Highly densified bodies from organopolysiloxanes filled with silicon carbide powders

Abstract: The preparation of highly densified ceramic bodies by the sintering of certain organopolysiloxanes filled with silicon carbide powders and metal-containing sintering aids is described. Such highly densified ceramic bodies can be prepared by either a pressureless sintering process or a hot press sintering process. The compositions of this invention can be formed into desired shapes and then sintered to form ceramic, shaped bodies with high densities. One advantage of the present invention is that the green bodies have relative high strengths and thus can be easily handled and, if desired, machined before sintered. The organopolysiloxanes useful in this invention must yield a ceramic char which contains free or excess carbon in addition to carbon in the form of silicon carbide upon pyrolysis to elevated temperatures.

Description: This invention relates to the preparation of highly densified ceramic bodies by the pyrolysis of certain organopolysiloxanes filled with silicon carbide powders and certain metal-containing sintering aids. Such highly densified ceramic bodies can be prepared by either a pressureless sintering process or an hot press sintering process. This invention also relates to novel compositions of matter consisting essentially of silicon carbide powder, a metal-containing sintering aid and a preceramic organopolysiloxane. These compositions of matter can be formed into desired shapes and then sintered to form ceramic shaped bodies with high densities. One advantage of the present invention is that the green bodies have relatively high strengths and thus can be easily handled and, if desired, machined before sintering. EP-A-0 148 277 describes a process for producing a silicon carbide sintered product, which comprises allowing an organosilicon polymer to be present on the surface of starting SiC particles of l mm or less in size, so as to precipitate superfine SiC particles produced from the organosilicon polymer onto the starting SiC particles in a heating step prior to the sintering step. Boron-, aluminum- and beryllium-containing compounds in addition to carbonaceous materials are suggested as sintering aids, aluminum and aluminum compounds such as aluminum nitride (AlN) being preferred. This invention relates to a composition of matter comprising in intimate admixture an organic silicon polymer, a silicon carbide powder and a metal-containing sintering aid, selected from iron, Fe₃C, magnesium, MgC₃, lithium, Li₂C₂, beryllium, Be₂C, boron, boron-containing compounds, aluminum, aluminum-containing compounds and metal oxides selected from thorium oxide, yttrium oxide, lanthanum oxide and cerium oxide, characterised in that the metal-containing sintering aid is present in a proportion of from 0.1 to 3.0 weight percent of the metal based on the weight of silicon carbide powder, and in that the organic silicon polymer is an organopolysiloxane containing units of general structure [R₃SiO 0.5 ], [R₂SiO], [RSiO 1.5 ] and [SiO₂] where each R is independently selected from the group consisting of hydrogen, alkyl radicals containing l to 20 carbon atoms, phenyl radicals and vinyl radicals, said polyorganosiloxane is capable of being converted to a ceramic material with-a yield above 20 weight percent of a ceramic char having at least 10 weight percent of free carbon derived from the organopolysiloxane by pyrolysis at elevated temperature to a stable ceramic char which does not significantly decrease in weight upon further exposure to heating at elevated temperature, the organopolysiloxane being present at a level such that said free carbon value is higher than 0.2 weight percent and not greater than 3 weight percent based on the total weight of the silicon carbide powder and the char derived from the preceramic organopolysiloxane. This invention also relates to a method of forming a handleable green body, which method comprises: (a) preparing a composition of matter as defined just above; and (b) forming said composition of matter into the desired shape under pressure at a temperature below 500°C. This invention further relates to a method of preparing a sintered body of silicon carbide, said method comprising: (a) forming a handleable green body by a method as defined just above; and (b) sintering the handleable green body in an inert atmosphere at a temperature above 1900°C to obtain a sintered body of silicon carbide with a density above 2.4 g/cm³. The present invention is concerned with the preparation of highly densified sintered bodies from organopolysiloxanes filled with silicon carbide powder. The sintered bodies produced from the practice of this invention have densities greater than about 75% of theoretical (i.e., densities greater than about 2.4 g/cm³). Such highly densified bodies are useful as light weight refractory ceramics. The theoretical density of silicon carbide is 3.21 g/cm³. The novel compositions of the present invention consist essentially of an organopolysiloxane filled with silicon carbide powder and a metal-containing sintering aid. These novel compositions can be used to prepare handleable green bodies. By "handleable green bodies", we mean green bodies which have sufficient green strength to be handled or machined prior to sintering. The high green strength is one significant advantage of the present invention; the high green strength allows the green body to be further processed and shaped prior to the final sintering step. Generally, green strengths of 3,448 kPa (500 psi) or more may be obtained in the practice of this invention. The green bodies may be formed by conventional techniques known in the art. Such methods include pressure molding, uniaxial pressing, isopressing, extrusion, transfer molding, injection molding and the like. The formed green bodies may be further shaped by machining if desired. Once shaped, the green bodies are fired to an elevated temperature under an inert atmosphere to convert the green bodies into ceramic articles having densities greater than about 75% of theoretical. It is preferred that the density of the ceramic article be greater than 85% of theoretical (2.7 g/cm³). It is more preferred that the density be greater than 2.9 g/cm³ (90% of theoretical); it is most preferred that the density be greater than 3.05 g/cm³ (95% of theoretical). The sintering step may be carried out using either a pressureless sintering process or a hot press sintering process. When employing the compositions of this invention, either process will produce a highly densified ceramic article. The hot press sintering process will generally produce higher density ceramic articles. Therefore, if the maximum density is desired, a hot press sintering process would be preferred. Generally, however, the pressureless sintering process is preferred because of the simplified operations involved. The sintering or pyrolysis step is carried out under an inert atmosphere such as nitrogen or argon. The growth of alpha-SiC grains can be reduced by sintering under a nitrogen-containing atmosphere. The sintering step to the final ceramic product is generally carried out at a temperature of 1900°C. or higher. Lower temperatures can be used but the ceramic product may not possess the desired density. The preferred sintering temperature is 2000 to 2200°C. with 2150°C. being most preferred. The organopolysiloxanes useful in this invention are generally well known in the art. The organopolysiloxanes must be capable of being converted to ceramic materials with a significant ceramic char yield. The ceramic char yield must be greater than 20 weight percent. Naturally, there will be less shrinkage if the ceramic char yield is higher. Therefore, it is preferred that organopolysiloxanes with ceramic char yields greater than 40 weight percent be employed in the practice of this invention. The organopolysiloxane must also yield a ceramic char containing free carbon. Using a rule of mixtures, the ceramic char must contain more than 30 weight percent total carbon in order for free carbon to be present. Organopolysiloxanes which yield ceramic chars with more than 40 weight percent total carbon are preferred. A 40 weight percent carbon-containing ceramic material contains, based on a rule of mixtures, 86 weight percent SiC and 14 weight percent free carbon. Most preferred are organopolysiloxanes which yield ceramic chars with more than 50 weight percent total carbon; a 50 weight percent carbon-containing ceramic material contains, based on a rule of mixtures, 72 weight percent SiC and 28 weight percent free carbon. It is necessary that the ceramic char contain at least 10 weight percent free carbon. It is more preferred that the ceramic char contain at least 25 weight percent free carbon. So long as the organopolysiloxane can be converted to a ceramic char with sufficient char yield and the derived ceramic char contains sufficient free carbon, the structure of the organopolysiloxane is not critical. The organopolysiloxane may contain units of general structure [R₃SiO 0.5 ], [R₂SiO], [RSiO 1.5 ] and [SiO₂] where each R is independently selected from the group consisting of hydrogen, alkyl radicals containing 1 to 20 carbon atoms, phenyl radicals and vinyl radicals. Generally, organopolysiloxanes which contain phenyl groups are preferred as such groups easily allow for the formation of ceramic chars with sufficient free carbon. Organopolysiloxanes which contain vinyl groups are also preferred since vinyl groups attached to silicon provide a mechanism whereby the organopolysiloxane can be cured prior to sintering. Preferred organopolysiloxanes contain varying amounts of [PhSiO 1.5 ], [MeSiO 1.5 ] and [PhViSiO] units. Especially preferred organopolysiloxanes are described by the unit formula [PhSiO 1.5 ][MeSiO 1.5 ][PhViSiO] where there are 10 to 90 mole percent [PhSiO 1.5 ] units, 0 to 50 mole percent [MeSiO 1.5 ] units and 10 to 90 mole percent [PhViSiO] units; more preferably, there are 20 to 30 mole percent [PhSiO 1.5 ] units, 30 to 50 mole percent [MeSiO 1.5 ] units and 30 to 50 mole percent [PhViSiO] units. Organopolysiloxanes useful in this invention may contain other siloxane units in addition to, or in place of, the siloxane units just mentioned. Examples of such siloxane units include [ViSiO 1.5 ], [PhMeSiO], [MeHSiO], [MeViSiO], [Ph₂SiO], [Me₂SiO], [Me₃SiO 0.5 ] and the like. Mixtures of organopolysiloxanes may also be employed. Generally, organopolysiloxanes where R is almost exclusively methyl are not suitable for use in this invention as there is insufficient free carbon in the resulting ceramic char. The organopolysiloxanes of this invention can be prepared by techniques well known in the art. The actual method used to prepare the organopolysiloxanes is not critical. Most commonly, the organopolysiloxanes are prepared by the hydrolysis of organochlorosilanes. Such methods, as well as others, are described in Noll, Chemistry and Technology of Silicones , chapter 5 (translated 2d Ger. Ed., Academic Press, 1968). Specific methods for preparation of suitable organopolysiloxanes are illustrated in the examples included in the present specification. In addition to the organopolysiloxane, other components in the compositions of this invention include silicon carbide powder and a metal-containing sintering aid. The silicon carbide powders useful in this invention are commercially available. Both alpha-SiC and beta-SiC powders, as well as mixtures, can be used. Generally, SiC powders with an average particle size of less than five micrometres (microns) are preferred; powders with an average particle size of less than one micrometre (micron) are more preferred. Suitable metal-containing sintering aids include iron, Fe₃C, magnesium, MgC₃, lithium, Li₂C₂, beryllium, Be₂C, boron, boron-containing compounds, aluminum, aluminum-containing compounds and metal oxides such as thorium oxide, yttrium oxide, lanthanum oxide and cerium oxide. Many of these metal-containing sintering aids are described in Negita, "Effective Sintering Aids for Silicon Carbide Ceramics: Reactivities of Silicon Carbide with Various Additives " 69 J. Am. Ceram. Soc. C-308 (1986). Other metal-containing sintering aids suggested by Negita might also be effective in the practice of this invention. Generally, the sintering aid should be present in an amount equivalent to from 0.1 to 3.0 weight percent of the metal based on the weight of the silicon carbide powder. Preferred sintering aids are selected from the group consisting of boron, boron-containing compounds, aluminum and aluminum-containing compounds. Examples of boron-containing sintering aids include boron carbide, lithium borohydride, trivinylboron, triphenylboron, silicon hexaboride, H₃BO₃, B₂O₃ and the like. Examples of aluminum-containing sintering aids include, for example, aluminum oxide, aluminum nitride and aluminum diboride and the like. The most preferred sintering aids are boron and boron carbide. Mixtures of sintering aids may also be used. The preceramic organopolysiloxane is present in the compositions of the present invention at such a level that the free carbon value of the composition is greater than 0.2 weight percent based on the total weight of the silicon carbide powder and the char derived from the preceramic organopolysiloxane. What is meant by "free carbon value of the mixture" in this invention is the amount of free or excess carbon derived from the organopolysiloxane during pyrolysis as expressed by a weight percentage based on the total weight of the silicon carbide powder and the char derived from the organopolysiloxane. The total amount of carbon in the ceramic char equals the amount of free or excess carbon plus the amount of carbon in the form of silicon carbide. The amount of free carbon derived from the organopolysiloxane is determined by pyrolysis of the organopolysiloxane, in the absence of any silicon carbide powder or sintering aid, to an elevated temperature under an inert atmosphere until a stable ceramic char is obtained. For purposes of this invention, a "stable ceramic char" is defined as the ceramic char produced at an elevated temperature which will not significantly decrease in weight upon further exposure at the elevated temperature. Normally, a stable ceramic char is produced upon pyrolysis at 1800°C. for about 30 minutes. Other elevated temperatures can be used to form the stable ceramic char but the length of exposure to elevated temperature will need to be increased for temperatures below 1800°C. Both the ceramic yield and the carbon content of the stable ceramic char are then determined. Using a rule of mixtures, the amount of SiC and free carbon of the stable ceramic char can be calculated. The amount of free carbon normally is expressed as the weight of free carbon produced per gram of preceramic organopolysiloxane. Knowing the amount of free carbon produced by pyrolysis of the organopolysiloxane, one can determine how much organopolysiloxane is required to obtain an organopolysiloxane/silicon carbide mixture with the desired free carbon value. Naturally, if one is using the same or a very similar organopolysiloxane to prepare a sintered body, it is not required that the amount of free carbon produced per gram of organopolysiloxane be determined every time. This procedure can perhaps be best illustrated by example. Assume an organopolysiloxane (100 g) which gives, upon pyrolysis to 1800°C., a char yield of 50 weight percent which contains 40 weight percent carbon and 60 weight percent silicon. Such a char contains 30 g (1.07 moles) silicon. Using a rule of mixtures, the char also contains 1.07 moles (12.8 g) of carbon in the form of SiC. Since the char contains 20 g carbon, the amount of free carbon in the char is 7.2 g (20 g minus 12.8 g). Thus, each gram of the preceramic organopolysiloxane yields 0.072 g free carbon. If a free carbon value for the mixture of 1.5 weight percent is desired, the following calculations can be performed. Let X equal the amount of organopolysiloxane required. The amount of char derived from the organopolysiloxane is 0.5 X (in grams, based on a 50% char yield); the amount of free carbon formed during the pyrolysis is 0.072 X (in grams). For a mixture containing 100 g of SiC powder, the equation 0.015 = (0.072 X )/(100 + 0.5 X ) is obtained where 0.072 X is the amount of free carbon derived from the organopolysiloxane and (100 + 0.5 X ) is the total weight of SiC powder and char derived from the organopolysiloxane. Solving the above equation for X , it is found that 23.3 g of the organopolysiloxane will give the desired 1.5% free carbon value of the mixture. Using this procedure, the amount of organopolysiloxane required to prepare the compositions of this invention can be determined. This procedure avoids the costly and time consuming trial and error method which might otherwise be required. The free carbon value of the mixture must be greater than 0.2 weight percent based on the total weight of the silicon carbide powder and the char derived from the organopolysiloxane. For free carbon values below 0.2 weight percent, the density of the sintered body will generally fall below 2.4 g/cm³ (75% of theoretical). It is generally preferred that the free carbon value of the mixture be greater than 0.5% and that the density of the resulting sintered body be greater than 85% of theoretical. It is more preferred that the free carbon value of the mixture be between 0.5 and 3.0 weight percent with a range of 1.0 to 2.0 weight percent being even more preferred. The optimum density is generally obtained when the free carbon value of the mixture is 1.5 weight percent. Once the amount of organopolysiloxane required in the mixture has been determined, the various components are combined in a manner which ensures an uniform and intimate mixture. Such a mixture is required to avoid areas of varying density throughout the sintered product. Uniform and intimate mixtures can be prepared by using conventional blending techniques. Examples of such techniques include grinding the various powders in either the dry or the wet state. Generally preferred is wet grinding where the various powders are mixed and ground with organic solvents, the solvent is removed and then the resulting mixture is further ground. Other mixing and grinding methods will be apparent to those skilled in the art. The uniform and intimate mixture may then be formed into the desired shape. Preferably the desired shape is formed under pressure using, for example, such methods as injection molding, uniaxial pressing, isopressing, extrusion and transfer molding. Once formed, the article may be further shaped by machining. Once the final shape has been obtained, the article is sintered in an inert atmosphere to a temperature of 1900°C. or above. The preferred sintering temperature is from 2000 to 2200°C. with 2150°C. being most preferred. Although not wishing to be limited by theory, it is thought that the free carbon derived from the preceramic organopolysiloxane plays two different roles in the formation of highly densified sintered bodies. First, it helps to remove oxygen present in the silicon carbide powder; and, secondly, it apparently acts as an additional sintering aid. Silicon carbide powders often contain so-called "free carbon." However, the "free carbon" present in the silicon carbide powder does not appear to be as active or as effective as free carbon generated in situ from the preceramic organopolysiloxane. It is not clear whether the free carbon produced in situ is more active chemically or whether it is simply more evenly dispersed. In any event, when the free carbon value of the mixture (as defined earlier) is 1.5 weight percent, sintered bodies with optimum densities are obtained. So that those skilled in the art can better appreciate and understand the invention, the following examples are given. Unless otherwise indicated, all percentages are by weight. Throughout this specification "Me" represents a methyl group, "Ph" represents a phenyl group and "Vi" represents a vinyl group. In the following examples, the analytical methods used were as follows: Proton NMR spectra were recorded on either a Varian® EM360 or EM390 spectrometer; fourier transform IR spectra were recorded on a Nicolet 5 DX spectrometer. Gel permeation chromatography (GPC) data were obtained on a Waters GPC equipped with a model 600E systems controller, a model 490 UV and model 410 Differential Defractometer detectors; all values are relative to polystyrene. Carbon analysis was done on a Control Equipment Corporation 240-XA Elemental Analyzer. Oxygen analysis was done on a Leco Oxygen Analyzer equipped with an Oxygen Determinator 316 (Model 783700) and an Electrode Furnace EF100. Silicon was determined by a fusion technique which consisted in converting the silicon material to soluble forms of silicon and analysing the solute for total silicon by atomic absorption spectrometry. Compounding was done on a Brabender Plasticorder (Model PL-V151) equipped with roller blades. Test bars were formed on a Carver laboratory press (Fred S. Carver Inc., Summit, N.J.). Pyrolysis was carried out in an Astro graphite element tube furnace Model 1000-3060-FP12 equipped with a Eurotherm Controller/Programmer Model 822. Flex strengths (using the four-point bend technique) were determined on either a Model TTC or Model 8562 Instron instrument. The SiC powder used was Ibiden UF silicon carbide which is a mixture of 5 to 8% alpha-SiC and 92 to 95% beta-SiC. The boron used was amorphous boron powder from Cerac Inc. Example 1 Sintered Bodies from (PhViSiO) 0.5 (MeHSiO) 0.5 . A -- Polymer Synthesis. A solution of 20.32 g (0.10 moles) of PhViSiCl₂ and 11.50 g (0.10 moles) of MeHSiCl₂ in 100 mL toluene was added dropwise to a stirring mixture of 37.1 g (0.35 moles) of Na₂CO₃ in 300 mL water. After stirring for one-half hour, the organic layer was collected and dried over MgSO₄. The toluene solution was filtered through a sintered glass frit. Concentration of the filtrate gave 16.6 g (79.6% yield) of a cloudy, viscous oil. IR (KBr, thin film): 3331 (broad, s), 3073 (w), 3032 (w), 3015 (w), 2972 (m), 2953 (w), 2164 (m), 1595 (w), 1427 (m), 1406 (m), 1271 (s), 1124 (s), 1082 (s), 907 (s), 872 (s), 766 (m), 702 cm-¹ (m). B -- Char Composition Calculations. A sample of the above polymer under argon was heated to 1500°C. at 10°C./min and held at 1500°C. for two hours before cooling to room temperature. The sample had a mass retention of 39.1% and contained 47.9% carbon, 48.9% silicon and 0.9% oxygen. The following calculations were made: 100 g of cured polymer gives 39.1 g of a ceramic char consisting of 47.9% carbon and 52.1% silicon (by difference). (In order to simplify the calculations, the amount of oxygen has been ignored.) The char consists of 29.1 g SiC (74%) and 10.0 g carbon (26%). Therefore, each gram of polymer, after pyrolysis, gives 0.291 g SiC and 0.100 g free carbon. C -- Test Bar Fabrication. A siloxane/SiC mixture was prepared using the following procedure: 10.00 g of the above siloxane polymer dissolved in 150 mL toluene was mixed with 50 g Ibiden SiC powder and 0.25 g boron in an ultrasonic bath for 5 minutes. The free carbon value of the blend was 1.9%. The slurry was transferred to a resin kettle and the solvent removed under vacuum. The residue was further dried. The dried powder was ground in a mortar and pestle and then passed through a 90 µm mesh sieve. The sieved powder was dry pressed into test bars (35x8x2 mm) in a tungsten carbide lined die with a Carver laboratory press at 179.3 MPa (26 ksi). The test bars were fired to 2100-2120°C. in an Astro tube furnace (argon atmosphere) using the following temperature program: room temperature to 300°C. at 26.7°C./min, 300 to 700°C. at 25°C./min, 700 to 1350°C. at 20°C./min, 1350°C. for 30 minutes, 1350°C. to the final temperature at 20°C./min and at the final temperature for 30 minutes. The density of the fired test bars averaged 2.71 g/cm³ (85% of theoretical). Example 2 Sintered Bodies from (MeSiO 1.5 ) 0.25 (PhMeSiO) 0.50 (PhSiO 1.5 ) 0.15 (Ph₂SiO) 0.10 . A -- Polymer Synthesis. A mixture of 37.4 g (0.25 moles) MeSiCl₃, 95.5 g (0.50 moles) PhMeSiCl₂, 31.7 g (.15 moles) PhSiCl₃ and 25.3 g (0.10 moles) Ph₂SiCl₂ dissolved in 184 g xylene was added (below the water surface) over a six minute period to a three-necked flask containing 86.2 g water and 15.6 g isopropyl alcohol. The flask was equipped with a drainage stopcock, thermometer, condenser, overhead mechanical stirrer and addition funnel. After stirring for five minutes, the water layer was removed. The resin layer was washed twice with warm tap water and transferred to a 3 liter flask where it was dried by azeotropic distillation and then bodied for 3 hours with zinc octoate (1.4% based on the total weight of the polymer) at 75% solids content. The solvent was removed and the resin dried at 125°C. at 2.666 kPa (20 torr). B -- Char Composition Calculations. A sample of the siloxane polymer was concentrated under vacuum to remove any remaining solvent and to determine the solids content. The residue was weighed in a graphite crucible and transferred to an Astro tube furnace. The furnace was twice evacuated to less than 2.666 kPa (20 torr) and backfilled with argon. Under an argon purge, the sample was heated to 1800°C. at 10°C./min and held at 1800°C. for 2 hours before cooling to room temperature. The sample had a mass retention of 41.5% and contained 50.0% carbon. The following calculations were made: 100 g of cured polymer gives 41.5 g of a ceramic char consisting of 50.0% (by difference) silicon and 50.0% carbon. The char consists of 29.6 g SiC (71.3%) and 11.9 g carbon (28.7%). Therefore, each gram of polymer, after pyrolysis, gives 0.296 g SiC and 0.119 g free carbon. C -- Test Bar Fabrication. Using the above data, the following mixture was prepared to give a blend with a 2.8% free carbon value and 0.3% boron: 6.69 g of the siloxane polymer (as a 50% solution in xylene) was mixed with 25.15 g Ibiden SiC powder, 0.077 g boron and 5 to 10 mL toluene in an hardened alumina mortar and pestle until a thick paste was obtained. The paste was dried under vacuum to remove residual solvent. The dried powder was ground in a mortar and pestle and then passed through a 90 µm mesh sieve. The sieved powder was dry pressed into test bars (35x8x2 mm) in a tungsten carbide lined die with a Carver laboratory press at 317.2 MPa (46 ksi). The test bars had an average flex strength of 6964 ± 283 kPa (1010 ± 41 psi). The test bars were fired to 2100°C. under an argon atmosphere using the same temperature profile as in Example 1 (Part B). The average density of the five fired test bars 3.13 ± 0.01 g/cm³ (97.4% of theoretical). Example 3 Sintered Bodies from (PhSi0 1.5 ) 0.21 (MeSiO 1.5 ) 0.29 (PhViSiO) 0.50 . A -- Polymer Synthesis. A solution of 71.76 g (0.35 moles) PhViSiCl₂, 31.7 g (0.15 moles) PhSiCl₃ and 29.8 g (0.20 moles) MeSiCl₃ in 50 mL toluene was added dropwise to a stirred mixture of 180 g Na₂C0₃ in 400 mL water and 250 mL toluene. After the addition was complete, the reaction mixture was stirred at room temperature for 45 minutes. The two phases were separated and the organic layer collected and concentrated under vacuum. The residue (79.0 g) was dissolved in 88.7 g toluene and refluxed over 0.10 g KOH. After all of the water had been removed using a Dean-Stark trap, the toluene solution was cooled to room temperature and 1.0 mL Me₃SiCl was added. After one hour, the solution was filtered through a medium glass frit. Concentration of the filtrate under vacuum gave 70.9 g (83.8% yield) of a tacky gum. The polymer was dissolved in 150 mL toluene and poured into 1.5 liters isopropanol. The precipitated polymer was collected and dried at 200°C. and 133 Pa (1 torr). Proton NMR (CDCl₃, delta-values): -0.36 to 0.40 (SiMe, broad singlet), 5.5 to 6.3 (SiVi, broad singlet) and 6.8 to 7.8 (SiPh, broad singlet); the SiMe/SiVi/SiPh molar ratio was 1.0/1.86/2.78. B -- Char Composition Calculations. A sample of the above polymer was weighed into a graphite crucible and transferred into an Astro tube furnace. The furnace was twice evacuated to less than 2.666 kPa (20 torr) and backfilled with argon. Under an argon atmosphere, the polymer sample was heated to 1800°C. at 10°/min and held at 1800°C. for two hours before cooling to room temperature. The sample had a mass retention of 38.6% and contained 52.7% carbon. The following calculations were made: 100 g of cured polymer gives 38.6 g of a ceramic char consisting of 47.3% (by difference) silicon and 52.77% carbon. The char consists of 26.09 g SiC (67.6%) and 12.51 g carbon (32.4%). Therefore, each gram of polymer, after pyrolysis, gives 0.261 g SiC and 0.125 g free carbon. C -- Test Bar Fabrication. Using the above data from Part B, the following mixture was prepared with a 1.7% free carbon value and 0.3% boron: 3.41 g of the above siloxane polymer dissolved in 10-15 mL toluene was mixed with 23.61 g Ibiden SiC powder and 0.077 g boron in an hardened alumina mortar and pestle until a thick paste was obtained. The paste was dried under vacuum to remove residual solvent. The dried powder was ground in a mortar and pestle and passed through a 90 µm mesh sieve. The sieved powder was dry pressed into test bars (35x8x2 mm) in a tungsten carbide lined die in a Carver laboratory press at 317.2 MPa (46 ksi). The average flex strength of the green test bars was 4.482 ± 758 kPa (650 ± 110 psi). The test bars were fired to 2100°C. under an argon atmosphere at a rate of 10°C./min with 30 minutes at 2100°C. The average density of the five fired test bars was 3.11 ± 0.02 g/cm³ (96.9% of theoretical). Example 4 Sintered Bodies with (PhSiO 1.5 ) 0.21 (MeSiO 1.5 ) 0.43 (PhViSiO) 0.36 . A -- Polymer Synthesis. A solution of 50.8 g (0.25 moles) PhViSiCl₂, 31.7 g (0.15 moles) PhSiCl₃ and 44.8 g (0.30 moles) MeSiCl₃ in 50 mL toluene was added dropwise to a stirred mixture of 180 g Na₂CO₃ in 400 mL water and 250 mL toluene. After the addition was complete, the reaction mixture was stirred at room temperature for 45 minutes. The two phases were separated and the organic layer collected and concentrated under vacuum. The residue (75.2 g) was dissolved in 150 g toluene and the solution refluxed over 0.103 g KOH by collecting the water using a Dean-Stark trap. After the water removal was complete, the toluene solution was cooled to room temperature and 1.0 mL Me₃SiCl was added. After one hour, the solution was filtered through an 0.2 µm membrane filter. The filtrate was concentrated under vacuum and the residue dissolved in 150 mL toluene. The toluene solution was poured into 1.5 liters isopropanol. The precipitated polymer was collected and dried at 200°C. and 133 Pa (1 torr). The yield was 41.9 g (54.8%). Proton NMR (CDCl₃, delta-values): -0.23 to 0.60 (SiMe, broad singlet), 5.6 to 6.4 (SiVi, broad singlet) and 6.9 to 8.0 (SiPh, broad singlet); the SiMe/SiVi/SiPh molar ratio was 2.7/1.0/1.1. GPC molecular weight (THF solvent): M w =4993 and M n =1215. B -- Char Composition Calculations. A sample of the above siloxane was weighed into a graphite crucible and transferred into an Astro tube furnace. The furnace was twice evacuated to less than 2.666 kPa (20 torr) and backfilled with argon. The sample was then fired to 1800°C. (room temperature to 1200°C. at 13°C./min, 1200 to 1800°C. at 5°C./min and 30 minutes at 1800°C.) under argon. The sample had a mass retention of 47.2% and contained 47.7% carbon. The following calculations were made: 100 g of cured polymer gives 47.2 g of a ceramic char consisting of 52.3% (by difference) silicon and 47.7% carbon. The char consists of 35.3 g SiC (74.8%) and 11.9 g carbon (25.3%). Therefore, each gram of polymer, after pyrolysis, gives 0.353 g SiC and 0.119 g free carbon. C -- Test Bar Fabrication. A siloxane/SiC mixture with a free carbon value of 1.5% was prepared using the calculations of Part B above and the following procedure: 3.138 g of the above siloxane polymer were mixed with 23.438 g Ibiden SiC powder and 0.075 g boron in an hardened alumina mortar and pestle until a thick paste was obtained. The paste was dried under vacuum to remove residual solvent. The dried powder was ground in a mortar and pestle and then passed through a 90 µm mesh sieve. The sieved powder was dry pressed into test bars (35x8x2 mm) in a tungsten carbide lined die with a Carver laboratory press at 317.2 MPa (46 ksi). The green test bars had an average flex strength of 7791 ± 483 kPa (1130 ± 70 psi). The test bars were fired to 2050°C. using the following temperature profile: room temperature to 300°C. at 11.2°C./min, 300 to 550°C. at 10°C./min, 550 to 700°C. at 6°C./min, 700 to 1350°C. at 32.4°C./min, 1350 to 2050°C. at 30°C./min and 2050°C. for 30 minutes. The average density of the fired test bars was 3.01 g/cm³ (93.8% of theoretical). The fired test bars had an average flex strength of 354.4 ± 36.5 MPa (36.9 ± 5.3 ksi). Example 5 Sintered Bodies with (PhsiO 1.5 ) 0.23 (MeSiO 1.5 ) 0.46 (PhViSiO) 0.31 . A -- Polymer Synthesis A solution of 40.6 g (0.20 moles) PhViSiCl₂, 31.7 g (0.15 moles) PhSiCl₃ and 44.8 g (0.30 moles) MeSiCl₃ in 50 mL toluene was added dropwise to a stirred mixture of 180 g Na₂C0₃ in 400 mL water and 250 mL toluene. After the addition was complete, the reaction mixture was stirred at room temperature for 45 minutes. The two phases were separated and the organic layer collected and concentrated under vacuum. The residue (75.4 g) was dissolved in 107.6 g toluene and the solution refluxed over 0.128 g KOH. The water was collected in a Dean-Stark trap. After all of the water was removed, the toluene solution was cooled to room temperature and 1.0 mL Me₃SiCl was added. After one hour, the solution was filtered through an 0.2 µm membrane filter. The filtrate was concentrated under vacuum. The residue was dissolved in 150 mL toluene and poured into 1.5 liters butanol. The precipitated polymer was collected and dried at 200°C. and 133 Pa (1 torr). The yield was 34.5 g (49.9%). Proton NMR (CDCl₃, delta-values): -0.33 to 0.50 (SiMe, broad singlet), 5.65 to 6.25 (SiVi, broad singlet) and 6.8 to 7.95 (SiPh, broad singlet); the SiMe/SiVi/SiPh molar ratio was 3.0/1.0/1.3. B -- Char Composition Calculations. A sample of the above polymer was fired to 1800°C. under an argon atmosphere using the following temperature profile: room temperature to 1200°C. at 13°C./min, 1200 to 1800°C. at 5°C./min and two hours at 1800°C. The sample had a mass retention of 42.6% and contained 46.8% carbon. The following calculations were made: 100 g of cured polymer gives 42.6 g of a ceramic char consisting of 53.2% (by difference) silicon and 46.8% carbon. The char consists of 32.4 g SiC (76.0%) and 10.2 g carbon (24.0%). Therefore, each gram of polymer, after pyrolysis, gives 0.324 g SiC and 0.102 g free carbon. C -- Test Bar Fabrication. A siloxane/SiC mixture with a free carbon value of 1.9% was prepared using the following procedure: 4.655 g of the above siloxane polymer was mixed with 22.750 g Ibiden SiC powder and 0.074 g boron in an hardened alumina mortar and pestle until a thick paste was obtained. The paste was dried under vacuum to remove residual solvent. The dried powder was ground in a mortar and pestle and then passed through a 90 µm mesh sieve. The sieved powder was dry pressed into test bars (35x8x2 mm) in a tungsten carbide lined die with a Carver laboratory press at 317.2 MPa (46 ksi). The green test bars had an average flex strength of 2687 ± 924 kPa (1840 ± 134 psi). The test bars were fired to 2050°C. in an argon atmosphere using the same temperature program as in Example 4 above. The average density of the fired test bars was 3.06 g/cm³ (95.3% of theoretical). The fired test bars had an average flex strength of 313.7 ± 46.9 MPa (45.5 ± 6.8 ksi).

Claims: A composition of matter comprising in intimate admixture an organic silicon polymer, a silicon carbide powder and a metal-containing sintering aid, selected from iron, Fe₃C, magnesium, MgC₃, lithium, Li₂C₂, beryllium, Be₂C, boron, boron-containing compounds, aluminum, aluminum-containing compounds and metal oxides selected from thorium oxide, yttrium oxide, lanthanum oxide and cerium oxide, characterised in that the metal-containing sintering aid is present in a proportion of from 0.1 to 3.0 weight percent of the metal based on the weight of silicon carbide powder, and in that the organic silicon polymer is an organopolysiloxane containing units of general structure [R₃SiO 0.5 ], [R₂SiO], [RSiO 1.5 ] and [SiO₂] where each R is independently selected from the group consisting of hydrogen, alkyl radicals containing 1 to 20 carbon atoms, phenyl radicals and vinyl radicals, said polyorganosiloxane is capable of being converted to a ceramic material with a yield above 20 weight percent of a ceramic char having at least 10 weight percent of free carbon derived from the organopolysiloxane by pyrolysis at elevated temperature to a stable ceramic char which does not significantly decrease in weight upon further exposure to heating at elevated temperature, the organopolysiloxane being present at a level such that said free carbon value is higher than 0.2 weight percent and not greater than 3 weight percent based on the total weight of the silicon carbide powder and the char derived from the preceramic organopolysiloxane. A composition of matter according to Claim 1, wherein the organopolysiloxane contains varying amounts of [PhSiO 1.5 ], [MeSiO 1.5 ] and [PhViSiO] units. A composition of matter according to Claim 2, wherein the organopolysiloxane is described by the unit formula [PhSiO 1.5 ][MeSiO 1.5 ][PhViSiO] where there are 10 to 90 mole percent [PhSiO 1.5 ] units, 0 to 50 mole percent [MeSiO 1.5 ] units and 10 to 90 mole percent [PhViSiO] units. A method of forming a handleable green body, which method comprises: (a) preparing a composition of matter as defined in Claim 1; and (b) forming said composition of matter into the desired shape under pressure at a temperature below 500°C. A method of preparing a sintered body of silicon carbide, said method comprising: (a) forming a handleable green body according to the method of Claim 4; and (b) sintering the handleable green body in an inert atmosphere at a temperature above 1900°C to obtain a sintered body of silicon carbide with a density above 2.4 g/cm³.

Inventors: ATWELL WILLIAM HENRY, BURNS GARY THOMAS, SAHA CHANDAN KUMAR, ATWELL, WILLIAM HENRY, BURNS, GARY THOMAS, SAHA, CHANDAN KUMAR
Applicants: DOW CORNING, DOW CORNING CORPORATION
Application year: 1989
Main classification: C04B35
IPC codes: C08K3, C08L83, C04B35