リン酸は液体であるため、混合過程
で不均一になり、前記したように局所的にリン濃
度の高い部分を形成し、低融点の化合物を生じ
る。このため、低融点化合物を中心にして焼結体
中に巨大なポアが生じるという重大な欠陥が発生
する。また、リン酸を含む坏土を押出成形してハ
ニカム構造体を得る場合、リン酸の腐食性のた
め、押出成形用の口金や押出成形機のシリンダー
が錆びたり腐食したりして著しく成形が困難とな
る。更には、プレス成形に応用する場合、リン酸
分のために粉体としての成形が本質的に不可能と
いう欠点ががる。
またZrP2O7、(ZrO)2P2O7、ZrO2、Zr(OH)4、
ZrSiO4、SiO2、Rのリン酸塩、Rのケイ酸塩及
びROは、通常、ZrP2O7が0〜82.9重量%、
(ZrO)2P2O7が0〜79.5重量%、ZrO2が0〜50.4
重量%、Zr(OH)4が0〜56.8重量%、ZrSiO4が0
〜38.0重量%、SiO2が0〜12.5重量%、Rのリン
酸塩が0〜44.9重量%、Rのケイ酸塩が0〜35.5
重量%、ROが0〜37.3重量%の割合で調合され
るが、このうちZrP2O7と(ZrO)2P2O7及びRの
リン酸塩のいずれか1種以上と、RO、Rのケイ
酸塩またはRのリン酸塩は必ずバツチ混合物に含
ませることが必要である。
また、原料成分であるROとしては、焼成中に
RO、即ち、酸化物に転換する水酸化物、炭酸
塩、硫酸塩等の安定化合物から選択して使用する
ことも可能である。
尚、通常、原料はその平均粒径が50μm以下、
好ましくは10μm以下のものを用いる。
本発明焼結体の焼成条件としては、焼成温度が
1400℃以上、好ましくは1400〜1800℃、焼成時間
が1〜24時間、好ましくは2〜10時間である。焼
成温度を1400℃以上とすることにより、RyZr4Six
P6-xO24が充分析出し、本発明の焼結体を得るこ
とができる。また、焼成時間が1時間未満の場
合、焼結が不充分であり、24時間を超えると、異
常粒成長による低強度化が起きるとともに、リン
分蒸発による異相の析出が起きる。
なお、以上に説明した本発明の好ましい態様を
まとめて示せば、次の通りである。
(a) Rが2〜3価の陽イオンとなり得る元素から
選ばれる一種以上の組合わせからなるRyZr4
P6O24(yは化学式の電気的中性条件を満たす
2/3以上1以下の数値を有する)組成固溶相、
および該固溶相からなる耐熱性焼結体。
(b) RがBa、Sr、Caのうちの一種以上から構成
されるRyZr4 SixP6-xO24(xは0以上2以下の
数値、yは1以上2以下の数値を有する)組成
固溶相、および該固溶相からなる耐熱性焼結
体。
(c) 1400℃で100時間熱処理した場合の重量減少
率が10%以下であるRyZr4 SixP6-xO24組成固溶
相からなる耐熱性焼結体。
(d) 開気孔率が50%以下、曲げ強度が100Kg/cm2
以上である、RyZr4 SixP6-xO24組成固溶相から
なる耐熱性焼結体。
(e) 1400℃で5時間熱処理後の自重軟化率が0.3
%以下である、RyZr4 SixP6-xO24組成固溶相か
らなる耐熱性焼結体。
(f) 1400℃で100時間熱処理の寸法変化率が1%
以下である、RyZr4 SixP6-xO24組成固溶相から
なる耐熱性焼結体。
(g) 室温から1400℃までの熱膨張係数が25×
10-7/℃以下である、RyZr4 SixP6-xO24組成固
溶相からなる焼結体。
(h) セラミツクハニカム構造体として用いるRy
Zr4 SixP6-xO24組成固溶相からなる焼結体。
(i) RyZr4 SixP6-xO24組成固溶相を主結晶相とし
て、ジルコンまたはジルコニア等耐熱性化合物
を第二結晶相として含む耐熱性複合体。
(j) RがBa、Sr、Caのうちの一種以上から構成
されるRyZr4 SixP6-xO24組成固溶相からなる焼
結体の製造方法。
(k) ROが焼成中にROに転換する水酸化物、炭
酸塩、硫酸塩から選ばれるRyZr4 SixP6-xO24組
成固溶相からなる焼結体の製造方法。
(l) 焼成温度が1400℃以上、焼成時間が1〜24時
間であるRyZr4 SixP6-xO24組成固溶相からなる
焼結体の製造方法。
[実施例]
以下、実施例に基づいて本発明を説明するが、
本発明がこれら実施例に限定されないことは明ら
かであろう。
(実施例、比較例)
第1表に記載する調合割合に従つて予め粒度調
整された、リン酸ジルコニル〔(ZrO)2P2O7〕、
ZrP2O7、炭酸カルシウム、炭酸ストロンチウム、
炭酸バリウム、イツトリア、ジルコン、炭酸ナト
リウム、リン酸水素アンモニウム、シリカ、リン
酸カルシウム、ジルコニアを混合した。なお比較
例25は、第1表に示す調合物の混合物をアルミナ
製るつぼに充填し、大気中電気炉に1000℃、12時
間保持した後粉砕し、バツチ混合物とした。リン
酸ジルコニルの粒度調整には、直径約5mmの
ZrO2焼結体玉石を充填した振動ミルを使用した
が、ポツトミルまたはアトライターにても粒度調
整可能である。ZrO2焼結体玉石はMgOで安定化
されたものとY2O3で安定化されたものを使用し
た。使用した玉石の化学組成を第2表に示す。ま
た、用いた原料の化学分析値を第3表に示す。
第1表に示す調合物の混合物100重量部に10%
PVA水溶液を5重量部添加して充分に混合し、
25×80×6mmの金型にて100Kg/cm2の圧力でプレ
ス成形後、2トン/cm2の圧力にてラバープレスを
行ない乾燥させた。この成形体を乾燥後、大気中
電気炉にて第1表に示す条件で焼成した。昇温速
度は5〜1700℃/hrであつた。焼成後、この焼成
体をJIS R1601(1981)に示される3×4×40mm
の抗折試験片に加工し、1400℃、100時間熱処理
時の重量減少量及び寸法変化率、40〜1400℃まで
の熱膨張係数、4点曲げ強度、自重軟化量、開気
孔率を測定した。熱膨張係数の測定には、高純度
アルミナ焼結体を用いた押棒示差式熱膨張計を使
用した。測定温度範囲は40〜1400℃である。4点
曲げ強度はJIS R1601に示される方法に従つて測
定した。自重軟化率は、第8図に示される30mmの
巾の支えの間に前記3×4×40mmの抗折試験片を
置き、大気中にて1400℃で5時間の熱処理を行な
い、その時の自重変形量△xを測定することによ
り次式にて求めた。
自重軟化率=△x/l×100(%)
開気孔率はアルキメデス法により測定した。融
点は、3×4×5mmの形状に切り出した焼結体を
1700℃の電気炉中にて10分間熱処理し、溶融する
かどうか目視にて判断した。
RyZr4 SixP6-xO24組成の固溶相は、JCPDS33
−321のCaZr4(PO4)6、JCPDS33−1360びSrZr4
(PO4)6、またはJCPDS34−95のBaZr4(PO4)6に
従つて指数付けを行い、指数付けが可能な場合に
固溶相が生成していると判断した。
その他の結晶相は、その有無のみのX線回折図
形により同定した。固溶相の格子定数は、Ry
Zr4SixP6-xO24の(018)面反射ピーク角度2θ、
(208)面反射ピーク角度から面間隔d018、および
d208を求め、以下の連立方程式に従つてaおよび
cを算出した。
1/d2 018=4/3a2+64/c2
1/d2 018=16/3a2+64/c2
[Industrial Application Field] The present invention is characterized in that R is a combination of one or more elements selected from elements that can be divalent to trivalent cations.
A solid solution phase with the composition R y Zr 4 Si x P 6-x O 24 (x is a number of 0 to 2, y is a number of 2/3 to 2 that satisfies the electrical neutrality condition of the chemical formula), Regarding the heat-resistant sintered body made of the solid solution phase and its manufacturing method, more specifically, R y Zr 4 Si x having excellent heat resistance and high temperature stability
The present invention relates to a solid solution phase having a P 6-x O 24 composition, a heat-resistant, high-strength sintered body comprising the solid solution phase that has excellent low expansion properties and high-temperature thermal stability, and a method for producing the same. [Prior Art] In recent years, with the progress of industrial technology, there has been an increasing demand for materials with excellent heat resistance and low expansion properties. In response to these demands, zirconyl phosphate [(ZrO) 2 P 2 O 7 ] has been found to be promising as a material with excellent heat resistance and low expansion. Furthermore, recently, zirconium phosphate of an alkali metal such as sodium has been proposed as a material having heat resistance and a low coefficient of thermal expansion. (Mat.Res.
Bull., Vol.19, pp.1451−1456 (1984), Journal
of Materials Science 16, 1633−1642 (1981),
and Ceramic Industry Association Journal 95 [5], pp. 531-537 (1987)) Furthermore, phosphate compounds of alkaline earth metals with specific compositions have also been proposed as having low expansion properties. (Mat.Res.Bull., Vol.20,
pp.99−106, 1985, and J.Am.Ceram.Soc., 70
[10] C-232 to C-236 (1987)) Also, in U.S. Patent No. 4,675,302, Ca 0.5
Ceramic materials having a basic composition of Ti 2 P 3 O 12 have been proposed as having excellent low expansion properties. [Problems to be Solved by the Invention] However, although phosphate compounds such as the above-mentioned zirconyl phosphate have the advantage of having excellent low expansion properties, they undergo thermal decomposition at high temperatures of 1200°C or higher, resulting in phosphorus It is mentioned that the (P) component evaporates. For example, when heat treated at 1400°C for 100 hours, there is a problem in that zirconyl phosphate shows a weight loss of 19% and sodium zirconium phosphate shows a weight loss of 36%. Furthermore, the ceramic material proposed in U.S. Patent No. 4,675,302 is mainly used for the substrate of a low-expansion optical reflector that does not undergo deformation even with temperature changes for artificial satellites. Second
As shown in the figure, the temperature change is intended to be at most about 500°C, and no consideration is given to stability, heat resistance, etc. at high temperatures of, for example, 1200°C or higher. On the other hand, CaZr 4 P 6 O 24 , SrZr 4 P 6 O 24 , BaZr 4 P 6 O 24
Compared to zirconyl phosphate, phosphate compounds such as phosphate have superior stability at high temperatures, and the weight loss after heat treatment at 1400℃ for 100 hours is less than 10%.
CaZr 4 P 6 O 24 has a negative thermal expansion coefficient and low strength, and SrZr 4 P 6 O 24 has high strength but a relatively high thermal expansion coefficient of 25 × 10 -7 /℃. can be,
Heat-resistant ceramics with high strength and low expansion properties have been desired. By the way, the method for producing phosphate compounds is as follows:
Na 2 CO 3 , ZrO 2 , ZrOCl 2・8H 2 O, SiO 2 ,
(NH 4 ) 2 HPO 4 , H 3 PO 4 , Nb 2 O 5 , Y 2 O 3 , SrCO 3 ,
A method using a combination of K 2 CO 3 , CaCO 3 and the like is known. [T.Oota and I.Yamai, Journal
of the American Ceramic Society, 69 , 1.
(1986)] However, in the above production method, during the decomposition process of ammonium phosphate or H 3 PO 4 ,
The P 2 O 5 component is generated independently, forming areas with a locally high phosphorus concentration, and producing low melting point compounds during sintering. For this reason, giant pores (voids) are created in the sintered body, mainly in the low melting point compound,
A serious defect will occur. [Means for Solving the Problem] Therefore, in order to solve the problems of the above-mentioned prior art, the present inventor conducted various studies and found that R is Ca,
When it is composed of elements that can form divalent to trivalent cations such as Sr, Ba, and Y, the heat resistance of the crystal phase and high temperature thermal stability are excellent .
Various R y Zr 4 P 6 O 24 ( 2 / 3≦y≦1,
(R is a combination of one or more elements that can be divalent or trivalent cations) Each compound forms a complete solid solution, and solid solution changes the properties of R y Zr 4 P 6 O 24 itself, such as thermal expansion behavior and It was discovered that thermal properties etc. can be controlled, and a sintered body with high strength and low expansion can be obtained while maintaining heat resistance and high temperature thermal stability. In addition, as shown in equation (1), it is possible to form a solid solution in which part of the P ions are replaced by Si ions and R ions at the same time, and by solid solution R y Zr 4 Si x
It was discovered that the properties of P 6-x O 24 itself, such as thermal expansion behavior and thermal properties, can be controlled, and a heat-resistant, low-expansion material with superior high-temperature thermal stability while maintaining heat resistance and strength can be obtained. This led to the completion of the present invention. R y Zr 4 P 6 O 24 +xSi 4+ +1/nR′ n+ −xP 5+ R y R′ 1/o ZrSi x P 6-x O 24 ……(1) (n is the valence of R) That is, According to the present invention, R is composed of one or more combinations of elements selected from elements that can be divalent to trivalent cations . satisfies the electrical neutrality condition of the chemical formula 2/
a solid solution phase having a composition of 3 or more and 2 or less, a heat-resistant sintered body consisting of the solid solution phase, and ZrP 2 O 7 ,
(ZrO) 2 P 2 O 7 , ZrO 2 , Zr(OH) 4 , ZrSiO 4 , SiO 2 ,
Ry by molding and firing a batch mixture selected from R phosphate, R silicate, and RO (R is an element that can be a divalent or trivalent cation) .
R y consisting of precipitating Zr 4 Si x P 6-x O 24
A method for producing a heat-resistant sintered body comprising a solid solution phase having a Zr 4 Si x P 6-x O 24 composition is provided. The solid solution phase of the present invention having a composition of R y Zr 4 Si x P 6-x O 24 can be applied not only as a sintered body alone but also as a composite with a heat-resistant compound such as zircon or zirconia. It can also be applied as a constituent compound. The solid solution phase of the present invention having a composition of R y Zr 4 Si x P 6-x O 24 is R
is a combination of one or more elements selected from elements that can become divalent or trivalent cations, and x is 0
It is necessary that the value be a value greater than or equal to 2 and y be a value greater than or equal to 2/3 and less than or equal to 2. If R contains a monovalent cation, the high temperature thermal stability will be poor, and if x exceeds 2, the heat resistance will decrease. By satisfying these conditions, a solid solution phase with excellent heat resistance and high temperature stability can be obtained. R is a combination of one or more elements that can become divalent or trivalent cations, and generally corresponds to a of the periodic table.
It is preferably composed of at least one of barium (Ba), strontium (Sr), and calcium (Ca). Furthermore, according to the sintered body of the present invention, the open porosity is
Within the range of 50% or less, the weight loss rate due to phosphorus evaporation after heat treatment at 1400℃ for 100 hours is reduced to 10%.
The bending strength can be as low as 100 Kg/cm 2 or more. In other words, when the open porosity exceeds 50%, the bending strength decreases.
It becomes less than 100Kg/cm 2 and does not satisfy the required strength when using ceramics as a practical material.
Furthermore, this sintered body has a softening rate under its own weight of 0.3% or less after heat treatment at 1400°C for 5 hours, which satisfies the requirements as a heat-resistant material. In addition, this sintered body has a small dimensional change rate,
When heat treated at 1400°C for 100 hours, the dimensional change rate was less than 1%, which also satisfies the requirements for a heat-resistant material. Furthermore, this sintered body has a low thermal expansion coefficient of 25×10 -7 /°C or less from room temperature to 1400°C, and has excellent thermal shock resistance. Therefore, the sintered body of the present invention having the above characteristics can be used in ceramic honeycomb structures such as automotive exhaust gas purification catalyst carriers, rotary regenerator type ceramic heat exchangers, heat transfer type heat exchangers, and turbocharger rotors. It is suitably applied to materials that require heat resistance and thermal stability at high temperatures, such as automobile housings, engine manifold insulation materials, diesel particulate filters, etc. Next, in the method for producing a heat-resistant sintered body according to the present invention, the raw materials are ZrP 2 O 7 , (ZrO) 2 P 2 O 7 ,
ZrO 2 , Zr(OH) 4 , ZrSiO 4 , SiO 2 , R phosphate,
It is characterized in that it is a batch mixture of powders consisting of a substance selected from R silicate and RO (R is an element that can be a divalent or trivalent cation). That is,
ZrP 2 O 7 , (ZrO) 2 P 2 O 7 , ZrO 2 , Zr(OH) 4 ,
ZrSiO 4 , SiO 2 , R phosphate, R silicate,
and RO are very stable compounds, hardly causing non-uniformity during the molding and firing process, and can be fired at high temperatures, making it possible to obtain ceramics with excellent heat resistance. On the other hand, when phosphoric acid, which is conventionally used, is used as a P 2 O 5 source, since phosphoric acid is a liquid, it becomes non-uniform during the mixing process, forming locally high-concentration areas as described above. and produces compounds with low melting points. For this reason, a serious defect occurs in which huge pores are formed in the sintered body mainly in the low melting point compound. In addition, when obtaining a honeycomb structure by extrusion molding clay containing phosphoric acid, the corrosive nature of phosphoric acid may cause the extrusion die or cylinder of the extrusion molding machine to rust or corrode, resulting in significant molding failure. It becomes difficult. Furthermore, when applied to press molding, it has the disadvantage that molding as a powder is essentially impossible due to the phosphoric acid content. Also ZrP 2 O 7 , (ZrO) 2 P 2 O 7 , ZrO 2 , Zr(OH) 4 ,
ZrSiO 4 , SiO 2 , R phosphate, R silicate and RO usually contain 0 to 82.9% by weight of ZrP 2 O 7 ,
(ZrO) 2 P 2 O 7 is 0-79.5% by weight, ZrO 2 is 0-50.4%
Weight %, Zr(OH) 4 is 0 to 56.8 weight %, ZrSiO 4 is 0
~38.0 wt%, SiO2 0-12.5 wt%, R phosphate 0-44.9 wt%, R silicate 0-35.5
% by weight, RO is blended at a ratio of 0 to 37.3% by weight, among which ZrP 2 O 7 , (ZrO) 2 P 2 O 7 and one or more of R phosphates, RO, R The silicate of R or the phosphate of R must necessarily be included in the batch mixture. In addition, RO, which is a raw material component, is
It is also possible to select and use RO, ie, stable compounds such as hydroxides, carbonates, and sulfates that are converted into oxides. In addition, the average particle size of the raw material is usually 50 μm or less,
Preferably, one with a diameter of 10 μm or less is used. As the firing conditions for the sintered body of the present invention, the firing temperature is
The temperature is 1400°C or higher, preferably 1400 to 1800°C, and the firing time is 1 to 24 hours, preferably 2 to 10 hours. By setting the firing temperature to 1400℃ or higher, R y Zr 4 Si x
P 6-x O 24 is fully analyzed and the sintered body of the present invention can be obtained. Furthermore, if the firing time is less than 1 hour, sintering is insufficient, and if it exceeds 24 hours, strength decreases due to abnormal grain growth and precipitation of different phases occurs due to evaporation of phosphorus. The preferred embodiments of the present invention explained above are summarized as follows. (a) R y Zr 4 consisting of a combination of one or more elements selected from elements in which R can be a divalent or trivalent cation
P 6 O 24 (y has a value of 2/3 or more and 1 or less that satisfies the electrical neutrality condition of the chemical formula) composition solid solution phase,
and a heat-resistant sintered body comprising the solid solution phase. (b) R is composed of one or more of Ba, Sr, and Ca R y Zr 4 Si x P 6-x O 24 (x is a number from 0 to 2, y is a number from 1 to 2) a heat-resistant sintered body comprising a solid solution phase, and a heat-resistant sintered body comprising the solid solution phase. (c) A heat-resistant sintered body consisting of a solid solution phase with a composition of R y Zr 4 Si x P 6-x O 24 whose weight loss rate is 10% or less when heat treated at 1400°C for 100 hours. (d) Open porosity is 50% or less, bending strength is 100Kg/cm 2
The above heat-resistant sintered body comprises a solid solution phase with a composition of R y Zr 4 Si x P 6-x O 24 . (e) Self-weight softening rate after heat treatment at 1400℃ for 5 hours is 0.3
% or less, a heat-resistant sintered body consisting of a solid solution phase with a composition of R y Zr 4 Si x P 6-x O 24 . (f) Dimensional change rate after heat treatment at 1400℃ for 100 hours is 1%
A heat-resistant sintered body having a solid solution phase having the following composition R y Zr 4 Si x P 6-x O 24 . (g) Thermal expansion coefficient from room temperature to 1400℃ is 25×
10 -7 /℃ or less, a sintered body consisting of a solid solution phase with a composition of R y Zr 4 Si x P 6-x O 24 . (h) R y used as ceramic honeycomb structure
A sintered body consisting of a solid solution phase with a composition of Zr 4 Si x P 6-x O 24 . (i) A heat-resistant composite containing a R y Zr 4 Si x P 6-x O 24 composition solid solution phase as a main crystalline phase and a heat-resistant compound such as zircon or zirconia as a second crystalline phase. (j) A method for producing a sintered body in which R is a solid solution phase having a composition R y Zr 4 Si x P 6-x O 24 composed of one or more of Ba, Sr, and Ca. (k) A method for producing a sintered body comprising a solid solution phase with a composition of R y Zr 4 Si x P 6-x O 24 selected from hydroxides, carbonates, and sulfates in which RO is converted to RO during firing. (l) A method for producing a sintered body comprising a solid solution phase having a composition of R y Zr 4 Si x P 6-x O 24 , wherein the firing temperature is 1400°C or higher and the firing time is 1 to 24 hours. [Examples] The present invention will be explained below based on Examples.
It will be clear that the invention is not limited to these examples. (Examples, Comparative Examples) Zirconyl phosphate [(ZrO) 2 P 2 O 7 ] whose particle size was adjusted in advance according to the formulation ratio listed in Table 1,
ZrP 2 O 7 , calcium carbonate, strontium carbonate,
Barium carbonate, ittria, zircon, sodium carbonate, ammonium hydrogen phosphate, silica, calcium phosphate, and zirconia were mixed. In Comparative Example 25, a mixture of the formulations shown in Table 1 was filled into an alumina crucible, held in an electric furnace in the atmosphere at 1000°C for 12 hours, and then pulverized to obtain a batch mixture. To adjust the particle size of zirconyl phosphate, a particle with a diameter of approximately 5 mm is used.
A vibrating mill filled with ZrO 2 sintered cobblestones was used, but the particle size can also be adjusted using a pot mill or attritor. ZrO 2 sintered cobblestones stabilized with MgO and Y 2 O 3 were used. The chemical composition of the boulders used is shown in Table 2. Further, chemical analysis values of the raw materials used are shown in Table 3. 10% in 100 parts by weight of the mixture of the formulations shown in Table 1
Add 5 parts by weight of PVA aqueous solution and mix thoroughly.
After press molding in a 25 x 80 x 6 mm mold at a pressure of 100 kg/cm 2 , a rubber press was performed at a pressure of 2 tons/cm 2 and dried. After drying, this molded body was fired in an electric furnace in the atmosphere under the conditions shown in Table 1. The heating rate was 5 to 1700°C/hr. After firing, this fired body is 3 x 4 x 40 mm as shown in JIS R1601 (1981).
The weight loss and dimensional change rate during heat treatment at 1400℃ for 100 hours, coefficient of thermal expansion from 40 to 1400℃, 4-point bending strength, softening under self-weight, and open porosity were measured. . A push rod differential thermal dilatometer using a high-purity alumina sintered body was used to measure the thermal expansion coefficient. The measurement temperature range is 40-1400℃. Four-point bending strength was measured according to the method shown in JIS R1601. The self-weight softening rate is calculated by placing the 3 x 4 x 40 mm bending test piece between supports with a width of 30 mm as shown in Figure 8, and heat-treating it at 1400°C for 5 hours in the air. By measuring the amount of deformation Δx, it was determined by the following formula. Self-weight softening rate=△x/l×100 (%) The open porosity was measured by the Archimedes method. The melting point is calculated using a sintered body cut into a shape of 3 x 4 x 5 mm.
It was heat-treated for 10 minutes in an electric furnace at 1700°C, and visually judged whether or not it melted. The solid solution phase with the composition R y Zr 4 Si x P 6-x O 24 is JCPDS33
−321 CaZr 4 (PO 4 ) 6 , JCPDS33−1360 and SrZr 4
(PO 4 ) 6 or BaZr 4 (PO 4 ) 6 of JCPDS34-95, and when indexing was possible, it was determined that a solid solution phase was generated. Other crystal phases were identified based on the X-ray diffraction pattern based on their presence or absence. The lattice constant of the solid solution phase is R y
(018) surface reflection peak angle 2θ of Zr 4 Si x P 6-x O 24 ,
(208) Plane spacing d 018 from the plane reflection peak angle, and
d 208 was determined, and a and c were calculated according to the following simultaneous equations. 1/d 2 018 = 4/3a 2 +64/c 2 1/d 2 018 = 16/3a 2 +64/c 2
【表】【table】
【表】【table】
【表】【table】
【表】【table】
【表】【table】
【表】【table】
【表】【table】
【表】【table】
【表】
第1表に示す実施例1〜19、比較例21〜26の結
果より明らかなように、Rを2〜3価の陽イオン
となり得る元素から選ばれる一種以上の組み合わ
せとし、xを0以上2以下とすることにより、本
発明に係るRyZr4 SixP6-xO24組成固溶相、および
該固溶相からなる耐熱性焼結体が得られる。ま
た、それら固溶相、および焼結体はZrP2O7、
(ZrO)2P2O7、ZrO2、Zr(OH)4、ZrSiO4、SiO2、
Rのリン酸塩、Rのケイ酸塩、及びRO(Rは2
〜3価の陽イオンとなり得る元素)から選ばれる
バツチ混合物を第1表に示す焼成条件にて焼結さ
せた時に得られた。
第1図にCaZr4P6O24−SrZr4P6O24固溶系およ
びCaZr4P6O24−BaZr4P6O24固溶系における化学
組成と結晶格子定数の関係を、第2図に
CaZr4P6O24−SrZr4P6O24固溶系における化学組
成と、焼結体の熱膨張係数および四点曲げ強度の
関係を、第3図にCaZr4P6O24−BaZr4P6O24固溶
系における化学組成と、焼結体の熱膨張係数およ
び四点曲げ強度の関係を、第4図にRyZr4 Six
P6-x固溶系における化学組成と焼結体を1400℃に
100時間保持したときの重量減少率の関係を、第
5図にRyZr4 SixP6-xO24組成固溶相の化学組成と
焼結体の熱膨張係数の関係を示す。
以上のことより、Rが2〜3価の陽イオンとな
り得る元素から選ばれる一種以上の組み合わせか
らなる場合に、結晶相の耐熱性や高温熱安定性が
優れ、さらに固溶によりRyZr4 P6O24(2/3≦y≦
1)組成固溶相そのものの特性が制御でき、耐熱
性、高温熱安定性に優れた高強度低膨張焼結体が
得られることがわかる。
加えてPイオンの一部をSrイオンとRイオン
で同時に置換した固溶相はより高温熱安定性に優
れ、RyZr4 SixP6-xO24組成の固溶相そのものの特
性を制御することができ、より高温熱安定性に優
れ、高強度で低膨張な耐熱性焼結体が得られるこ
とがわかる。
なお、第6図はRyZr4 SixP6-xO24組成固溶相か
らなる焼結体の開気孔率と曲げ強度の関係を示す
グラフである。
また、第7図は実施例16の焼結体の室温におけ
る粉末X線回折図形を示すもので、Sr1.5
Zr4SiP5O24組成の固溶相単相からなることを示
す。
[発明の効果]
以上説明した通り、本発明のRが2〜3価の陽
イオンとなり得る元素から選ばれる一種以上の組
み合わせからなるRyZr4 SixP6-xO24(xは0以上
2以下の数値、yは化学式の電気的中性条件を満
たす2/3以上2以下の数値を有する)組成固溶相、
該固溶相からなる耐熱性焼結体、およびその製造
方法によれば、RyZr4 SixP6-xO24組成固溶相、お
よび高強度かつ低膨張であり、高温安定性に優れ
る耐熱性焼結体を得ることができる。
従つて、このRyZr4 SixP6-xO24組成固溶相、お
よび該固溶相からなる焼結体は耐熱性、低膨張性
および高温安定性が要求される、例えば押出成形
等によりハニカム構造体に成形した場合には回転
蓄熱式セラミツク熱交換体伝熱式熱交換体および
デイーゼルパテイキユレートフイルター、更に、
泥漿鋳込成形法やプレス成形法、射出成形法等に
より成形されるセラミツクターボチヤージヤーロ
ーター用ハウジングまたはエンジンマニホールド
内の断熱材等、に広く応用できる。[Table] As is clear from the results of Examples 1 to 19 and Comparative Examples 21 to 26 shown in Table 1, R is a combination of one or more elements selected from elements that can become divalent to trivalent cations, and x is By setting it to 0 or more and 2 or less, a R y Zr 4 Si x P 6-x O 24 composition solid solution phase according to the present invention and a heat-resistant sintered body made of the solid solution phase can be obtained. In addition, these solid solution phases and sintered bodies are ZrP 2 O 7 ,
(ZrO) 2 P 2 O 7 , ZrO 2 , Zr(OH) 4 , ZrSiO 4 , SiO 2 ,
R phosphate, R silicate, and RO (R is 2
- Elements that can become trivalent cations) were sintered under the firing conditions shown in Table 1. Figure 1 shows the relationship between chemical composition and crystal lattice constant in the CaZr 4 P 6 O 24 -SrZr 4 P 6 O 24 solid solution system and the CaZr 4 P 6 O 24 -BaZr 4 P 6 O 24 solid solution system, and Figure 2 shows the relationship between the chemical composition and crystal lattice constant.
Figure 3 shows the relationship between the chemical composition in the CaZr 4 P 6 O 24 -SrZr 4 P 6 O 24 solid solution system, the thermal expansion coefficient and the four-point bending strength of the sintered body. The relationship between the chemical composition in the 6 O 24 solid solution system, the thermal expansion coefficient and the four-point bending strength of the sintered body is shown in Figure 4. R y Zr 4 Si x
Chemical composition and sintered body in P 6-x solid solution system at 1400℃
Figure 5 shows the relationship between the weight loss rate when held for 100 hours, and the relationship between the chemical composition of the R y Zr 4 Si x P 6-x O 24 solid solution phase and the coefficient of thermal expansion of the sintered body. From the above, when R consists of a combination of one or more selected from elements that can be divalent to trivalent cations, the heat resistance of the crystal phase and high temperature thermal stability are excellent, and furthermore, R y Zr 4 P 6 O 24 (2/3≦y≦
1) Composition It is found that the properties of the solid solution phase itself can be controlled, and a high-strength, low-expansion sintered body with excellent heat resistance and high-temperature thermal stability can be obtained. In addition, the solid solution phase in which part of the P ions are replaced with Sr ions and R ions at the same time has better high-temperature thermal stability, and the properties of the solid solution phase itself with the composition R y Zr 4 Si x P 6-x O 24 are improved. It can be seen that a heat-resistant sintered body with excellent high-temperature thermal stability, high strength, and low expansion can be obtained. Note that FIG. 6 is a graph showing the relationship between the open porosity and the bending strength of a sintered body consisting of a solid solution phase with a composition of R y Zr 4 Si x P 6-x O 24 . In addition, FIG. 7 shows the powder X-ray diffraction pattern of the sintered body of Example 16 at room temperature, and shows Sr 1.5
This shows that it consists of a single solid solution phase with a composition of Zr 4 SiP 5 O 24 . [Effect of the invention] As explained above, R of the present invention is R y Zr 4 Si x P 6-x O 24 (x is 0 2 or less, y has a value of 2/3 or more and 2 or less that satisfies the electrical neutrality condition of the chemical formula) Composition solid solution phase,
According to the heat-resistant sintered body consisting of the solid solution phase and its manufacturing method, it has a solid solution phase of R y Zr 4 Si x P 6-x O 24 composition, high strength, low expansion, and high temperature stability. A sintered body with excellent heat resistance can be obtained. Therefore, this R y Zr 4 Si x P 6-x O 24 composition solid solution phase and the sintered body made of the solid solution phase are required to have heat resistance, low expansion property, and high temperature stability, such as extrusion molding. When formed into a honeycomb structure by, for example, a rotating heat storage type ceramic heat exchanger, a heat transfer type heat exchanger, a diesel particulate filter, and
It can be widely applied to insulation materials in ceramic turbo charger rotor housings or engine manifolds molded by slurry casting, press molding, injection molding, etc.
第1図はCaZr4P6O24−SrZr4P6O24組成固溶相、
およびCaZr4P6O24−BaZr4P6O24組成固溶相の化
学組成と格子定数の関係を示すグラフ、第2図は
CaZr4P6O24−SrZr4P6O24組成固溶相からなる焼
結体の化学組成と、室温〜1400℃までの熱膨張係
数および四点曲げ強度の関係を示すグラフ、第3
図はCaZr4P6O24−BaZr4P6O24組成固溶相からな
る焼結体の化学組成と室温〜1400℃までの熱膨張
係数および四点曲げ強度の関係を示すグラフ、第
4図は、実施例1〜10、14〜18、比較例21〜25の
1400℃、100時間熱処理時の重量減少率を示す棒
グラフ、第5図はRyZr4 SixP6-xO24組成固溶相か
らなる焼結体の化学組成と、室温〜1400℃までの
熱膨張係数の関係を示すグラフ、第6図はRyZr4
SixP6-xO24組成固溶相からなる焼結体の開気孔率
と四点曲げ強度の関係を示すグラフ、第7図は実
施例16の室温における粉末X線回折図形を示すグ
ラフ、第8図は自重軟化率の測定方法を示す図で
ある。
Figure 1 shows CaZr 4 P 6 O 24 -SrZr 4 P 6 O 24 composition solid solution phase,
and CaZr 4 P 6 O 24 −BaZr 4 P 6 O 24 composition A graph showing the relationship between the chemical composition of the solid solution phase and the lattice constant, Figure 2 is
CaZr 4 P 6 O 24 −SrZr 4 P 6 O 24 Composition Graph showing the relationship between the chemical composition of a sintered body consisting of a solid solution phase, the coefficient of thermal expansion from room temperature to 1400°C, and the four-point bending strength, Part 3
The figure is a graph showing the relationship between the chemical composition of a sintered body consisting of a solid solution phase of CaZr 4 P 6 O 24 -BaZr 4 P 6 O 24 , the coefficient of thermal expansion from room temperature to 1400°C, and the four-point bending strength. The figure shows Examples 1 to 10, 14 to 18, and Comparative Examples 21 to 25.
A bar graph showing the weight loss rate during heat treatment at 1400℃ for 100 hours. Figure 5 shows the chemical composition of the sintered body consisting of a solid solution phase of R y Zr 4 Si x P 6-x O 24 and the weight loss rate from room temperature to 1400℃. Figure 6 is a graph showing the relationship between the thermal expansion coefficients of R y Zr 4
A graph showing the relationship between open porosity and four-point bending strength of a sintered body consisting of a solid solution phase with a composition of Si x P 6-x O 24. Figure 7 is a graph showing the powder X-ray diffraction pattern of Example 16 at room temperature. , FIG. 8 is a diagram showing a method of measuring the self-weight softening rate.
Claims (1)
選ばれる一種以上の組み合わせからなるRyZr4Six
P6-xO24(xは0以上2以下の数値、yは化学式の
電気的中性条件を満たす2/3以上2以下の数値を
有する)組成の固溶相。 2 請求項1記載の固溶相からなる耐熱性焼結
体。 3 ZrP2O7、(ZrO)2P2O7、ZrO2、Zr(OH)4、
ZrSiO4、SiO2、Rのリン酸塩、Rのケイ酸塩、
及びRO(Rは2〜3価の陽イオンとなり得る元
素)から選ばれるバツチ混合物を成形し焼成する
ことにより請求項1記載の固溶相を析出させ、結
晶相の主成分が請求項1記載の固溶相からなる焼
結体を得ることを特徴とする耐熱性焼結体の製造
方法。[Claims] R y Zr 4 Si x where 1 R is a combination of one or more elements selected from elements that can be divalent to trivalent cations.
A solid solution phase with a composition of P 6-x O 24 (x has a value of 0 or more and 2 or less, and y has a value of 2/3 or more and 2 or less that satisfies the electrical neutrality condition of the chemical formula). 2. A heat-resistant sintered body comprising the solid solution phase according to claim 1. 3 ZrP 2 O 7 , (ZrO) 2 P 2 O 7 , ZrO 2 , Zr(OH) 4 ,
ZrSiO 4 , SiO 2 , R phosphate, R silicate,
and RO (R is an element that can be a divalent to trivalent cation) and calcined to precipitate the solid solution phase according to claim 1, and the main component of the crystal phase is according to claim 1. A method for producing a heat-resistant sintered body, characterized by obtaining a sintered body consisting of a solid solution phase.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP63188798A JPH0238354A (en) | 1988-07-28 | 1988-07-28 | Solid solution phase of ryzr4sixp6-xo24 composition, heat-resistant calcined compact consisting of said solid solution phase and production thereof |
| US07/232,667 US4925816A (en) | 1987-08-29 | 1988-08-16 | Novel solid solution, heat-resistant sintered body and method of producing the same |
| EP88307961A EP0306242B1 (en) | 1987-08-29 | 1988-08-26 | Heat-resistant materials and method of producing them |
| DE3886856T DE3886856T2 (en) | 1987-08-29 | 1988-08-26 | Refractory materials and processes for their manufacture. |
| KR1019890006735A KR910009890B1 (en) | 1988-05-16 | 1989-05-15 | Novel solid solution heat-resistant sintered body and method of producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP63188798A JPH0238354A (en) | 1988-07-28 | 1988-07-28 | Solid solution phase of ryzr4sixp6-xo24 composition, heat-resistant calcined compact consisting of said solid solution phase and production thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0238354A JPH0238354A (en) | 1990-02-07 |
| JPH0547498B2 true JPH0547498B2 (en) | 1993-07-16 |
Family
ID=16229987
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP63188798A Granted JPH0238354A (en) | 1987-08-29 | 1988-07-28 | Solid solution phase of ryzr4sixp6-xo24 composition, heat-resistant calcined compact consisting of said solid solution phase and production thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0238354A (en) |
-
1988
- 1988-07-28 JP JP63188798A patent/JPH0238354A/en active Granted
Non-Patent Citations (1)
| Title |
|---|
| SEMIANNUAL PROGRESS FOR THE PERIOD=1987 * |
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0238354A (en) | 1990-02-07 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| Agrawal et al. | Synthesis and sintering of Ca0. 5Zr2P3O12-a low thermal expansion material | |
| EP0306242B1 (en) | Heat-resistant materials and method of producing them | |
| US5488018A (en) | Ultra low thermal expansion, highly thermal shock resistant ceramic | |
| US5254510A (en) | Heat resistive phosphate sintered bodies and a process for producing the same | |
| EP0260893B1 (en) | Heat resisting low expansion zirconyl phosphate-zircon composite bodies and process for producing the same | |
| US5128288A (en) | Phosphate compounds, sintered bodies thereof and manufacture of the sintered bodies | |
| US5217934A (en) | Heat resistive phosphate-zircon composite bodies and process for producing same | |
| Dhas et al. | Combustion synthesis and properties of the NASICON family of materials | |
| CA1179486A (en) | Process for manufacturing cordierite compositions | |
| JPH0547498B2 (en) | ||
| JP2500809B2 (en) | Heat-resistant phosphate compound sintered body and method for producing the same | |
| EP0294115B1 (en) | Zirconyl phosphate sintered bodies and production thereof | |
| US4968648A (en) | Heat-resisting phosphate based compound sintered bodies and production thereof | |
| KR910009890B1 (en) | Novel solid solution heat-resistant sintered body and method of producing the same | |
| EP0416796B1 (en) | Heat resistive phosphate-zircon composite bodies and process for producing same | |
| ES2296275T3 (en) | NEW PROCEDURE FOR THE PRODUCTION OF NZP CERAMIC BODIES THAT HAVE HIGH POROSITY AND HIGH MECHANICAL RESISTANCE. | |
| JPS63297269A (en) | Heat-resistant, low-heat expansion zirconyl phosphate-zircon composite sintered product and production thereof | |
| JPH0520385B2 (en) | ||
| Kenawy et al. | Synthesis of (xMgO-yAl2O3-5SiO2) Ceramic via the Sol-Gel Technique in Air and under Nitrogen Gas Flow | |
| JPH09268053A (en) | Phosphate sintered body | |
| JPH04357159A (en) | Phosphate-based sintered body and its manufacturing method | |
| JPH04295040A (en) | Phosphate sintered body and its production | |
| GR1009288B (en) | An environmentally friendly method for the producrion of nzp cermaic structures with controlled characteristics |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20080716 Year of fee payment: 15 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20090716 Year of fee payment: 16 |
|
| EXPY | Cancellation because of completion of term | ||
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20090716 Year of fee payment: 16 |