A METHOD OF MANUFACTURING A SINGLE CRYSTAL OF BAPB1-XBIX03

Abstract: A method of manufacturing a single crystal of BaPb 1-x Bi x O₃ comprises dissolving BaPb 1-x Bi x O₃ in an aqueous solution and subjecting the resulting solution to a hydrothermal process which applies heat and pressure to the crystal within an aqueous solution. The aqueous solution comprises a nitrate as the main component.

Description: This invention relates to methods of manufacturing single crystals of BaPb 1-x Bi x O₃. Such single crystals are useful as super-conducting elements, semiconducting elements or optoelectronic elements widely used in the electronics industry, etc. BaPb 1-x Bi x O₃ (barium-lead-bismuth oxide) where x is the so-called "composition factor" with a Perovskite structure, shows super-conductivity in the range of 0.05 ≦ x ≦ 0.30, semi-metallic characteristics in the range of x < 0.05, and semiconductivity in the range of 0.30 < x. The super-conductive transition temperature Tc is a maximum (13°K) when x is approximately 0.25. This is the highest known temperature at which an oxide material that does not include transition metal elements exhibits super-conductivity. Attention has focussed on these barium-lead-bismuth oxide compounds because of their super-conductivity and because the super-­ conductivity depends on their exact composition. Further, the compounds of this type include semi-­ metallic materials and their carrier density N(O) at the Fermi surface is extraordinarily small as a super-­ conductor. Therefore, these compounds have a resistance rate which is several orders of magnitude greater than ordinary metal super-conductors, at temperatures slightly higher than Tc. This characteristic is required for materials used for super-conductive switches. When barium-lead-bismuth oxide compounds are formed as single crystals they are relatively stable and crystals which are transparent in the infra-red region, can be expected to be useful for optical electronic elements at very low temperatures. Conventionally, growing a single crystal of BaPb 1-x Bi x O₃ is carried out by crystallisation utilising a flux. In one method, potassium chloride (KCl) is used as the main component of the flux. KCl flux is favoured as the flux to dissolve BaPb 1-x Bi x O₃, but to dissolve KCl and to melt KCl in BaPb 1-x Bi x O₃, a high temperature of about 1000°C is necessary, and thus potassium ions remain inside the single crystals of BaPb 1-x Bi x O₃. Consequently, the impurity density is relatively large. Also, as the crystal grows at a temperature higher than the transition point (500°C to 600°C) of BaPb 1-x Bi x O₃, a crystal phase transition occurs on cooling and, therefore, strains occur within the crystal. Another method uses a PbO₂-Bi₂O₃-BaPbO₃ non-stoichiometric solution. In this case, there is an advantage that the inclusion of impurities will be greatly reduced, but, when crystallising BaPb 1-x Bi x O₃ from a non-­ stoichiometric solution, control of the composition factor x , that determines the characteristics of the resulting crystal, is very difficult. Also, strains accompanying the phase transition occur as stated above. The above prior methods are disclosed in Akinori Katsui; Japanese Journal of Applied Physics, Vol. 21 No. 9., (1982) Page 553 to 554. With the conventional method of manufacturing single crystals of BaPb 1-x Bi x O₃ the impurity density within the material is relatively large, and also, the change of the composition factor x is relatively wide. Also the conventional methods have serious disadvantages, such as the reproducibility of the composition factor x is poor, and as a result of the phase transition heat strains remain because high temperatures of about 1000°C are used. These disadvantages are the primary factors that prevent sharp transition to super-conductivity of the resulting single crystal. EP-A-0199440 discloses a method of manufacturing a single crystal of BaPb 1-x Bi x O₃ by hydrothermal synthesis using a chloride aqueous solution. It is thought that the above disadvantages of the prior art, e.g. impurities, the change of composition factor x and strains, are caused by crystallising BaPb 1-x Bi x O₃ from a solution which has a relatively high viscosity and large composition change, at a very high temperature. The present invention seeks to provide a method of manufacturing a single crystal of BaPb 1-x Bi x O₃ by hydrothermal synthesis, which enable the crystal to grow at a relatively low temperature below 500°C so that it is possible to improve the characteristics of the resultant single crystal avoiding its phase transition. According to one aspect of the present invention there is provided a method of manufacturing a single crystal of BaPb 1-x Bi x O₃ by dissolving BaPb 1-x Bi x O₃ in an aqueous solution and subjecting the resulting solution to a hydrothermal process which applies heat and pressure to the crystal within an aqueous solution, characterised in that the aqueous solution comprises a nitrate as the main component. The hydrothermal process may be carried out at a temperature above 350°C. Said hydrothermal process may be carried out in a pressure vessel and the single crystal of BaPb 1-x Bi x O₃ is grown on an upper wall inside the pressure vessel. According to a further aspect of the present invention there is provided a method of manufacturing a single crystal of BaPb 1-x Bi x O₃ comprising: providing a starting material comprised of BaCO₃, PbO₂ and Bi₂O₃ mixed together in desired proportions; preparing a nutrient composed of polycrystalline BaPb 1-x Bi x O₃ obtained from the starting material; and subjecting the nutrient in an aqueous solution to a hydrothermal process at a temperature above 350°C to effect growth of the single crystal of BaPb 1-x Bi x O₃ characterised in that the aqueous solution includes a nitrate. Said hydrothermal process may be carried out in a pressure vessel, a temperature gradient being maintained between upper and lower portions of the pressure vessel. According to still another aspect of the present invention there is provided a method of manufacturing a single crystal of BaPb 1-x Bi x O₃ comprising: providing a nutrient composed of polycrystalline BaPb 1-x Bi x O₃; and subjecting the nutrient in an aqueous solution to a hydrothermal process at a temperature above 350°C to establish a temperature gradient within the aqueous solution effective to promote the growth of the single crystal of BaPb 1-x Bi x O₃ characterised in that the aqueous solution includes a nitrate. Said nitrate may be any one or more of LiNO₃, KNO₃ and NaNO₃. The single crystal of BaPb 1-x Bi x O₃ may be grown as a thin film on a substrate, for example, of SrTiO₃. Said substrate is preferably maintained about 40°C lower than the nutrient. The method may include quickly cooling the single crystal of BaPb 1-x Bi x O₃ after the hydrothermal process. The aqueous solution preferably includes an oxygen-generating compound, for example, any one or more of KClO₃, NaClO₃ and NaClO₄. According to another aspect of the present invention there is provided a method of manufacturing BaPb 1-x Bi x O₃ single crystal wherein BaPb 1-x Bi x O₃ is grown by hydrothermal synthesis which applies heat and pressure to the crystal within an aqueous solution comprising a nitrate as the main component. According to still another aspect of the present invention there is provided a method of manufacturing BaPb 1-x Bi x O₃ comprising: providing a starting material comprised of BaCO₃, PbO₂ and Bi₂O mixed together in the desired proportions; preparing a nutrient composed of BaPb 1-x Bi x O₃ polycrystalline; and hydrothermally synthesising the nutrient within a nitrate aqueous solution at a temperature above 350°C to effect the growth of BaPb 1-x Bi x O₃ single crystal. According to a still further aspect of the present invention there is provided a method of manufacturing BaPb 1-x Bi x O₃ single crystal comprising: providing a nutrient composed of BaPb 1-x Bi x O₃ polycrystalline; and hydrothermally synthesising the nutrient within a nitrate aqueous solution at the nutrient temperature above 350°C to establish a temperature gradient within the nitrate aqueous solution effective to promote the growth of BaPb 1-x Bi x O₃ single crystal. The invention is illustrated, merely by way of example, in the accompanying drawings, in which:- Figure 1 is a sectional view of an autoclave used in Example 3 of a method according to the present invention; Figure 2 is a characteristic diagram showing the variation of cubic imitated lattice constant a corresponding to composition factor x ; Figure 3 is a sectional diagram showing the structure of an autoclave used in Example 1 of a method according to the present invention; and Figure 4 is a graph illustrating super-conducting characteristics of a single crystal of BaPb 1-x Bi x O₃ obtained by a method according to the present invention and a conventional method. In hydrothermal synthesis, the starting material is dissolved in a solution of an appropriate solvent at an appropriate temperature and pressure, and the intended crystal is crystallised or grown on a suitable substrate. The growth temperature is generally from 300°C to 600°C and this temperature is very low as compared to the prior art methods. By selecting and arranging the temperature, pressure, and kind of solvent, and controlling the starting material and the substrate on which the crystal is to grow, a single crystal with very few defects can be grown. The following are Examples of the present invention. EXAMPLE 1 Commercially available high purity reagents BaCo₃, PbO₂, Bi₂O₃ were used as the starting material and adjustment of the amount thereof was effected so that the super-conductive composition factor x = 0.2, x = 0.3 within BaPb 1-x Bi x O₃ respectively. After the adjustment, the starting material was blended in a mortar and baked for one whole day at 850°C in a stream of oxygen. To complete the reaction, the above process was repeated. When the resulting powder samples were examined using an X-ray diffractometer, they were observed to have BaPb 1-x Bi x O₃ single phase. From measurements made the relation between lattice constant a (cubic imitated lattice constant) and composition factor x was as shown in Figure 2. Referring to Figure 2, the composition factors x corresponding to lattice constant a are respectively x = 0.21, x = 0.27. For a hydrothermal process, a test tube type autoclave 8 of stelite 25 was utilised. Figure 3 is a sectional diagram showing the structure of the autoclave. The autoclave 8 was pressure-sealed by a cover 10, through a sealing ring 9. The measurement of temperature within the autoclave was conducted through a temperature measuring hole 11. As a test tube a gold capsule of 3mm or 5mm diameter was utilised. A powder sample of BaPb 1-x Bi x O₃ produced as above and a solvent were poured into the gold capsule, and the hydrothermal process was carried out. In this case distilled water filled the inside of the autoclave to maintain a pressure balance between the inner and outer surfaces of the gold capsule. Three different solvents, namely 3 mol NaNO₃ aqueous solution, 3 mol KNO₃ aqueous solution, and 3 mol LiNO₃ aqueous solution were utilised, and the hydrothermal process was conducted for 7 days at a pressure of 1000kg/cm², and at a temperature of 410 to 450°C. The results are as shown in Table 1 where o indicates that crystallisation occurred. It was observed that, with any of the above solvents, the samples were dissolved into and re-­ precipitated from the solution, and crystals were grown. The same result was obtained with the respective samples of composition factor x = 0.21, x = 0.27. When each of the resulting crystals was powdered and examined using an X-ray diffractometer, it was observed that all were of BaPb 1-x Bi x O₃ single phase. The crystals with the best crystallisation characteristic and growth speed were obtained using NaNO₃ or KNO₃ aqueous solution as the solvent. EXAMPLE 2 Example 1 was repeated utilising 3 mol NaNO₃ aqueous solution as the solvent, but at a temperature of 300 to 450°C. The results are shown in Table 2, where X indicates that crystallisation did not occur, and o indicates that crystallisation occurred. When the process temperature was 350°C, neither dissolution nor re-crystallisation was observed, and the sample remained in the lower part of the gold capsule. However, when the temperature was above 400°C, the sample was dissolved and re-crystallised, crystals with a diameter of about 2mm being grown. The same results were obtained with samples having composition factor x = 0.21 or x = 0.27. When the temperature was 450°C, even larger crystals were obtained but twin crystals were occasionally generated, the crystal surface being coarse with many secondary grains attached to it. These defects are thought to occur because secondary nucleation generates upon cooling. When the resulting crystals were powdered and examined using an X-ray diffractometer, it was observed that they were all BaPb 1-x Bi x O₃ single phase. The composition factor x was determined and the same relation as shown in Figure 2 was found viz: Therefore, x = 0.21 changed to x = 0.20, and x = 0.27 changed to x = 0.25, but the composition gap between the adjusted starting material and the resulting crystal was minute for practical purposes. Moreover, the relationship between composition factor x of starting material (nutrient) and composition factor x of resulting crystal were examined. When the composition factor x of starting material was equal to 0.1 or 0.3, the composition factor x of resulting crystal was 0.095 or 0.29 respectively. In the case of using a nitrate aqueous solution as the solvent single crystals of BaPb 1-x Bi x O₃ with a desired composition factor x were easily manufactured with suitable adjustment to the starting material. EXAMPLE 3 Figure 1 shows a test tube type autoclave 1 used in this Example. The autoclave 1 was of stelite 25 as in Example 1, but had a platinum plate inner lining to avoid contamination by impurities. The autoclave 1 was pressure-sealed with a cover 3, through a sealing ring 2. Nutrient 4 was provided at the bottom of the autoclave. This nutrient 4 was obtained by grinding and powdering polycrystalline BaPb 1-x Bi x O₃ which was obtained in Example 2 and having a composition factor of either x = 0.20 or x = 0.25. Then a substrate 6 was mounted on an upper part of the autoclave above the nutrient 4, in a substrate support frame 5. The substrate 6 was a crystal of SrTiO₃ which has similar crystal structure and similar atom bond lengths to BaPb 1-x Bi x O₃, the (001) crystal surface being used. Instead of the (001) surface, the (111) surface or the (110) surface could also be used. A buffer plate 7 was mounted on the substrate support frame 5 between the nutrient 4 and the substrate 6. 3 mol NaNO₃ aqueous solution as a solvent was charged in the autoclave in an amount such that a predetermined temperature and pressure could subsequently be obtained. A hydrothermal process under the same conditions as in Table 2 was initiated. These conditions were: temperature of substrate 6 = 360°C temperature of nutrient 4 = 400°C pressure = 1000kg/cm² growth period = 7 days. After completion of the hydrothermal process, the autoclave was subjected to sudden cooling, to prevent the generation of secondary nucleation. As a result, a thin film with a uniform thickness was formed on the substrate 6. When this film was examined using an X-ray diffractometer as in Example 1, it was identified to be a single crystal of BaPb 1-x Bi x O₃. The composition factor x was found to be x = 0.20 or x = 0.24 respectively, no large change being observed as compared to the composition factor of the nutrient. When the super-conductive characteristics of the BaPb 1-x Bi x O₃ thin film with the composition factor x = 0.24, was measured, it was confirmed that it showed super-conductivity when the super-conductive transition was at a range of 10.0°K to 11.7°K. The super-­ conducting characteristic is shown in Figure 4. In the super-conducting characteristic curve of Figure 4, the temperature (°K) is plotted on the abscissa and the susceptibility (10⁻² e.m.u./g) as the super-conducting characteristic is plotted on the ordinate. From Figure 4, it will be appreciated that the crystal (x = 0.24) obtained by the hydrothermal process of Example 3 has greatly improved super-­ conducting characteristics over the crystal (x = 0.29) obtained by the conventional flux method. EXAMPLE 4 Example 4 was similar to Example 3 but a different solvent was used. The conditions were as follows: temperature of substrate 6 = 360°C temperature of nutrient 4 = 400°C solvent = aqueous solution which was 3 mol NaNO₃ aqueous solution to which 2% of the total weight of 2.0 mol KClO₃ aqueous solution was added pressure = 1000kg/cm² growth period = 7 days As in Example 3, quenching was carried out after the hydrothermal process. In this Example, a thin film was also formed on the (001) surface of the SrTiO₃ substrate. This film was confirmed using an X-ray diffractometer to be a BaPb 1-x Bi x O₃ thin film, and its super-conductivity similarly was observed at a range of 10.0°K to 11.7°K at the super-conductive transition temperature, but compared to Example 3 its super-­ conductivity was clearer and better defined. This is thought to be because a peroxide such as NaClO₃ was added to the solution, and this generated active oxygen. This generated oxygen prevented any oxygen deficiency inside the crystal, and atomic valence of the crystal was automatically controlled. Thus the mobility characteristic or super-conductive characteristic of the crystal was improved. Another advantage of using NaClO₃ is that after it has given up its oxygen it becomes NaCl in the aqueous solution. It thus has the advantage that it does not create impurities in the resulting crystals. NaClO₃ is not the only oxygen-generating compound that could be used: sodium perchlorate (NaClO₄) can be used in appropriate amounts. As stated above, compared to the conventional KCl flux method or the crystallisation method from a non-­ stoichiometric solution, with the present invention there are several beneficial effects. For example, there is a very low level of potassium ion impurities in the crystals because the method according to the present invention utilises low viscosity nitrate aqueous solution at a relatively low temperature of 400 to 450°C. Also, as the appearance of super-conductivity of the single crystal of BaPb 1-x Bi x O₃ is important, reproducibility of a given composition factor x is very efficient. Consequently the present invention has a big industrial advantage in that single crystals with a desired composition factor x are easily manufactured with suitable adjustment of the composition of the starting material. Similarly, as the method is carried out at a relatively low temperature of about 400°C defects such as strain or heat strain accompanying the phase transition is very small. Therefore, a more perfect crystal can be obtained, and at the same time, by adding oxygen-generating compounds such as peroxide compounds to the solvent the oxygen deficiency is reduced and the atomic valence is controlled. Consequently, it is possible to improve crystal perfection. In accordance with the method according to the present invention, by obtaining a crystal with uniform composition factor x , improvement of super-conductivity is confirmed, and its effect is very large. Also, because the temperature is approximately 400°C, it is very easy to conduct hydrothermal growth of single crystals of BaPb 1-x Bi x O₃ on an industrial scale using existing equipment and apparatus. As described above, in accordance with the present invention, single crystals of BaPb 1-x Bi x O₃ valuable as super-conductive elements or optical electronic elements and having more perfect characteristics with little defects can be obtained.

Claims: 1. A method of manufacturing a single crystal of BaPb1-xBixO₃ by dissolving BaPb1-xBixO₃ in an aqueous solution and subjecting the resulting solution to a hydrothermal process which applies heat and pressure to the crystal within an aqueous solution, characterised in that the aqueous solution comprises a nitrate as the main component. 2. A method as claimed in claim 1 characterised in that the hydrothermal process is carried out at a temperature above 350°C. 3. A method as claimed in claim 1 or 2 characterised in that said hydrothermal process is carried out in a pressure vessel and the single crystal of BaPb1-xBixO₃ is grown on an upper wall inside the pressure vessel. 4. A method of manufacturing a single crystal of BaPb1-xBixO₃ comprising: providing a starting material comprised of BaCO₃, PbO₂ and Bi₂O₃ mixed together in desired proportions; preparing a nutrient composed of polycrystalline BaPb1-xBixO₃ obtained from the starting material; and subjecting the nutrient in an aqueous solution to a hydrothermal process at a temperature above 350°C to effect growth of the single crystal of BaPb1-xBixO₃ characterised in that the aqueous solution includes a nitrate. 5. A method as claimed in claim 4 characterised in that said hydrothermal process is carried out in a pressure vessel, a temperature gradient being maintained between upper and lower portions of the pressure vessel. 6. A method of manufacturing a single crystal of BaPb1-xBixO₃ comprising: providing a nutrient composed of polycrystalline BaPb1-xBixO₃; and subjecting the nutrient in an aqueous solution to a hydrothermal process at a temperature above 350°C to establish a temperature gradient within the aqueous solution effective to promote the growth of the single crystal of BaPb1-xBixO₃ characterised in that the aqueous solution includes a nitrate. 7. A method as claimed in any preceding claim characterised in that said nitrate is any one or more of LiNO₃, KNO₃ and NaNO₃. 8. A method as claimed in any preceding claim characterised in that the single crystal of BaPb1-xBixO₃ is grown as a thin film on a substrate. 9. A method as claimed in claim 8 when dependent upon claim 7 characterised in that said substrate is maintained about 40°C lower than the nutrient. 10. A method as claimed in any preceding claim characterised by including quickly cooling the single crystal of BaPb1-xBixO₃ after the hydrothermal process. 11. A method as claimed in any preceding claim characterised in that the aqueous solution includes an oxygen-generating compound. 12. A method as claimed in claim 11 characterised in that the oxygen-generating compound is any one or more of KClO₃, NaClO₃ and NaClO₄.

Inventors: HIRANO, SHINICHI C/O 123 MEIDAI YADACHO SYUKUSHA, KURODA, HIROSHI C/O SEIKO INSTRUMENTS INC., TOYOKUNI, RYO C/O SEIKO INSTRUMENTS INC.,
Applicants: HIRANO, SHINICHI, SEIKO INSTRUMENTS INC.
Application year: 1987
Main classification: C30B7
IPC codes: C30B7, C30B29