SINTERABLE NITRIDES

Abstract: Sinterable metal nitride powders are disclosed in which the metal is aluminum, yttrium, cerium, zirconium, or titanium, and in which the particles have a surface area of at least 8 square metres per gram and an average particle diameter less than 0.5 micrometres. Preferably the particles have a surface area of at least 12 square metres per gram. A method of making the sinterable metal nitride powder is provided in which a homogeneous combination of a soluble or colloidally dispersible compound of the metal with a water soluble, oxygenated carbonaceous compound is formed in an aqueous medium, the pH of the aqueous medium is adjusted to form a gel or precipitate of a chemically or electro-statically bonded product of the metal and the carbonaceous compound, drying the product and calcining the dried product in a nitriding atmosphere. Preferably the ratio of the oxygenated carbonaceous compound to the metal compound provides carbon in excess of the stoichiometric amount required to reduce the compound to the metal. Suitable carbonaceous compounds include polyacrylic acids, polymethacrylic acids, carboxymethylcellulose, methylcellulose and sucrose. The high surface area, high purity powders may be sintered at lower than usual temperatures to make metal nitride articles of theoretical density.

Description: SINTERABLE NITRIDES This invention relates to metal nitride powders, in which the metal is aluminum, yttrium, cerium, zirconium, or titanium, their method of preparation and use. The metal nitrides have a high surface area, uniform ' fine particle size and high purity. Ceramic- articles prepared from metal nitride powders are of great use in industry because of their excellent thermal, electrical and mechanical properties. Aluminum nitride is particularly useful as a ceramic substrate due to its high thermal conductivity, high electrical resist¬ ivity and the fact that its coeficient of thermal expansion matches that of silicon. The preparation of such ceramic articles involves consolidation of the metal nitride as a powder into the desired shape followed by sintering to forrr a dense body. In order to form a dense article it is necessary to start with the metal nitride in the form of a powder having a fine particle size and a high specific surface area. To achieve the desired values of thermal conductivity, electrical resistivity and mechanical prop¬ erties it is most important that the powder is pure and able to sinter to its theoretical density. Therefore, in order to produce a useful ceramic article of a metal nitride possessing the desired properties, it is necessary to begin with very fine, high surface area, high purity powders. For the commercial production of aluminum nitride powder two methods are in common use. The direct nitriding method involves exposing metallic aluminum to a nitrogen or ammonia atmosphere at elevated temperatures. Pulverization of both the original aluminum and the resulting aluminum nitride is required, with the disadvantages of introducing impurities and causing partial oxidation of the nitride. Moreover, unreacted aluminum remains as an impurity, degrading the properties of the aluminum nitride. In the second method, called a carbothermic reduction process, alumina and carbon powders are intimately mixed and heated under nitrogen or ammonia, followed by a second heating step in air to remove any residual carbon. Residual alumina remains as an impurity, and milling is usually required to reduce the aluminum nitride particles to a size suitable for fabrication by sintering. Such processes also require high reaction temperatures and lengthy reaction times. A carbothermic process for providing aluminum nitride is described in US-A-4 618 592. The process requires intimate mixing of fine powders of alumina and carbon of high purity in a liquid medium followed by the nitriding step. An alternative carbothermic process is described in US-A-4 643 859. In this process an alkoxide of aluminum is first formed and then blended with carbon particles in a suitable solvent. The alkoxide blend is then hydrolysed, the solvents removed and the resulting powder calcined under nitrogen. Both the above described carbothermic processes of forming aluminum nitride have disadvantages and are unable to provide the necessary pure, high surface area and small size particles required for use in sintering fabrication methods. The present invention provides improved sinterable particles of aluminum and certain other metal nitrides and a method for their preparation. According to the present invention there is provided a sinterable metal nitride powder in which the metal is aluminum, yttrium, cerium, zirconium, or titanium, (hereafter referred to as 'the metals'), characterised in that the particles have a surface area of at least 8 square meters per gram and an average particle diameter less than 0.5 micrometers. Preferably the particles have a surface • area of at least 12 square meters per gram. In their preferred form the particles have an average particle diameter less than about 0.5 micrometers, most preferably less than about 0.2 micrometers, an oxygen content less than about 3 weight percent, most preferably . less than about 2 weight percent, and a metal impurity content less than about 1,000 parts per million by weight (ppm) , most preferably less than about 100 ppm. There is also provided a method of making the sinterable aluminum, yttrium, cerium, zirconium, or titanium, metal nitride powders characterised in that a homogeneous combination of a soluble or colloidally dispersible compound of the metal with a water soluble, oxygenated carbonaceous compound is formed in an aqueous medium, the pH of the aqueous medium is adjusted to forrr, a gel or precipitate of a chemically or electrostatically bonded product of the metal and the carbonaceous compound. ' The product is dried and the dried product is calcined in nitriding atmosphere. In a preferred embodiment a salt of the metal is prepared by mixing an aqueous solution or dispersion of a compound of the metal with an aqueous solution or dispersion of a carboxylic acid compound to form a precipitate of the metal salt of the carboxylic acid compound. The pH at the precipitation stage is adjusted to a level at which only the etal-carboxylic acid salt precipitates. The precipitate of metal carboxylate is separated and calcined in a nitriding atmosphere, such as nitrogen or ammonia. In another preferred embodiment a colloidal hydrated oxide of the metal, such as colloidal hydrated alumina, is mixed with a water soluble, oxygenated, carbonaceous compound, such as sucrose or methyl cellulose, in an aqueous medium, the pH is adjusted to form a gel and the latter is dried and then calcined in a nitriding atmosphere. Although the described method is capable of producing the metal nitride powders with extremely high surface areas, e.g. 8 square meters per gram or much higher, the method also has important advantages even for producing powders of lower surface area. These advantages include short reaction times and low reaction temperatures during manufacture. The starting materials employed in the embodiment of the method of the invention which is referred to as the "poly eric-chelation" procedure, and which will be described first, are (1) the metals in the form of water- soluble or water-dispersible compounds; and (2) water- soluble or water-dispersible carboxylic acid compounds or their salts. The aqueous solution or dispersion of the metal compound is mixed with the aqueous solution or dispersion of the carboxylic acid compound, preferably in amounts providing at least one equivalent of carboxyl group per equivalent of the metal cation. The pH level of the mixture after mixing should be such that the precipitation of undesirable metal salts, e.g. hydroxides, oxides, nitrates or chlorides, is avoided. The resulting precipitate is separated, e.g. by decantation, centrifugat- ion or filtration, optionally washed, and dried. The resulting metal carboxylate is then calcined in a nitriding atmosphere such as nitrogen, optionally followed by oxidative heating to remove residual carbon. Suitable heating schedules are detailed in the examples. It is an important advantage of the process of the invention that the addition of particulate carbon is un- necessary in contrast to the prior carbothermic processes. The intermixing of the reactants at the atomic level in the method of the invention, as distinguished from the mechan¬ ical particulate mixing in the carbothermic process, allows nitridation to be completed at a lower maximum temperature and in a shorter time than in the prior processes. This avoids undesirable particle growth and premature sintering of the particles. The resulting metal nitride particles are of extremely small and uniform particle size, high surface area, and high purity. They are thus highly suited for the fabrication of ceramic articles by sinter¬ ing, e.g. hot pressing or pressureless methods, and are indeed found to sinter at relatively low temperatures to bodies of theoretical density. Furthermore they can be sintered without sintering aids, or with no more than a low concentration of sintering aid, thus yielding a sintered article of high purity and conseguently, high thermal conductivity. The metal nitrides produced by the method of the invention have a particle surface area of at least eight square meters per gram, and preferably at least twelve square meters per gram, an average particle diameter less than 0.5 micrometers, most preferably less than about 0.2 micrometers, an oxygen content of three weight percent, most preferably less than two weight percent, and a metal impurity content, i.e. metals other than the species of the desired nitride, of less than about 1,000 ppm, most preferably less than 100 ppm. These properties can be measured by well-known standard methods. For example, surface area can be determined by nitrogen desorption according to the method of Brunauer, Emmett " and Teller (the "BET" method). Particle size is determined by measurement of scanning electron micrographs, and oxygen content is determined from the metal oxide concentration in the powder, if any. The metal impurity content is expressed as elemental metal content, which may be present as free metals or as metal compounds, and can be measured by atomic absorption or X-ray fluorescence. Particularly significant sinterable nitrides having these properties and made by the method of the invention are aluminum nitride, yttrium nitride, cerium nitride, zirconium nitride, and titanium nitride. The method of the invention can make use of any of the water-soluble or water-dispersible compounds of the metals, such as aluminum, yttrium, cerium, zirconium or titanium or their mixtures. Examples of such compounds include, e.g. the metal halides, nitrates and alkoxides, as well as water dispersible oxides such as boehmite (pseudoboehmite) . Specific compounds include aluminum nitrate, aluminum chloride, yttrium nitrate, aluminum sec-butoxide and boehmite. Specific useful water-soluble or water- dispersible carboxylic acid compounds include compounds such as polymers of acrylic acid, methacrylic acid, carboxymethylcellulose, butenoic acid, sorbic acid, crotonic acid, maleic acid, itaconic acid or their salts, provided that they are water-soluble or dispersible. Molecular weights of the polymers are only limited by the convenience of handling. The heating times and temperatures required for nitridation will vary with the composition of the reactants. However, as noted above, the atomic scale intermixing of the reactants provided by the process of the invention will permit nitridation to be completed at lower maximum temperatures and shorter times than required in existing commercial processes, with resulting improvement in product particle size and uniformity, e.g. reduced neck growth and sintering. The process of the invention involves simple operations and makes use of relatively inexpensive and readily available starting materials. The disadvantages of the carbothermic reduction process, such as the need for finely divided solid reactants, arduous mechanical milling and pulverizing with concomitant risk of contamination, and need for high calcining temperatures for long periods of time, are avoided. As already noted, the nitride products of the invention are of high surface area, uniform fine particle s ze and high purity, and thus highly suitable for fabrication by sintering. The process is also very adaptable, giving the ability to modify surface area and particle size by adjusting the nitridation conditions. An important advantage of the method and the product is that because of the high surface area of the nitride powders, sintered articles of substantially theoretical density, i.e. at least 99 percent of the theoretical density, can be prepared at relatively low temperatures and using short times. In the case of aluminum nitride, a temperature as low as 1600 C and a time as short as three hours can be used. In addition, low levels of sintering aids are adequate resulting in greater product purity and thus improved properties such as thermal conductivity and mechanical strength. The following example illustrates the preparation of aluminum nitride by the method of the invention using aluminum chloride hexahydrate as the source of the metal cation. EXAMPLE I An aluminum ion solution was made of 50 g of aluminum chloride hexahydrate in 207.1 ml of distilled water. An amount of polymeric acid was then calculated to achieve a final molar ratio of trivalent aluminum ions to carboxylic acid moieties of 0.33. As a polymeric acid 106.9 g of a polyacrylic acid designated 'Goodrite' K-732 and supplied by B. F. Goodrich (molecular weight about 5100 and 50 percent solids) was diluted with 622 ml of distilled water. The polymeric acid solution was added to the aluminum ion solution by mixing with a high torque propeller mixer. No precipitation occurred and the pH of the mixture was approximately 1.9. A concentrated aqueous solution of ammonium hydroxide was then added to the solution until the pH reached 3. As the pH increased a white gelatinous material was formed. The solution was left overnight so that the material settled and the mother liquor was removed by decantation. The material was then washed with distilled water several times and allowed to dry overnight at a temperature of 110°C. The material was converted to nitride by the following procedure in a controlled atmosphere using a programmable electric furnace with a nitrogen flow rate in the range 0.35 to 0.40 1/min. Temperature Rate of Change 20 - 1100°C 10°C/min 1100°C 60 in hold 1100 - 1450°C 10°C/min 1450°C 180 min hold 1450 - 20°C 10°C/min The nitride was then heated to 500°C in air for one hour to remove any excess carbon. The BET gas absorption method was used to characterize the surface area of the resulting aluminum nitride. The 2 surface area was found to be 22 m /g as compared to values for commercially supplied aluminum nitride of 1 - 5 2 m /g. X-ray diffraction analysis showed that the aluminum nitride produced was phase pure with no detectable aluminum oxide such as is commonly seen in aluminum nitride produced by the carbothermic reduction process. Scanning Electron Micrograph (SEM) analysis showed an average particle size of 0.15 micrometers. X-ray peak broadening confirmed that the powder was of sub-micron size. A sample of the aluminum nitride was sintered. As a sintering aid, one percent by weight of calcium oxide, in the form of calcium carbonate, was added to the aluminum nitride and the mixture milled for one hour in heptane using a ball mill having an interior surface of polyethyl¬ ene and milling medium surfaces of alumina. The resulting powder was separated, dried and pressed at 280 MPa in a cylindrical die to form disks of 9 mm diameter and 2 mm thickness. The disks were sintered in flowing nitrogen at 0.5 1/min and atmospheric pressure using the following schedule: Temperature Rate of Change 20-1900°C 20°C/min 1900°C hold 60 min 1900-20°C 10°C/min The resulting sintered disks were of substantially theoretical density, of uniform icrostructure and- were translucent. Three additional samples of the same aluminum nitride powder were mixed, respectively, with zero, 0.5 and 1 percent by weight of calcium oxide, added in the form of calcium carbonate, sintering aid and sintered in flowing nitrogen at atmospheric pressure using the following schedule: Temperature Rate of Change 20-1700°C 20°C/min 1700°C hold 180 min 1700-20°C 10°C/min In each case the resulting sintered disks were of substantially theoretical density. Thus a product of theoretical density can be made from the high surface area powder of the invention with or without the addition of a sintering aid. At least a small amount of sintering aid is useful when a translucent sintered article is desired. In the following example dispersible alumina was used in place of aluminum chloride hexahydrate in the preparat¬ ion of aluminum nitride. EXAMPLE II 1.5 g of "Disperal" , a boehmite, A10(OH)xH_0, also known as pseudoboehmite, and supplied by the Remet Chemical Corp. , was mixed in 10 ml distilled water. The pH of the mixture was adjusted with 6N hydrochloric acid to form a stable dispersion at which point the pH was 1.5. The dispersion was centrifuged to remove a small amount of undispersed material. A solution was prepared by mixing 10 g of the polyacrylic acid designated 'Goodrite' K-732 with 20 ml of distilled water. The pH was adjusted to 5 with a concentrated aqueous solution of ammonium hydroxide. This solution was then added to the "Disperal" dispersion while mixing. The pH was observed to be about 5. The pH was then adjusted with 6N hydrochloric acid to a final value of 1.5. The mixture was dried overnight at a temperature of 110°C and the resulting solid ground to a powder. Nitridation was carried out using the calcination schedule described for Example I to provide an aluminum nitride powder having 2 a surface area of 12 m /g and similar X-ray- diffraction properties to those of the product of Example I. The average particle size was 0.1 micrometer. In a third example aluminum sec-butoxide was used in the preparation of aluminum nitride. EXAMPLE III 5.5 g of aluminum sec-butoxide was diluted with 5 ml sec-butyl alcohol. A second solution was prepared by mixing 10 g of the polyacrylic acid with 20 ml distilled water. The pH was adjusted to 5 with a concentrated aqueous solution of ammonium hydroxide. The aluminum sec-butoxide solution was then added to the polymer solution while mixing. The pH was observed to be 5. The precipitate that formed was mixed for one hour to ensure complete hydrolysis of the aluminum sec-butoxide. The pH was then adjusted with hydrochloric acid until the value fell to 1.5. The precipitate was dried overnight at 110°C and ground to form a fine powder. Nitridation was carried out using the calcination schedule described for Example I to provide an aluminum nitride powder having a 2 surface area of 8 m /g and similar X-ray diffraction properties to those of the product of Example I. SEM micrographs revealed the average particle diameter to be less than 0.1 micrometer. EXAMPLE IV A solution was made by dissolving 7.6 g of yttrium nitrate hexahydrate in 100 ml of distilled water. An amount of polymeric acid was then calculated to achieve a final molar ratio of trivalent yttrium ions to carboxylic acid moieties of 0.33. In this example 8.7 g of the poly¬ acrylic acid, designated 'Goodrite' K-732, was added to the above solution with stirring action. No precipitation occurred until the pH was raised to about 5 -by dropwise addition of an aqueous ammonium hydroxide solution. The gel precipitate was dried for about 24 hours at 60 C. Nitridation was carried out using the following schedule in a controlled atmosphere, programmable, electric furnace with a nitrogen flow rate of 0.35 - 0.40 1/min: Temperature Rate of Change 20 - 1100°C 10°C/min 1100°C 60 min hold 1100 - 1500°C 10°C/min 1500°C 180 min hold 1500 - 20°C 10°C/min X-ray diffraction analysis showed that phase pure yttrium nitride was formed by the process. The foregoing examples I-IV have demonstrated the embodiment of the invention known as the poly eric-chelat- ion procedure wherein electrostatic attraction of a polymer to an aluminum or yttrium source is utilized to obtain a highly homogeneous metal compound/carbon mixture. Further examples of this embodiment and examples of the sol-gel procedure are provided below. The latter examples illustrate the preparation of some sol-gel precursors and the preparation of nitrides from these precursors. Chemical precursors to be nitrided in accordance with the invention were prepared by the sol-gel procedure and by the polymeric-chelation procedure as follows: Sol-gel Preparation In the following sol-gel precursor examples, V and VI, a pseudoboehmite, AlO(OH)xH 2 0, was used as the alumina source. The pseudoboehmite was gelled in various carbon- containing water based systems in order to obtain a highly homogeneous alumina/carbon mixture. The carbon sources were sucrose and ethylcellulose. General procedures for each mix are detailed in the examples. Example V Dispersible Alumina/Sucrose The precursor was prepared by gelling colloidal hydrated alumina in a sucrose solution. A stable colloidal hydrated alumina dispersion was prepared by mixing 5 g "Disperal" pseudoboehmite in 20 ml distilled water. The pH was adjusted with 6N hydrochloric acid to form a stable dispersion, at which point the solids content was about 20 percent by weight and the pH of the solution about 1.5. The dispersion was centrifuged at 1500 rpm for 5 minutes and the decantate removed for use. This step was necessary to remove any large particles of undispersed material. At this point the decantate solids content was slightly lower than the solids content of the original dispersion providing excess carbon for the formation of aluminum nitride. Separately a solution was prepared by dissolving 4.88 g sucrose in 15 ml distilled water and 5 ml ethanol. The sucrose solution was then added to the "Disperal" decantate while stirring and 6N hydrochloric acid was added until a gel formed at a pH value of about 1. Example VI Alumina/Methylcellulose This precursor was prepared by combining colloidal hydrated alumina and methylcellulose. Again a stable colloidal hydrated alumina dispersion was prepared as described in Example V. Separately a solution was prepared by adding 9.19 g methylcellulose to 368 ml distilled water while stirring rapidly. When all the methylcellulose was dissolved the viscosity increased significantly. At this time the viscous solution was added to the "Disperal" decantate while stirring and 6N hydrochloric acid was added until the pH was about 1.5. At this point the viscosity was sufficient to prevent migration of materials. Polymeric-Chelation Preparation In a further series of precursor examples electro¬ static attraction of a polymer to an aluminum source was utilised as in Examples I-IV to obtain a highly homogeneous alumina/carbon mixture. Polyacrylic acid, containing ionised carboxyl groups was used as the carbon source that was electrostatically attracted to colloidal hydrated alumina particles or chelated with aluminum cations in a water medium. The aluminum sources consisted of dispersible alumina, aluminum alkoxides and aluminum salts. Example VII Dispersible Alumina/Polyacrylic Acid This precursor was prepared by electrostatically attracting polyacrylic acid chains to the surface of colloidal hydrated alumina. A dispersion was prepared by mixing 5 g "Disperal" in 33.5 ml distilled water. The pK was adjusted with 6N hydrochloric acid to form a stable dispersion at which point the pH was about 1.5. The dispersion was then centrifuged for 5 minutes and the decantate removed for use. A separate solution was prepared by adding 33.5 g of the polyacrylic acid, designated 'Goodrite' K-732, to 67 ml distilled water at which point the solids content was about 17 percent by weight and the pH about 3. The "Disperal" decantate was then added to the polyacrylic acid solution while stirring at which time no reaction occurred. The pH of the solution at this stage was about 1.7. A precipitate was then formed by increasing the pH by addition of a concentrated aqueous solution of ammonium hydroxide until the pH was about 3. The material was stirred for one hour, allowed to rest for 24 hours, and restirred for one hour to ensure that the reaction was complete. Example VIII Aluminum Alkoxide/Polyacrylic Acid This precursor was prepared by electrostatically attracting polyacrylic acid chains to the surface of colloidal hydrated alumina. Aluminum sec-butoxide was used to form a stable colloidal hydrated alumina dispers¬ ion. To prepare the dispersion 18 g of aluminum sec-butoxide was diluted with 17 ml sec-butanol and then added to 34 ml distilled water to start hydrolysis. The pH was then lowered to about 1.5 by adding 6N hydrochloric acid. The contents were then held at 60°C for 12 hours to complete peptization and for the dispersion to become clear. The polyacrylic acid solution was prepared by repeating the procedures of Example VII. The colloidal dispersion was then added to the polyacrylic acid solution while stirring at which time no reaction occurred. The pH was about 1.7. A precipitate was then formed as before by increasing the pH to 3. Example IX Aluminum Salt/Polyacrylic Acid This precursor was prepared by chelating aluminum cations to ionized carboxyl groups on polyacrylic acid chains. A solution containing hexahydrated aluminum cations [Al(H_0), ] was prepared by dissolving 10 g aluminum chloride hexahydrate in 40 ml distilled water. The pH of the solution was approximately 1.7 after all the salt had dissolved. A separate solution was prepared by adding 20 g of the polyacrylic acid, designated 'Goodrite' K-732, to 80 ml distilled water to give a mixture having a solids content of about 10 percent by weight and a pH of about 3.3. An amount of polyacrylic acid was then calculated to achieve a final molar ratio of trivalent aluminum ions to carboxylic acid moieties of 0.33. (This ratio was used to ensure that there were enough carboxyl groups in the solution to balance charge with the aluminum species.) The aluminum salt solution was then added to the polyacrylic acid solution while stirring at which time no reaction occurred. The pH at this time was about 1.7. A precipitate was then formed by raising the pH to 3. Example X Drying and Nitridation Procedures Each of the gels and precipitates of Examples V - IX was dried at 110°C for 24 hours. The solid remaining was then crushed using a porcelain mortar and pestle to form a powder. Prior to nitridation the powders were stored at 80 C to prevent hydration of the materials. Nitridation was conducted in a tungsten mesh resistance furnace capable of vacuum, inert or reducing atmospheres. Precursor powders were loaded into a cylindrical graphite crucible measuring 63.5 mm in diameter and 24.5 mm in height which was lined with graphite foil. Preliminary runs were conducted in flowing nitrogen with a flow rate of 0.5 1/min. Prepurified grade nitrogen with a minimum purity of 99.998, containing 3 ppm or less of water and 5 ppm or less of oxygen was, used. The heating schedule was: Temperature Rate of Change 20 - 1100°C 10°C/min 1100°C 60 min hold 1100 - 1450°C 10°C/min Temperature Rate of Change 1450°C 180 min hold 1450 - 20°C 10°C/min Powders obtained after nitridation of the sol-gel and the poly eric-chelation precursors of Examples V - IX were oxidized at 650 C to remove excess carbon. The powders were analyzed using X-ray diffraction to determine aluminum nitride or residual alumina content. Using these results the following steps were taken to increase the aluminum nitride yield. A. Elevated Nitridation Temperature The precusor of nitrided powder containing residual alumina, namely the sol-gel precursor using methyl¬ cellulose, was subjected to increased nitridation temperatures in an effort to increase the aluminum nitride yield. The heating schedule was identical with the previous schedule except that the upper temperature was increased from 1450 C to 1500 C. As before pre¬ purified nitrogen was used with a flow rate of 0.5 1/mιn. B. Increased Carbon Content • A second step taken to increase aluminum nitride yield was to increase the initial carbon content in the precursors in order to ensure that the molar ratio of the carbonaceous polymer to the metal compound was sufficient to supply carbon in stoichiometric excess for reduction of the metal and avoidance of metal oxide in the product. In the sol-gel precursor utilizing methylcellullose as a carbon source the amount of methylcellulose was doubled in an effort to eliminate residual alumina. The methyl- cellulose precursor was prepared as in Example VI except the amount of methylcellulose was now 18.38 g. The pre¬ cursor was then dried and nitrided according to the schedule shown in Example X. The amount of carbon in the precursor utilizing sucrose was left unchanged because of the 100 percent yield of aluminum nitride at the higher nitridation temperature. The carbon content, or amount of polyacrylic acid, from the polymeric-chelation precursors was high because of the excess amount of polyacrylic acid required to achieve effective chelation of the aluminum sources. Thus the polymeric-chelation precursors were left unchanged. C. Polymeric-Chelation Modified pH Treatment Because chelation depends on ionization of the carboxyl groups, which is a function of pH for polyacrylic acid, the pH was varied to evaluate any changes that might occur. In the polymeric-chelation preparations of Examples VII - IX the pH of the polyacrylic acid/aluminum salt source after mixing was adjusted to approximately 3.0. To study the effects of pH further precursors were prepared in the same manner as in Example IX except that the final pH after mixing was adjusted to 5.0 in one case and 8.0 in another. The precursors were dried and nitrided according to the schedule shown in Example X. The precursors were evaluated during and after the nitridation treatment using several characterization tech¬ niques in an effort to determine reaction paths leading to the formation of aluminum nitride. Thermogravimetric analysis (TGA), differential thermal analysis (DTA) and X-ray diffraction (XRD) were used. The final nitrided powders were evaluated using scanning electron microscopy (SEM), BET gas absorption and oxygen content analysis to compare the final properties. A series of sintering tests was also conducted on what appeared to be the best powder. Sintering Procedures Powders obtained from the polymeric-chelation process using an aluminum salt as an aluminum source were subject- ed to a series of sintering tests. One gram batches of aluminum nitride powder were ball milled in heptane for one hour with zero, 0.5 and 1 percent by weight of calcium oxide, added as calcium carbonate, as a sintering aid. A 250 ml polyethylene container filled about one third with 12.5 mm cylindrical alumina media was used. After milling the slurry was dried and lightly crushed to form a fine powder. The powder was pressed at 280 MPa in a cylindrical die to form disks of 12.5 mm diameter and 2 mm thickness. A 'Centorr', model M-60, tungsten mesh resistance furnace was used for sintering. The disks were placed on a polished 98 percent aluminum nitride setter which was set in a cylindrical graphite crucible. The disks were then covered with graphite foil followed with a thin layer of aluminum nitride powder. Sintering was conducted in flowing prepurified grade nitrogen with a flow rate of 0.5 1/min. The heating schedule was: Temperature Rate of Change 20 - 1700°C 20°C/min 1700°C 180 min hold 1700 - 20°C 10°C/min Sintered disks were then tested for bulk properties such as bulk density, apparent porosity and percent theoretical density by the Archimedes Balance Technique, ASTM C373-72(82). Fracture surfaces were examined with the scanning electron microscope to determine grain size and morphology. Results Observed in Tests of Sol-gel Precursors of Examples V and VI In preparing the precursors by gelation of colloidal hydrated alumina it appears that the carbon source influences the appearance of the gel before and after drying. » Gels formed with only dispersible alumina become transluscent glassy solids after drying. The precursors containing sucrose and methylcellulose dried to form glassy solids and brown fibrous solids respectively suggesting soluble carbon sources also have an effect on the properties of the gel. Results Observed in Tests of Polymeric-Chelation Precursors of Examples VII - IX The methods used to prepare the precursors consisted of an electrostatic attraction and a chelation technique. Each precursor formed a white precipitate which converted to a chalk-like substance during drying. The precursors prepared by electrostatic attraction of the polyacrylic acid to colloidal hydrated alumina were yellow-white in color after drying which suggested free polymer in the solution. However the precursor prepared by chelating aluminum cations with polyacrylic acid was white in color after drying suggesting that chelation occurred with all the polymer in solution. In the electrostatic attraction technique it is believed that polyacrylic acid chains are attracted to the surface of the colloidal hydrated alumina. The poly¬ acrylic acid chains become charged above a pH of about 2 when the carboxyl groups ionize to form -COO~ side groups. At this point the chains are attracted to the positive surface of the colloidal hydrated alumina. This is supported by the fact that a precipitate forms in this system at a pH greater than 2. The precipitate is believed to be formed by polyacrylic bridges among the alumina particles In the chelation technique it is believed that aluminum species, primarily Al(H 2 0) , are chelated with the ionized carboxyl side groups located on the poly¬ acrylic acid chains. For this to occur the pH of the mixture should remain below 3.3 to ensure that aluminum hydroxide does not form. If aluminum hydroxide forms then the electrostatic attraction process mentioned above will become involved. In the chelation process aluminum species with positive charges are believed to cause cross-linking betwen polyacrylic acid chains causing the thick white precipitate to form. All of the precursor combinations nitrided at 1450 C appeared as a fluffy dark black powder except for the dispersible alumina/ ethylcellulose powder which appeared light black. After the powders were oxidized at 650°C to remove excess carbon all the powders appeared light gray in color. X-ray diffraction results showed only aluminum nitride in all the powders except those prepared from the methylcellulose precursors which contained residual alumina. Sol-Gel Optimization The sol-gel precursor based on dispersible alumina/ methylcellulose with the methylcellulose, or carbon, content doubled was dark black after nitriding at 1450 C. X-ray diffraction results showed only aluminum nitride in this powder. Thus the residual alumina in the original nitrided precursor was reduced by increasing the amount of methylcellulose and, hence, the carbon content to well above the stoichiometric amount for the reduction reaction. Polymeric-Chelation Modified pH Treatment The polymeric-chelation precursors which were prepared with adjusted final pH values of 5 and 8 instead of 3 were both dark black after nitriding at 1450°C. X-ray diffraction results showed a single phase aluminum nitride powder was formed. Thus phase pure aluminum nitride can be formed regardless of pH in the range 3 to 8. Above pH values of 3.5 the hexahyrated aluminum ion, AKH-O) , disappears and aluminum hydroxide, Al(OH),, particles are precipitated. At this point it is believed that the polyacrylic acid is electrostatically attracted to the positive surface of the hydrated alumina. This is valid for pH values less than 9, the point of zero change (Pzc) , for alumina. Another possible explanation is than aluminum hydroxide does not form and the aluminum- species in solution continues to be chelated.with the ionized carboxyl groups on the polyacrylic acid side chains. Test results show that the formation temperature for aluminum nitride decreases from greater than 1450°C to about 1360 C when colloidal hydrated alumina is replaced with an aluminum salt and the carbon source is soluble and capable of being attracted to the aluminum source, e.g. the carbon source is anionic. By changing to a soluble nonionic and then to a soluble anionic carbon source with the colloidal hydrated alumina, the formation temperature appears to decrease below 1450 C. Thus reduction and nitridation of alumina in the sol-gel powders utilizing colloidal hydrated alumina is estimated to occur up to 100 degrees higher than the polymeric-chelation powders which utilize aluminum salts. This effect is presumably due to the near atomic scale separation of the aluminum, oxygen and carbon species obtained in the polymeric-chelation precursors which results in shorter diffusion distances for the reduction of the alumina or the removal of oxygen from the system. Sintering Results The nitride powders derived from aluminum salt/poly- acrylic acid, as in Example IX, were sintered at 1700°C. Disks from the powder containing zero, 0.5 and 1 percent by weight of calcium oxide as a sintering aid appeared opaque gray, translucent gray, and translucent gray-white respectively. All disks showed no apparent porosity and were more than 98 percent of the theoretical density, 3.26 g/cc. The grains in the disk with 0.5 and 1 weight percent of calcium oxide added are larger and more angular than those in the disk with no sintering aid. It appears that the addition of sintering aid enhances grain growth at these low sintering temperatures by formation of a CaO-Al_0, liquid phase at the grain boundaries.

Claims: C L A IM S - 24 - 1. A sinterable metal nitride powder in which the metal is aluminum, yttrium, cerium, zirconium, or titanium, characterized in that the particles have a surface area of at least 8 square metres per gram and an average particle diameter less than 0.5 micrometres. 2. A sinterable metal nitride powder according to claim 1, characterized in that the particles have a surface area of at least 12 square metres per gram. 3. A sinterable metal nitride powder according to claims 1 or 2, characterized in that the particles contain less than 3 percent by weight of oxygen and less than 1,000 parts per million of metal impurities. 4. A sinterable metal nitride powder according to any of the preceding claims, characterized in that the particles have a surface area of at least 15 square metres per gram and an average particle diameter less than 0.2 micrometres, 5. A method of making a sinterable metal nitride powder according to claim 1, characterized in that a homogeneous combination of a soluble or colloidally dispersible compound of the metal with a water soluble, oxygenated carbonaceous compound is formed in an aqueous medium, the pH of the aqueous medium is adjusted to form a gel or precipitate of a chemically or electrostatically bonded product of the metal and the carbonaceous compound, drying the product and calcining the dried product in a nitriding atmosphere. 6. A method of making a sinterable metal nitride powder according to claim 5, characterized in that the ratio of the oxygenated carbonaceous compound to the metal compound provides carbon in excess of the stoichiometric amount required to reduce the compound to the metal. 7. A method of making a sinterable metal nitride powder according to claims 5 or 7, characterized in that the oxygenated carbonaceous compound is a sugar or methylcellulose. 8. A method of making a sinterable metal nitride powder according to claims 5 or 6, characterized in that the oxygenated carbonaceous compound is a polymer. 9. A method of making a sinterable metal nitride powder according to claim 8, characterized in that the oygenated carbonaceous compound is a polymeric carboxylic acid. 10. A method of making a sinterable metal nitride powder according to claim 9, characterized in that the pH of the aqueous medium is adjusted to a level at which only the metal-carboxylic acid salt precipitates. 11. A method of making a sinterable metal nitride powder according to claims 9 or 10, characterized in that the oxygenated carbonaceous compound is a polyacrylic acid, a poly ethacrylic acid or a carboxymethylcellulose. 12. A method of making a sinterable metal nitride powder according to any of the claims 5 to 11, characterized in that the metal compound is colloidal hydrated alumina. 13. A method of making a sinterable metal nitride powder according to any of the claims 5 to 11, characterized in that the metal compound is aluminum chloride or aluminum nitrate. 14. A method of making a sinterable metal nitride powder according , to any of the claims 5 to 13, characterized in that the calcining temperature does not exceed 1500°C anc the calcining treatment does not exceed one hour. 15. A method of forming a sintered article by subjecting a powder as claimed in any of the claims 1 to 4 to sintering conditions, characterized in that the powder is sintered at a temperature in the range 1350 to 2000°C with up to 5 percent of a sintering aid as oxide equivalent. 16. A method of forming a sintered article according to claim 15, characterized in that the powder is sintered at a temperature in the range 1350 to 1700°C. 17. An aluminum, yttrium, cerium, zirconium, or titanium, nitride article fabricated by sintering according to either claim 15 or claim 16.

Inventors: AXELSON SCOTT R, HEXEMER RICHARD L, MCCLUSKEY PHILIP H, MROZ THOMAS J, AXELSON, SCOTT, R., HEXEMER, RICHARD, L., MCCLUSKEY, PHILIP, H., MROZ, THOMAS, J.
Applicants: UNIV ALFRED RES, ALFRED UNIVERSITY
Application year: 1988
Main classification: C04B35
IPC codes: C01B21, C04B35