LOW EXPANSION CERAMICS AND METHOD OF PRODUCING THE SAME

Abstract: Cordierite series dense and low expansion ceramics of excellent thermal shock resistant property, airtight property, heat resistant property and high dimensional stability at high temperatures can be provided by incorporating 2-10% by weight of P₂O₅ in the cordierite ceramics and acid treating the fired or sintered body to selectively remove mainly P₂O₅ to less than 2% by weight from the sintered body.

Description: The present invention relates to low expansion ceramics, more particularly cordierite series dense, low expansion ceramics of excellent thermal shock resistant property, airtight property and heat resistant property. Recently, accompanying the rapid progress in industrial technologies, demands for industrial materials of superior heat resistance and thermal shock resistance have been increased. Thermal shock resistance of a ceramics is influenced by the thermal expansion coefficient (herein abbreviated to "CTE"), thermal conductivity, strength, elastic modulus, Poisson's ratio, etc. of the ceramics, by shape and size of products, and further by heating or cooling conditions of the ceramics, namely, heat transfer rate of the ceramics. It is known that thermal shock resistance of ceramics is influenced largely by the thermal expansion coefficient, among the aforementioned factors, and is largely dependent exclusively on the thermal expansion coefficient especially when the heat transfer rate of the ceramics is large. Therefore, it has been sought to develop low expansion ceramics of excellent thermal shock resistance. Cordierite is known as a ceramic substance of relatively low expansion. However, it is generally difficult to produce dense cordierite by sintering. Particularly, when it is desired to produce low expansion cordierite of an average thermal expansion coefficient of not over than 2.0×10⁻⁶/°C in a temperature range of from ambient to 800°C, it has been necessary to restrict the amount of impurities such as calcia, alkaline earth metals, potassium, sodium and the like which act as a flux in producing the cordierite to a very minor amount, so that the resultant cordierite has a very small amount of glass phase and is very porous. Particularly, cordierite honeycomb structures which are recently widely used as substrates for catalysts for purifying exhaust gas of automobiles require an average thermal expansion coefficient of not over than 1.5×10⁻⁶/°C in a temperature range of from ambient to 800°C, so that a raw material such as talc, kaolin, alumina or the like raw material of a low impurity or flux content is used. As a result, the open porosity of the cordierite produced is 25-45% at the minimum. Accordingly, if such cordierite ceramics is used, for instance, as a honeycomb structure body of a regenerator type heat exchanger, the honeycomb body has such a large open porosity that the pores, particularly the communicated pores, on the partition walls which define the passages of the honeycomb structure, cause leakage of fluids between a heating fluid and a heat recovery fluid. Hence, serious drawbacks occur that efficiency of the heat exchanger and efficiency of the total system wherein the heat exchanger is used become inferior. Similarly, if such cordierite of high open porosity is used e.g. as a housing of a turbocharger or an exhaust manifold of an engine, a serious drawback occurs that the interior air of high pressure leaks to the exterior of the manifold etc. due to the high open porosity. Therefore, it has been sought to develop dense and low expansion cordierite ceramics of good thermal shock resistance. Moreover, for structural materials which are exposed to such high temperatures, dimensional stability at high temperatures within ±0.05% in practical use, has been sought. Hitherto, for obtaining a dense cordierite ceramics, a method has been known wherein a batch of composition for preparation of cordierite is melted, moulded and subjected crystallization treatment to obtain glass ceramics. For example, the report of Topping and Murthy described in Journal of the Canadian Ceramic Society, 46 , 1977 proposed to substitute AlPO₄ for SiO₂ in cordierite by 20% by weight at the maximum. According to the report, a composition of main components of raw materials including added AlPO₄ is melted and cooled to form cordierite glass, and reheated and cooled to produce cordierite crystals. Thus obtained cordierite is dense. However, the cordierite has a drawback of still large thermal expansion coefficient of 2.15×10⁻⁶/°C at the minimum, because orientation of precipitated cordierite crystal phases was unable to be controlled. JP-A-59-13,741 and JP-A-59-92,943 propose crystallized glass bodies produced by preparing compositions of main components of raw materials containing Y₂O₃ or ZnO with B₂O₃ and/or P₂O₅ added , firing the compositions to produce crystallized glass components, pulverizing or grinding the crystallized glass components to form glass frits of 2-7 µm, forming or moulding the glass frits to a desired shape, and refiring the shaped glass frits to obtain the crystallized glass bodies which, however, has a drawback of large thermal expansion coefficients of 2.4-2.6×10⁻⁶/°C. US-A-3,885,977 discloses a low expansion cordierite ceramics wherein crystal phases of cordierite ceramics are oriented in plane due to the use of planar clay or laminated clay in raw materials for the cordierite ceramics. Typically, the chemical composition is 46.6-53.0% SiO₂, 33-41% Al₂O₃ and 11.5 to 16.5% MgO by weight. Thermal expansion coefficients of 1.0×10⁻⁶/°C can be achieved. However, the porosity of such materials remains high. US-A-3,958,058 discloses a process in which a starting crystalline cordierite material is leached by acid to effect selective removal of MgO and Al₂O₃. The product is an amorphous SiO₂-rich phase, which is not a cordierite phase. Low thermal expansion coefficients, below 0.54×10⁻⁶/°C can be obtained. Besides, these prior art documents do not mention dimensional stability of the ceramics, when held at high temperatures for a long time. An object of the present invention is to obviate the drawbacks of the prior art mentioned above. Another object of the present invention is to provide dense and low expansion ceramics without vitrifying the ceramics. By the present invention it is possible to provide dense and low expansion cordierite series ceramics of low open porosity of 25% by volume or less and CTE of 2.0×10⁻⁶/°C or less and high dimensional stability, i.e., a low dimensional change of ±0.05% or less when held at a temperature of 500-1,200°C for 1,000 hrs. In one aspect, the present invention is set out in claim 1. In preferred embodiments of the present invention, the ceramics have CTE of 1.0×10⁻⁶/°C or less. In some embodiments of the present invention, the ceramics have a dimensional change of not more than ±0.05% when held at a temperature of 500-1,200°C for 1,000 hrs. Total pore volume of pores of diameters of 5 µm or more (abbreviated as "TVP of +5 µm", hereinafter) is usually about 0.06 ml/g or less in the present ceramics. In another aspect, the present invention provides a method as set out in claim 5. The shaping or forming of the prepared batch to a shaped body of a desired shape may be by a shaping treatment such as cast moulding including slip casting etc., plastic moulding including extrusion moulding etc., press forming, and the like. Preferably, the firing is effected at 1,250-1,450°C for 2-20 hrs. If the firing temperature is below 1,250°C, the cordierite phases may not be formed sufficiently, while if the firing temperature is above 1,450°C the sintered body may be softened and deformed. Though the formation of the cordierite phases depends largely on the firing temperature, the cordierite phases may not be formed sufficiently, if the firing time is less than 2 hrs. While, if the firing time exceeds 20 hours, the sintered body may be liable to soften and deformed depending on the firing temperature. In some embodiments of the present invention, the acid treated body is heat treated at a temperature in the range of 1,150°C to the firing temperature to heal the defects formed in the sintered body by the acid treatment, thereby to diminish the dimensional change rate when held at 500-1,200°C for 1,000 hrs. to not more than ±0.05%. P₂O₅ contained in the raw materials of cordierite series ceramics is converted to AlPO₄ during the firing of the raw materials, and substitutes a part of SiO₂ in the cordierite crystals to form a cordierite series solid solution having a melting point which is slightly lower than that of unsubstituted cordierite ceramics. As a result, the amount of the liquid phase produced during the firing or sintering is increased, so that dense cordierite is easily produced. Moreover, most of the liquid phase is crystallized in the cordierite series solid solution during the cooling following the sintering, so that the CTE is not increased. This is a difference from those cordierite ceramics wherein calcia, alkaline earths, potassium, sodium or the like flux is added to densify the cordierite ceramics. In addition, the raw materials can be selected from talc, clay, alumina, bluesite, magnesite, aluminum hydroxide and the like that are used for producing conventional cordierite ceramics, so as to orient the cordierite crystals in the ceramics, so that dense and low expansion ceramics of cordierite series ceramics can be obtained with low CTE of 2.0×10⁻⁶/°C or less. In addition, if the acid treated ceramics is heat treated at a temperature in the range of 1,150°C to the firing temperature, the defects formed in the sintered body by the acid treatment are healed, so that the dimensional change of the heat treated ceramics becomes lessened to a small value of ±0.05% or less even when it is held in a prolonged thermal usage condition of 500-1,200°C for 1,000 hrs. Though P₂O₅ added in the raw materials combines with Al₂O₃ to form AlPO₄ when firing the raw materials, AlPO₄ can not be detected by analysis and the amount of P₂O₅ can be detected by analysis of the fired raw materials as well as the amount of Al₂O₃. Mg in the cordierite phase of the dense and low expansion ceramics can be replaced or substituted partially by Zn and/or Fe by 10 mol % at the maximum to provide useful iron cordierite, zinc cordierite or iron zinc cordierite which fall within the scope of the present invention. P₂O₅ source material is preferably selected from the group consisting of aluminum phosphate, magnesium phosphate, zinc phosphate, iron phosphate and combinations thereof. MgO source material, Al₂O₃ source material and SiO₂ source material are preferably selected mainly from the group consisting of bluesite, magnesite, talc, clay, alumina and aluminum hydroxide. Further, magnesium oxide, silica etc. can be included in the group. If the MgO source material such as bluesite, magnesite, talc and the like having an average particle diameter of not over than 5 µm is used in the raw materials, dense cordierite series ceramics of sufficiently airtight property can be obtained wherein the diameter of the remaining open pores are suppressed to not over than 5 µm and the open porosity is not over than 25% by volume. The present invention is based on a novel finding that dense and low expansion cordierite series ceramics of low open porosity of 25% by volume or less and low CTE of 2.0×10⁻⁶/°C or less can be obtained by solid solving 2-10% by weight of P₂O₅ in cordierite phases to convert P₂O₅ to AlPO₄ by firing, and acid treating the fired or sintered body of open porosity of 15% by volume or less to selectively remove mainly P₂O₅ from the sintered body to a low P₂O₅ content of less than 2% by weight. The present invention is also based on a novel finding that dense and low expansion ceramics of dimensional change of ±0.05% or less when held at a temperature of 500-1,200°C for 1,000 hrs. can be obtained by heat treating the acid treated sintered body at a temperature of 1,150°C- the firing temperature for a time sufficient to heal the defects formed in the sintered body by the acid treatment. The lower limit of P₂O₅ of 2% by weight in the raw materials is because sufficient amount of liquid phase for densifying the cordierite ceramics is not produced, so that dense cordierite series ceramics can not be obtained, if the amount of P₂O₅ is below the lower limit. The upper limit of P₂O₅ of 10% by weight in the raw materials is because an excessive amount of P₂O₅ exceeds the solid soluble amount permissible for converting P₂O₅ to AlPO₄ in the cordierite, so that highly expansive cordierite series ceramics are produced. The reason why the dimensional change of the cordierite series ceramics when held at 500-1,200°C for 1,000 hrs. is defined to not over than ±0.05% is because the cordierite series ceramics can not be used practically as mechanical parts for high temperature use, if the dimensional change exceeds the defined value. The reason of defining the chemical composition of the batch of the raw materials of the cordierite series ceramics to the range as mentioned above is because cordierite phase are not produced sufficiently, so that highly expansive cordierite ceramics are produced, if the chemical composition of the batch is beyond the range specified above. The reason for selectively removing P₂O₅ from the sintered body to the low P₂O₅ content of less than 2% by weight by the acid treatment is because a P₂O₅ content of not less than 2% by weight can not achieve the desired sufficient low expansion effect of the ceramics. The reason for defining the chemical composition of the cordierite series ceramics after acid treatment to the range as mentioned above is because otherwise the purposed dense and low expansion ceramics of open porosity of 25% by volume or less and CTE of 2.0×10⁻⁶/°C or less are not provided. TVP of +5 µm is usually restricted to 0.06 ml/g or less, because leakage of pressurized gas depends on TVP of +5 µm, and leakage of the cordierite series ceramics can be reduced to half or less than that of convertional cordierite by restricting TVP of +5 µm to 0.06 ml/g or less. Mg in the cordierite phase 2MgO·2Al₂O₃·5SiO₂ of the ceramics can be substituted or replaced partially by Zn and/or Fe by 10 mol % at the maximum, because such substitution affords cordierite series ceramics of properties substantially equal to those of the cordierite series ceramics of the present invention not containing 2n or Fe. The reason for limiting the heat treatment temperature to the range of 1,150°C to the firing temperature is because at less than 1,150°C the defects formed in the sintered body by the acid treatment are not easily removed, while at more than the firing temperature recrystallization occurs and microstructures of the ceramics changes widely so that the desired properties cannot be achieved. The reason for selecting a P₂O₅ source from the group consisting of aluminum phosphate, magnesium phosphate, zinc phosphate, iron phosphate and mixtures thereof is because phosphoric acid is liquid so that it is difficult to mix and an inhomogeneous mixture results. Besides, phosphoric acid causes the ceramic materials to locally melt at low temperatures below the formation temperature of cordierite thereby to produce macropores, so that it is preferably added in the aforementioned form of water-insoluble phosphates of relatively higher melting points in the raw materials. The reasons for selecting MgO source material, Al₂O₃ source material and SiO₂ source material from the group consisting of bluesite, magnesite, talc, clay, alumina and aluminum hydroxide is because the cordierite series ceramics produced from these raw materials are particularly low expansive. Further, magnesium oxide for the MgO source material, silica and the like material for the SiO₂ source material can be included in the group for the same reason. Average particle diameter of MgO source material is restricted to 5 µm or less, because the cordierite series ceramics produced by sintering have remaining pores in the skeleton of MgO source material particles, which skeleton pores become a cause of open pores, so that such restriction can suppress the formation of open pores of diameters of more than 5 µm and the desired highly airtight cordierite series ceramics can be obtained. For a better understanding of the present invention, reference is made to the accompanying drawings, in which: Figs. 1 and 11 are graphs showing relations between P₂O₅ content and open porosity or CTE of cordierite series ceramic honeycomb structure bodies; Fig. 2 is a graph showing time dependency of weight decrease in % of ceramic honeycomb structures when acid treated the honeycomb structures with 1.5N-sulfuric acid at 95°C; Fig. 3 is a graph showing time dependency of weight decrease rate in % of respective ingredients of the honeycomb structures when acid-treated the honeycomb structures with 1.5N-sulfuric acid at 95°C; Fig. 4 is a graph showing time dependency of CTE of the honeycomb structures when acid-treated the honeycomb structures with 1.5N-sulfuric acid at 95°C; Fig. 5 is a graph showing a relation between TVP of +5 µm and leakage of pressurized air of 1.4 kg/cm² through the thin partition walls of ceramic honeycomb structures; Fig. 6 is a graph showing pore diameters distribution curves; Figs. 7 and 8 are enlarged microscopic graphs showing microstructures of conventional low expansion ceramics; Figs. 9 and 13 are enlarged microscopic graphs showing microstructures respectively of embodiments of the low expansion ceramics of the present invention; Fig. 10 is an X-ray diffraction chart used for identification of a crystal phase of an embodiment of the present invention; and Fig. 12 is a graph showing time dependency of the dimensional change of the ceramic honeycomb structures of the present invention when held at 1,200°C. Hereinafter, the present invention will be explained in more detail with reference to examples, in which "parts" refers to parts by weight unless otherwise specified. Examples 1-13 and Referential Examples 1-10 Raw materials bluesite, magnesite, talc, alumina, aluminum hydroxide, clay, aluminum phosphate, magnesium phosphate and iron phosphate are prepared and mixed according to the recipes shown in the later-described Table 1. Particles of the raw materials were preliminarily adjusted to desired sizes. Chemical analysis values of the raw materials used are shown in the later-described Table 2. 100 parts of the mixture is added with 5-10 parts of water and 20 parts of starch paste (water content 80%), kneaded completely by a kneader, and extruded by a vacuum extruder to columnar bodies of 65 mm square and 120 mm length of honeycomb structure of a triangular cell shape of pitch of 1.0 mm and partition wall thickness of 0.10 mm. The honeycomb structure bodies are dried, fired at the firing conditions described in Table 1, and then acid treated with sulfuric acid, nitric acid or hydrochoric acid to obtain cordierite series ceramic honeycomb structures of Examples 1-13 and Referential Examples 1-10. The various cordierite series ceramic honeycomb structures of Table 1 so obtained are analyzed for comparison respectively for cordierite crystal contents by X-ray diffraction on powder thereof, CTE and open porosities. TVP of +5 µm are determined by mercury-urging type porosimeter. Leakage or leaked amounts of pressurized air through the thin partition walls thereof are measured by the following way. One end surface of the cordierite series ceramic honeycomb structure is airtightly sealed by a rubber packing of 65 mm × 65 mm size with a square hole of 20 mm × 20 mm at the center, and the other end surface of the honeycomb structure is airtightly sealed with a rubber packing of the same size but without the centeral square hole, and then pressurized air of pressure of 1.4 kg/cm² is introduced into the honeycomb structure through the central hole of the rubber packing to measure a flow rate of the pressurized air leaking to the exterior through unit surface area of the partition walls of the honeycomb structure per unit of time so as to express the leakage by the dimension of kg/m²·sec. The results are also shown in Table 1 and attached Figs. 1-6 based on Table 1. Fig. 1 shows influences or effects of P₂O₅ content of the raw materials on open porosity and CTE of the product cordierite series ceramics, based on the results of Table 1. Similarly, attached Fig. 2 is epicted based on the results of Table 1. In Table 1, the symbol * is for a talc raw material of an average particle diameter of 2.0 µm, the symbol ** is for talc raw materials of an average particle diameter of 10.0 µm, and those without the symbols are for talc raw materials of an average particle diameter of 5.0 µm. As seen from the above Table 1 and attached Fig. 1, by acid treating the sintered body produced by firing the batches of the raw materials of the chemical composition comprising 7.5-20.0% by weight of MgO, 22.0-44.3% by weight of Al₂O₃, 37.0-60.0% by weight of SiO₂ and 2.0-10.0% by weight of P₂O₅, the low expansion ceramics of open porosities of not more than 25% by volume, CTE of not more than 2.0×10⁻⁶/°C and the chemical composition comprising 8.0.-20.5% by weight of MgO, 24.0-45.0% by weight of Al₂O₃, 40.5-61.0% by weight of SiO₂ and less than 2% by weight of P₂O₅ of the present invention can be obtained. Also, it can be seen from Table 1 that partial substitution of Mg in the cordierite phases by Zn or Fe can provide the low expansion ceramics of the present invention. Fig. 2 shows relations between weight decrease in % of the sintered body of the recipe of Example 4 and Referential Example 1 fired in the firing condition of Table 1 and treating time when treated with 1.5N-sulfuric acid at 95°C. Fig. 3 shows a relation between weight decrease rate in % of respective chemical ingredients of the sintered body of the recipe of Example 4 and fired in the firing condition of Table 1 and treating time when treated with 1.5N-sulfuric acid at 95°C. Fig. 4 shows relations between CTE of the sintered bodies of the recipe of Example 4 and Referential Example 1 fired in the firing conditions of Table 1 and treating time when treated with 1.5N-sulfuric acid at 95°C. As seen from Fig. 4, the fired body containing P₂O₅ according to the present invention exchbits a remarkable effect of decrease of CTE by the acid treatment, compared with that not containing P₂O₅. Further, as seen from attached Fig. 5, a high correlation is recognized to exist between the leakages and TVP of ±5 µm, and the leakage can be decreased generally to less than half of that of ordinary cordierites (Referential Example 1) by achieving TVP of ±5 µm to not over than 0.06 cc/g, so that the airtight property of the cordierite series ceramics of the present invention are considerably improved. The leakage of the ceramic honeycomb structure of Example 6 which has a small value of TVP of +5 µm of about 0.01 ml/g as shown in Fig. 6 is considerably smaller than the value of about 0.075 ml/g of Referential Examples 1 and 3 derived from Fig. 6. Therefore, in the present ceramics, CTE is less than that of ordinary cordierite, so that excellent thermal shock resistant property is also obtained. Therefore, the cordierite series ceramics of the present invention can achieve excellent airtight and thermal shock resistant properties suited well to structural material for high temperature use. Figs. 7 and 8 are microstructures respectively of the ceramics of Referential Examples 1 and 10, showing the structures are porous and have many large pores. Figs. 9 and 13 are microstructures respectively of the ceramics of Examples 4 and 13, showing the structures are dense and have few large pores. Fig. 10 is an X-ray diffraction chart of the ceramics of Example 4 by CuKα ray, showing that the main crystal phase is cordierite phase. Examples 14-29 The low expansion ceramics obtained in Examples 1-13 are acid treated with sulfuric, nitric or hydrochloric acid to selectively remove mainly P₂O₅, and further heat treated in the range 1,150°C to the firing temperature as shown in the following Table 3 to produce cordierite series ceramic honeycomb structures of Examples 14-26. Table 3 shows also cordierite series honeycomb structures of Examples 27-29 which are produced in the similar manner as in Examples 14-26 by using the chemical compositions, the recipes, the firing conditions, acid treatment conditions and the heat treatment conditons of Table 3. Cordierite crystal phases, CTE, the open porosity, TVP of +5 µm, and the leakage are measured in the same manner as mentioned above, and further the dimensional change in % of the ceramic honeycomb structures held at 1,200°C for 1,000 hrs. are measured with the aid of a micrometer by producing and using specimens of the honeycomb structure of a size of 5 mm x 5 mm and 50 mm length. The results are shown also in Table 1 and 3. In Table 3, for the talc particle size the symbols * and ** and the items without the symbols have the same significance as in Table 1. The results are also shown in Figs. 11-13, partially. As apparent from the results of Examples 5, 6, 12, 13 and 14-29 and Referential Examples 1-10 in Tables 1 and 3, by acid treating the sintered body of the chemical composition comprising 7.5-20.0% by weight of MgO, 22.0-44.3% by weight of Al₂O₃, 37.0-60.0% by weight of SiO₂ and 2.0-10.0% by weight of P₂O₅, the purposed low expansion ceramics of the chemical composition comprising 8.0-20.5% by weight of MgO, 24.0-45.0% by weight of Al₂O₃, 40.5-61.0% by weight of SiO₂ and less than 2% by weight of P₂O₅, open porosity of not over than 25% by volume and CTE of 2.0×10⁻⁶/°C or less can be obtained. It can be also seen from Table 3 that low expansion ceramics of the present invention can be obtained also when MgO in the raw materials is substituted partially by Zn or Fe. As seen from Fig. 12, by heat treating the specimens at a high temperature in the range 1,150°C to the firing temperature according to an aspect of the present invention, cordierite series ceramics of more preferable dimensional stability can be obtained which, after held at 1,200°C for 1,000 hrs., has small dimensional change of ±0.05% or less, so that they are particularly suited to structural materials for high temperature use which necessitate superior airtight property and excellent thermal shock resistant property owing to low CTE. There are no substantial change in pore diameters distribution curves and microstructures of the heat treated cordierite series ceramics caused by the heat treatment, and airtight property and low expansion property of the heat treated cordierite series ceramics do not suffer from adverse influences by the heat treatment. Furthermore, dimensional stability of the product cordierite series ceramics is promoted. This is presumably due to the healing of the defects formed in the sintered body by the acid treatment. As seen from Fig. 13, the cordierite series ceramics of Example 17 has few large pores and is more dense as compared with those of Referential Examples 1 and 10 shown in Figs. 7 and 8. As described in detail in the foregoing descriptions, the present invention provides dense and low expansion ceramics with decreased dimensional change at high temperatures, while maintaining the low expansion property of cordierite, so that the low expansion ceramics of the present invention can be used in practice not only as ceramic regenerators (CRG), but also broadly as ceramic recuperators (CRP), ceramic turbocharger rotor (CTR) housing, gas turbine rotors, nuclear reactor materials, and various automobile parts such as engine muffler, exhaust port, exhaust manifold and exhaust gas purifying catalyst carrier, heat exchangers.

Claims: A low expansion ceramic having a chemical composition comprising 8.0-20.5% by weight of MgO, 24.0-45.0% by weight of Al₂O₃, 40.5-61.0% by weight of SiO₂, the Mg in the cordierite phase optionally being partially substituted by Zn and/or Fe by 10 mol% at maximum and having a cordierite phase as a main crystal phase and an average thermal expansion coefficient of not more than 2.0x10⁻⁶/°C in the temperature range of 25-800°C, characterized in that said chemical composition includes 0.1 to less than 2.0% by weight of P₂O₅ and the ceramics has an open porosity of not more than 25% by volume. A low expansion ceramic as defined in claim 1, which has an average thermal expansion coefficient of not more than 1.0x10⁻⁶/°C in the temperature range of 25-800°C. A low expansion ceramic as defined in claim 1 or claim 2, which has a dimensional change of not more than ±0.05% when held at a temperature of 500-1200°C for 1000 hrs. A low expansion ceramic as defined in any one of claims 1 to 3, which has a total pore volume of pores of diameters of not less than 5 µm of not more than 0.06 ml/g. A method of producing a low expansion ceramic, comprising, preparing a batch of raw materials of a chemical composition comprising Mg, Al, Si and P in amounts expressed as MgO, Al₂O₃, SiO₂ and P₂O₅ of 7.5-20.0% by weight of MgO, 22.0-44.3% by weight of Al₂O₃, 37.0-60.0% by weight of SiO₂ and 2.0-10.0% by weight of P₂O₅, forming the prepared batch to a shaped body, drying the shaped body, firing the dried shaped body to obtain a sintered body, and acid treating the sintered body to selectively remove mainly P₂O₅ from the sintered body to obtain a low expansion ceramics which has a P₂O₅ content of less than 2% by weight, a cordierite phase as a main crystal phase, an open porosity of not more than 25% by volume and an average thermal expansion coefficient of not more than 2.0x10⁻⁶/°C in the temperature range of 25-800°C, said Mg in said raw material batch being optionally partially substituted so as to provide substitution of Mg in the cordierite phase by Zn and/or Fe by 10 mol% at maximum. A method as defined in claim 5, further comprising heat treating the acid treated body at a temperature in the range of 1,150°C to said firing temperature. A method as defined in claim 5 or claim 6 wherein a source material of said P₂O₅ is selected from aluminum phosphate, magnesium phosphate, zinc phosphate and iron phosphate, and source material for said MgO, source material for said Al₂O₃ and source material for said SiO₂ are selected mainly from bluesite, magnesite, talc, clay, alumina and aluminum hydroxide. A method as defined in any one of claims 5 to 7 wherein the source material for said MgO has an average particle diameter of not more than 5 µm.

Inventors: MATSUHISA, TADAAKI, WATANABE, KEIICHIRO 4E, CORP. NAKANOMACHI HOUSE
Applicants: NGK INSULATORS, LTD.
Application year: 1986
Main classification: C04B35
IPC codes: C04B35