Production of ultrastructural ceramics

Abstract: A process for the production of high-performance ceramics and ceramic precursors is disclosed which comprises reacting an organometallic precursor with a reactant in a supercritical fluid and exposing the organometallic prod­ uct to a ceramic material. A critical temperature (or pressure) is required to produce the supercritical fluid which is the maximum temperature (or pressure) at which a gas or vapor may be liquified by the application of a critical pressure (or temperature). Nitrogen-containing ceramics such as nitrides, oxynitrides and carbonnitrides, and carbide ceramics are produced by reacting precursors such as alkyl halosilanes and dialkyl silanes in the presence of a supercritical fluid such as nitrogen, hydrogen, ammonia and mixtures thereof for the nitrogen-containing ceramics and in the presence of hydrocarbons, hydrogen or mixtures thereof for the carbide ceramics. The high performance ceramics produced find particular application in the automobile industry.

Description: This invention relates to the production of ultra-structural ceramics. "Ultra-structural" ceramics refers to nitrides, oxynitrides, carbides, oxycarbides, borides and combinations thereof. Nitride ceramics are predominantly composed of nitrogen and at least one element of Si, Sc, rare earths, Nb, Ta, V, Al and Ce. Oxynitride ceramics are predominantly composed of oxygen, nitrogen and at least one of Y, Al, Si, Li, Sr, Mg, Be, La, Ce and the rare earths. Carbide ceramics are predominantly composed of carbon or carbon and at least one element from Si, Ti, W, B Zr, Hf, Cr, Nb and Ta. Oxycarbide ceramics are predominantly composed of oxygen, carbon and at least one of Si, Al, B, Ti, Zr, Hf, Sc, Y, Nb and Ta. Boride ceramics are predominantly composed of boron and at least one of Al, Si, Ti, Zr, Hf, V, Ta, Nb and W. High performance ceramics are finding their way more and more into automobile applications. Advanced ceramics have high compressive strength and hardness combined with useful strength. On the other hand, however, ceramics are brittle. Ceramics fail catastrophically, are flaw-sensitive, and are difficult to prepare reproducibly. All these characteristics must be taken into consideration for any potential application. Automotive applications often require tribological surfaces with minimal lubrication or high temperature performance. Specific strength and modulus are particularly useful for unsprung mass components. Low heat rejection engines have the potential for increased efficiency. Increased efficiency requires higher operating temperatures, which, in turn, requires materials that can tolerate such temperatures, namely, ceramics. In a ceramic gas turbine engine, the ceramic parts are the combustor, nose cone, stators, rotors, rotor shrouds, and regenerators. Hot gas from the combustor is directed by the nose cone and stators against the blades of the rotors. The exhaust passes through the regenerators, which recover much of the residual heat, passing it on to the inlet air directed to the combustor. Of these ceramic components, the most demanding is the turbine rotor, which is subject to high mechanical stress, high temperature, thermal shock, and an oxidizing atmosphere. Silicon nitride (Si₃N₄) and silicon carbide (SiC) are useful for many applications. These materials form essentially covalent, three-dimensional structures and are extremely refractory. Because of their refractory nature, they are generally formed into solid bodies from powder by sintering, with or without external pressure. However, because of the high strength of their chemical bonds, atomic diffusion coefficients are extremely low below their respective decomposition temperatures ( ∼ 1900°C for Si₃N₄ and ∼ 3000°C for SiC), and the pure materials do not sinter well even under pressure (hot pressing). To achieve dense Si₃N₄ or SiC bodies, additives called sintering aids must be mixed with the powders before firing. Alternatively, a somewhat indirect sintering process called reaction bonding can be used. Hot pressing, incidentally, is unsatisfactory for preparing ceramic bodies of complex shape. Simple shapes can be machined into complex ones, but the cost is prohibitive. Si₃N₄ exists in two hexagonal crystalline forms that have similar atomic arrangements; the β form, however, is slightly more symmetric than the α. The relationship between the two forms is not entirely clear, because the α readily transforms into the β form on heating, but the reverse transformation has not been reported. Because silicon oxide (SiO₂) is more stable than Si₃N₄, the nitride owes its oxidation resistance to a passive oxide surface layer. A number of reactions can be used to prepare Si₃N₄, among them the direct nitriding of silicon the reaction of silicon tetrachloride with ammonia and the reaction of silica, carbon, and nitrogen Other methods for the production of silicon nitride are illustrated in United States patents Nos. 4,073,845; 4,177,230; 4,264,565; 4,397,828; 4,399,115 and 4,405,589. A method for making Si₃N₄ which is finding more industrial use is the use of organometallic halides to make polymeric silicon nitride precursors. However, one problem with silicon nitride made from organometallic precursors is its excessive residual halide content. Organometallic halides are nitrogen-deficient and prone to excessive carbon content. Cross-linking and oligomer formation are associated with high carbon content and insoluble polymers. Organometallic halides often have volatile products and reduced yields. Control over product quality has been limited. The following United States patents illustrate how to make polymeric precursors for silicon nitride: United States patents Nos. 3,809,713; 4,097,294; 4,395,460 and 4,612,383. United States patent No. 4,676,966 illustrates the making of silicon carbide from organosilicon compounds. The article appearing in the British Polymer Journal , Vol. 18, pp. 355-358 (1986) discloses polymeric routes to silicon carbide. The most commonly-used sintering aids for Si₃N₄ are magnesium oxide (MgO) and yttrium oxide (Y₂O₃). These additives apparently act by forming relatively low melting silicates with the passive silica layer on each nitride particle, and with any impurity oxides present. At sintering, or at hot pressing temperatures ( ∼ 1700°C), this silicate is liquid and promotes liquid-phase sintering. On cooling, it forms a glassy intergranular layer that binds the Si₃N₄ grains together. This makes an extremely strong material at room temperature, with flexural strengths of over 6.895 x 10⁸Pa. Unfortunately, at temperatures above about 1000°C, the glassy intergranular layer softens, leading to a substantial loss of strength and resistance to creep. In this respect, Y₂O₃ appears to be a better sintering aid than MgO, because strength is retained to a higher temperature. However, a different problem has been encountered with some Y₂O₃-sintered and hot-pressed silicon nitrides, namely, intermediate temperature oxidation. At around 1000°C, although not at higher or lower temperatures, some of these materials appear to be quite prone to oxidation. Recent evidence suggests that this susceptibility to intermediate temperature oxidation is characteristic of certain intergranular phase compositions and that the problem might be minimized by suitable composition control. The technique of preparing reaction-bonded Si₃N₄ bodies involves forming the desired shape from silicon powder and then nitriding it. By choosing the proper density for the silicon powder body, it is possible, in principle, to obtain a fully dense Si₃N₄ body with the same size and shape as the original silicon powder body, the Si₃N₄ formed just filling the pores. However, in practice the interiors of bodies with densities greater than about a theoretical value of 85% cannot be fully nitrided because a dense Si₃N₄ outer layer seals off the interior from access to nitrogen. Because the optimum nitriding temperature ( ∼ 1400°C) is close to the melting point of silicon, and because the nitriding reaction is exothermic, great care is exercised to avoid the formation of molten blobs of silicon in the interior that, because they are larger than the solid silicon particles, do not nitride completely and become sources of mechanical weakness in the product when they solidify. A relatively elaborate nitriding cycle, taking about a week, is employed. The nitriding rate is increased if a little iron is mixed with the silicon powder compact. The iron appears to break up or modify the passive oxide layer on the Si particles so that nitriding can proceed more easily. Because reaction-bonded Si₃N₄ (RBSN) is not fully dense and is about 15% pores, it is not as strong or oxidation resistant as hot-pressed material. On the other hand, because it lacks sintering aids, it retains its strength well at elevated temperature. A recently developed variant of RBSN is sintered RBSN. This material is prepared by first making RBSN with sintering aid (e.g. Y₂O₃) included, and then firing it to bring about further sintering. Densities near to a theoretical value are achieved, with mechanical properties comparable to those of hot-pressed silicon nitride. The advantages of this technique are the ability to form complex shapes and the reduced shrinkage during firing (because one starts with RBSN), which, in turn, yields greater consistency in final size and shape. SiC, the other high-performance ceramic seriously considered for highly-stressed gas turbine applications, exists in cubic (β) and hexagonal (α) close-packed versions. The β form is unique but the α form has many variants, called polytypes, which involve long period changes in the layer-stacking sequence. Most SiC powder is still made by the Acheson process, essentially the reaction of SiO₂ with carbon, with post-treatment to make it suitable for sintering, although other syntheses are also used. As is the case with Si₃N₄, SiC bodies can be prepared by sintering, hot pressing, and a form of reaction bonding. It is just as difficult to sinter or hot press pure SiC as it is to sinter or hot press pure Si₃N₄. Again, sintering aids are used, but in the case of SiC different aids and higher temperatures are required. For hot pressing, the usual additive is aluminum oxide (Al₂O₃), which may form a liquid with the passive oxide layer and provide a medium for liquid-phase sintering. As with hot-pressed Si₃N₄, there is evidence of a decrease in strength at high temperature, suggesting the presence of a glassy grain boundary phase. Sintering of SiC is usually carried out at 2000°C or above, using carbon and boron as sintering aids. It is believed that the carbon removes the passive silica layer, whereas the boron enters the SiC grains, modifying their surface energy to enhance sintering. Liquid-phase sintering does not appear to be involved, and strength is retained to very high temperature. Reaction-bonded SiC bodies are made by forming the desired shape from SiC powder, an organic binder, and, in some cases, carbon powder. This body is carbonized to convert the organic binder to carbon and then silicided in liquid silicon to convert the carbon to SiC. The resulting bodies can be quite strong but always contain residual silicon which causes them to weaken at about 1300°C. The increase in strength with temperature up to about 1200°C is believed to result from the plastic flow of silicon serving to heal the cracks. As mentioned above, polymeric precursors to ceramics have been widely investigated. Polymeric precursors are conducive to part shape flexibility, control of chemistry on a molecular level, and high purity starting materials. Polymers can be used with ceramic powders as binders to improve density, provide green strength, and/or supply sintering aids uniformly. The density of reaction bonded silicon nitride (RBSN), usually about 70%, can be increased by infiltrating polymeric silicon nitride precursors. Fibers such as Nicalon or Nextel are made from polymeric precursors. Polymer ceramic precursors, also referred to as sol-gels, can be used to make monoliths. Silicon nitride made from low-cost precursors have enjoyed limited success in the past due to residual constituents. The usefulness of more complex precursors to silicon nitride is limited by extremely high cost. A general object of the present invention is to make ceramic materials and ceramic precursors by utilizing reaction conditions which utilize supercritical temperatures and pressures and specifically to produce nitrogen-based ceramics such as nitrides, oxynitrides and carbonitrides, as well as carbide ceramics from organometallic precursors under conditions of supercritical temperatures and supercritical pressures. Another specific object of the present invention is a method for producing ceramic materials such as silicon nitride from organometallic precursors such as alkyl halosilanes and dialkylsilanes under conditions of supercritical temperature and supercritical pressure. Another object of the present invention is to overcome the disadvantages of organometallic halide precursor polymers by using supercritical fluid extraction technology. According to the present invention we provide a process of making a polymeric precursor of a ceramic, by reacting a supercritical fluid. A first embodiment of the process comprises reacting a compound containing silicon or aluminum with a supercritical fluid which contains, for the production of a nitrogenous ceramic, a nitrogen atom in its molecule and maintaining the reactants under conditions to form the precursor and removing the by-products formed. A second embodiment comprises reacting a silicon-containing reagent selected from silicon tetrachloride, trichlorosilanes, alkyltrichlorosilanes, trialkylsilanes, trialkylchlorosilanes, dialkyldichlorosilanes and dialkylsilanes with a nitrogen-containing supercritical fluid and maintaining the reactants under conditions to form the precursor and removing the by-products formed. A third embodiment, for making a precursor of a carbide ceramic, comprises reacting a compound selected from an organometallic compound containing silicon, a silicon salt, a silane and mixtures thereof with a hydrocarbon supercritical fluid; and maintaining the reactants under conditions to form the precursor and removing the by-products formed. A Supercritical fluid is required for the process and can be created either (1) by raising the temperature of a confined liquid to the supercritical temperature, or (2) by increasing the pressure of a confined liquid to the supercritical pressure, or (3) by raising both temperature and pressure simultaneously. It is useful to first define what is meant by critical temperature and critical pressure. The critical temperature is the maximum temperature at which a gas or vapor can be liquified by application of the critical pressure. The critical pressure is the pressure of a vapor at its critical point as is defined by where ∂ = partial derivative ∂² = second partial derivative P = pressure V = volume T = temperature. The critical point is the point where two phases, which are continually approximating each other, become identical and form but one phase. With a liquid in equilibrium with its vapor, the critical point is such a combination of temperature and pressure that the specific volumes of the liquid and its vapor are identical, and there is no distinction between the two states. The historic disadvantages of organometallic halide precursor polymers can be overcome by Supercritical Fluid Extraction (SFE) technology. The technology of supercritical fluids is fully described in Kirk Othmer, Encyclopedia of Chemical Technology , pp. 872-893. SFE has the advantages of distillation, liquid extraction, and pressure-assured densification. Slight changes in temperature and pressure in the critical region cause extremely large changes in solvent density and dissolving power. SFE has wide flexibility for extractive separation by varying pressure, temperature, choice of solvent, and entrainers (additives). Otherwise insoluble polymers dissolve in supercritical fluids at 2 to 7 orders of magnitude in excess of amounts predicted by the ideal gas law. SFE is capable of both high solubility-based extraction due to supercritical fluid density of the solvent near liquid density and nearly-complete solvent-extract separation due to supercritical fluid density of the solvent near gaseous density. In addition to density, the viscosity and diffusivity for supercritical fluids are intermediate between those of a liquid and a gas. (See Table 1). A supercritical fluid has a density near that of a liquid for high solubility, however, its diffusivity is orders of magnitude greater for improved mass transfer rates. Supercritical solvents are more capable of penetrating the micropores of a solid. Physical Properties of a Typical Gas, Supercritical Fluid, and Liquid PROPERTY GAS SUPERCRITICAL FLUID LIQUID density, g/cm³ 10⁻³ 0.3 1 viscosity, mPa·s (=cP) 10⁻² 0.1 1 diffusion coefficient, cm²/s 0.1 10⁻³ 5 x 10⁻⁶ SFE is carried out at temperatures up to 500°C and pressures up to 8000 psi in an autoclave. Confinement in an autoclave increases yields of product from otherwise too volatile reactants. High pressure is conducive to polymerization and densification. In the critical region at pressures (P/P c ) of 1.2, the fluid is highly compressible. Cubic equations of state and random mixing rules predict solubility less than actual solubility. Attractive forces lead to large negative values for the partial molar volume of the solute. The mixture becomes highly oriented. The present process can use supercritical ammonia as both a solvent and a reactant with and without the conjoint presence of hydrogen at supercritical partial pressure. Liquid ammonia is a powerful solvent, recognized by Cheronis in 1947 (U.S.-A-2,564,674) for its value as a source of nitrogen for reaction with organic silicon tri-halides and other organometallic halides containing silicon. Supercritical ammonia is vastly more useful because it can simultaneously dissolve an increasingly intractable polymer, supply nitrogen, and extract reaction products. Supercritical hydrogen reacts with some of the methyltrichlorosilane or dimethydichlorosilane to polymerize the reactants and act as an entrainer to further facilitate extraction. Controlling the amount of hydrogen in the reaction controls the amount of cross-linking and oligomer formation. The presence of hydrogen minimizes residual carbon content in the ceramic product. Any hydrogen content is approximately 10⁻⁵ molar in the silane reactants. Hydrogen can be added to the autoclave, or metals such as Mg can be added to strip hydrogen from the ammonia. Magnesium reacts to form an amide if a small amount of ammonium chloride is present to act as a catalyst: Other metals such as Al, Be, Y, Ce, Ca, Ti, Zr, Hf, Li, Fe, Cr, Co and Ni can fulfill much the same role as Mg. These metals have the added benefit of forming an oxynitride second phase with oxygen contaminants. The amount of a reactant is suitably 5% by weight in liquid ammonia. Concentration is limited by the solubility of reactants and the products of the reaction. Large amounts of NH₄Cl·HCl are produced during polymerization. Efficient removal of NH₄Cl·HCl and methylamine by-products is critical to the quality of the ceramic product. Ammonium chloride is soluble in an amount of up to 96.33mg/cc in liquid ammonia and in even higher (though as yet undetermined) concentrations in supercritical ammonia. A supercritical ammonia solution with NH₄Cl·HCl can be withdrawn from a pressure vessel and decompressed to precipitate NH₄Cl·HCl. Ammonia can then be compressed and recycled. The production of crack-free monoliths require careful attention to pressurization and heating rates. The system should be "soaked" at points of extraction to assure complete extraction. Heat and pressure distribution within the pressure vessel must be evenly distributed at all times. The autoclave is purged with argon gas before loading with reactants. Hydrogen gas is slowly added to the autoclave. Ammonia pressure should not be increased faster than 8.895 x 10⁶Pa (1000 psi) per hour but preferably 1.379 x 10⁶Pa (200 psi) to 2.068 x 10⁶Pa (300 psi) per hour. Pressure is increased to the supercritical region of the solvent NH₃, approximately 1.140 x 10⁷Pa (1,653.8 psi) to 1.482 x 10⁷Pa (2,149.9 psi). More or less pressure may be required depending on the use of second phase additives, solute-solute reactions, or organometallic reactants. The temperature is slowly increased at a rate not exceeding 50°C per hour, but preferably about 30°C per hour up to as high a temperature as 500°C, though typically only 300°C to 400°C. After extracting organic and halide compounds from the polymerized reactants, the autoclave is slowly decompressed (not exceeding 3.447 x 10⁶Pa/hr (500 psi/hr) and cooled (not faster than 100°C per hour) and the remaining "green-form" ceramic removed. Green-form silicon nitride is slowly pyrolyzed at 1000°C for 30 minutes at rates as slow as 30°C per hour through the 300°-700°C region. Over 1000°C, the furnace is pressurized from 2.585x10⁶Pa (375 psi) to 5.17x10⁶Pa (750 psi) to prevent oxynitride bubbling as the temperature is increased to further assure transformation to the beta phase when cooling. Depending on second phase content, final sintering is at temperatures of 1370°C to 1750°C. A paramagnetic phase containing metals such as Fe or other paramagnetic metals in the periodic table of the elements can be added to the silicon nitride. The use of a paramagnetic phase allows for orientation during supercritical fluid extraction, pyrolysis and/or sintering. The silane reagents for making silicon-containing ceramics are selected from silicon tetrachloride, alkyltrichlorosilanes, trialkylchlorosilanes, dialkyldichlorosilanes and dialkylsilanes wherein the alkyl group can be primary, secondary or tertiary branch -ed and may contain one to ten carbon atoms. The silanes generally belong to the following formulae: R' n SiCl₄-n and R' n SiH₂ wherein R' is an aliphatic group containing 1 to 10 carbon atoms or an amyl group containing alkyl substitution and n is 1,2 or 3 in the case of the halosilanes and n is 2 in the case of the silane. Typical examples of the above compounds are: dimethyldichlorosilane, diethyldichlorosilane, dimethylsilane, diethylsilane, dipropyldichlorosilane, dipropyl silane, trichloromethyl silane, trichloroethyl silane, trichloropropyl silane, dichlorodibutyl silane, chlorotriethyl silane and chlorotripropyl silane; chloroalkenyl silanes such as trichlorovinyl silane, dichlorodivinyl silane, trichloroallyl silane and chlorotriallyl silane; chloroaryl silanes such as trichlorophenyl silane, dichlorophenyl silane, chlorotriphenyl silane, trichlorotolyl silane and dichloroditolyl silane; and chloroalkaryl silanes such as trichlorobenzyl silane and dichlorodibenzyl silane. The nitrogen-containing reactant in the present invention is typically ammonia but other nitrogen-containing materials such as hydrazine or primary or secondary amines can be used. For making carbide ceramics, a hydrocarbon such as methane, ethane, propane, butane or a hydrocarbon containing up to 20 carbon atoms can be used. The temperature range for making the carbide ceramics is between about room temperature (20 to 25°C) and 285°C. The pressures are typically between 1.275 x 10⁶Pa (185 psi) to as high as 5.516x10⁷Pa(8000 psi). Preferably the pressure of methane is 4.620 x 10⁶Pa to 6.033 x 10⁶Pa, of ethane is 4.882 x 10⁶Pa to 6.387 x 10⁶Pa, of propane is 4.240 x 10⁶Pa to 5.55 x 10⁶Pa, of butane is 3.792 x 10⁶Pa to 4.964 x 10⁶Pa, of pentane is 3.378 x 10⁶Pa to 4.413 x 10⁶Pa, of hexane is 3.033 x 10⁶Pa to 3.965 x 10⁶Pa, and of hydrogen is 1.275 x 10⁶Pa to 1.689 x 10⁶Pa. The process of the present invention may further incorporate an additive selected from metal halides including YCl₃, AlCl₃, MgCl₂ and BeCl₂. Halides of the following metals are also useful: Ce, Ca, Fe, Ti, Zr, Hf, Co, and Ni. Mixtures of the above halides may be added to the reaction mixture in the formation of nitride, oxynitride, carbide, oxycarbide and boride ceramics. In the formation of nitrogen-based ceramics, the metal halides are added so as to form an oxynitride phase. Metal analogs of the halides can also be used. The halides are useful as sintering aids. Metal hydrides of metals such as Y, Mg, Be, Ca, Ti, Zr, and Hf, and oxides and hydroxides of Y, Mg, Be, Ce, Ca, Fe, Ti, Zr, Hf, Co and Ni can also be added to form the oxynitride second phase. Oxygen-containing organometallic additives can also be incorporated to form the oxynitride second phase. In the process for making the carbide polymeric precursors and ceramics, metal hydrides made from metals such as B, Ti, Be and Mg are also useful. Certain catalysts are also used to activate Si-H, Si-N, Si-Si and Si-C bonds in the process for making the carbide precursors and ceramics. The catalyst can be homogeneous, heterogeneous or a metal complex or cluster. Examples of the above catalysts include H₄Ru₄(CO)₁₂, Ru₃(CO)₁₂, Fe₃(CO)₁₂, Rh₆(CO)₁₂, Co₂(CO)₈(Ph₃P)₂Rh(CO)H (where Ph is phenyl), H₂PtCl₆, nickel cyclooctadiene complex, Os₃(CO)₁₂, Ir₄(CO)₁₂, (Ph₃P)₂Ir(CO)H, (where Ph is phenyl), Pd(OAc)₂, TiCl₂, (Ph₃P)₃RhCl, H₂O s3 (CO)₁₀, Pd(Ph₃P)₄, Fe₃(CO)₁₂/ Ru₃(CO)₁₂ and mixtures thereof. Other catalyst compositions include: Pt/C, Pt/BaSO₄, Cr, Pd/C, Co/C, Pt black, Co black, Pd black, Ir/Al₂O₃, Pt/SiO₂, Ph/TiO₂, Rh/La₂O₃, Pd/Ag alloy, LaNi₅, PtO₂. Polymeric precursors which can be used to make silicon carbide are those described in the British Polymer Journal , Vol. 18, pages 355-358 (1986). The polymeric precursors for making silicon nitride and their methods of preparation are exemplified in United States patents Nos. 2,564,764, 3,809,713, 4,097,294, 4,395,460 and 4,612,383. All of the above polymers can be made using supercritical temperatures and pressures and can also be purified by supercritical fluid extraction. Organometallic halide compounds and/or organometallic hydride compounds can be reacted under an inert, a nitrogen, or an ammonia atmosphere to polymerize and/or cure to "green form" ceramics. Pyrolysis over 750°C yields a ceramic. The present process uses Supercritical Fluid Extraction (SFE) to eliminate the need for complex and expensive organometallic precursors. Examples The following Examples illustrate in more detail the present invention. Example 1 A reaction fluid was first prepared by mixing 179.5 cc dimethyldichlorosilane (C₂H₆Cl₂Si) with 27.19 gm Fe₂O₃, 13.91 gm anhydrous YCl₃, and 3.92 gm anhydrous AlCl₃ in a pressure vessel at 3.489 x 10⁶Pa (506 psi) to 4.537 x 10⁶Pa (658 psi) to form a supercritical fluid under inert atmosphere. The supercritical fluid is infiltrated into a compress of silicon nitride powder weighing 221.9 gm. Anhydrous ammonia is added to the pressure vessel at a rate of 1.379 x 10⁶ Pa/hr (200 psi/hr) until the pressure reaches the supercritical region for ammonia, 1.140 x 10⁷Pa (1.654 psi) to 1.482 x 10⁷Pa (2150 psi). The vessel is heated at 20°C/hr to 30°C/hr rate to 400°C and "soaked" for 1 hour to completely react the silane to the silicon nitride and extract the by-products. The supercritical ammonia solution containing by-products is bled away from the silicon nitride at 1.379 x 10⁶Pa/hr (200 psi/hr) rate into a tank. By-products precipitate from the ammonia as the ammonia decompresses. Ammonium chloride hydrogen chloride and amine by-products can be distilled and resold. Ammonia gas can be liquified for re-use or used for fertilizer. The "green-form" silicon nitride is slowly heated under 3.447 x 10⁶Pa (500 psi) nitrogen to 800°C at a rate of 20°C to 30°C/hr to completely cure the material, and it is then further heated to 1650°C to crystallise it. Example 2 Example 1 was repeated but the ammonia added contained up to 10⁻⁵ molar hydrogen. Example 3 Example 1 was repeated, except that reaction-bonded silicon nitride is used instead of pressed silicon nitride powder. Example 4 AlON was made by reacting 5% AlOCl in anhydrous ammonia with 10⁻⁵M hydrogen. 100 gm of the resultant AlOCl is mixed with 8.21 gm YCl₃, 7.17 gm SiCl₄ and 50 ppm FeCl₃ and placed in a pressure vessel. Anhydrous ammonia is added to the vessel at 3.447 x 10⁶Pa/hr (500 psi/hr) until 5.516 x 10⁷Pa (8000 psi) is reached. The mixture is heated at 20°C/hr to 30°C/hr rate to 400°C and soaked for one hour until halides are extracted as NH₄Cl. Ammonia with NH₄Cl in solution is diverted at a rate of 1.379 x 10⁶Pa/hr (200 psi/hr) into a closed vessel to precipitate the ammonium chloride and recover the ammonia. The green-form AlON is heated at 20°C/hr to 30°C/hr rate to 1400°C under 3.447 x 10⁶Pa (500 psi) N₂ to fully cure the ceramic. Example 5 Silicon nitride fibers were made by mixing 100 cc of dimethyldichlorosilane, C₂H₆Cl₂Si, 3.295 gm Fe₂O₃, 1.69 gm YCl₃, and 0.475 gm AlCl₃ with anhydrous ammonia in a pressure vessel. Materials are polymerized as the temperature is raised at 20°C/hr to 30°C/hr to 400°C and the ammonia pressure is increased to the supercritical region 1.161 x 10⁷Pa (1684 psi) to 1.482 x 10⁷Pa (2150 psi) at a rate of 1.379 x 10⁶Pa/hr (200 psi/hr). The pressure vessel is tapped to educt viscous polymer through spinnerets into a vessel maintained at a slightly reduced pressure. The fiber is drawn under light tension through an electromagnet and a furnace to align iron compound crystals as well as silicon nitride crystals in the fiber as it is cured to a ceramic filament at 800°C. Example 6 Silicon carbide is made from dimethyldichlorosilane (C₂H₆Cl₂Si) in a supercritical methane atmosphere. Dimethyldichlorosilane is placed in a pressure vessel with 10⁻⁵M hydrogen with 0.5 wt. % B in the form of BH₃.NH₂C(CH₃)₃. The mixture is pressurized with methane at 3,447 x 10⁵ Pa/hr (50 psi/hr) rate to 3.489 x 10⁶ Pa (506 psi) to 4.537 x 10⁶Pa (658 psi) and "soaked" for 1 hour or more depending on the size of the sample. Pressure is raised to 6.668 x 10⁶ Pa (970 psi) to 8.688 x 10⁶ Pa (1260 psi) at 3.447 x 10⁵ Pa/hr (50 psi/hr) rate. The temperature of the system is increased to 350°C at 20°C/hr to 30°C/hr rate and held at temperature for 1 hour. Because supercritical Fluid Extraction results in near theoretical yields, stoichiometric carbon can be controlled by the mole ratio of reactants in the autoclave. Green form silicon carbide is heated under 3.447 x 10⁶ Pa (500 psi) argon to 1000°C at 20°C/hr to 30°C/hr rate. Beyond 1000°C the temperature can be rapidly raised to 2050°C. Example 7 A reaction fluid was first prepared by mixing 220.6 cc diethyldichlorosilane (C₄H₁₀Cl₂Si) with 27.19 gm Fe₂O₃, 13.91 gm anhydrous YCl₃, and 3.92 gm anhydrous AlCl₃ in a pressure vessel at 3.489 x 10⁶ to 4.537 x 10⁶Pa (506 psi to 658 psi) to form a supercritical fluid under inert atmosphere. The supercritical fluid is infiltrated into a silicon nitride powder compress weighing 221.9 gm. Anhydrous ammonia is added to the pressure vessel at a 200 psi/hr rate until the pressure reaches the supercritical region for ammonia, 1.140 x 10⁷ to 1.482 x 10⁷ Pa (1654 psi to 2150 psi). The vessel is heated at a 20°C/hr to 30°C/hr rate to 400°C and "soaked" for one hour to completely react the silane to silicon nitride and extract the by-products. The supercritical ammonia solution containing by-products is bled away from the silicon nitride 1.379 x 10⁶ Pa/hr (200 psi/hr) rate into a tank. By-products precipitate from the ammonia as the ammonia decompresses. Ammonium chloride, HCl and amine by-products can be distilled and resold. Ammonia gas can be liquified for re-use or used for fertilizer. The "green form" silicon nitride is slowly heated under 3.447 x 10⁶ Pa (500 psi) nitrogen to 800°C at a rate of 20°C/hr to 30°C/hr to completely cure the material. Silicon nitride is then heated to 1650°C. Example 8 Example 7 was repeated, and additionally up to 10⁻⁵ molar H₂ was added to the reactants. Example 9 Example 7 was repeated except that reaction-bonded silicon nitride was used instead of pressed silicon nitride powder. Example 10 Example 4 was repeated except that the pressure of the anhydrous ammonia added to the vessel was 2.758 x 10⁶Pa/hr (400 psi/hr) until a pressure of 5.516 x 10⁷Pa (8000 psi) was reached; AlON was again obtained and heated to cure it. Example 11 Example 5 was repeated but using as the silane 122.9 cc of diethyldichlorosilane; fibers were formed in the same manner. Example 12 Example 6 was repeated but using as the silane diethyldichlorosilane (C₄H₁₀Cl₂Si). Silicon carbide was again obtained.

Claims: A process of making a polymeric precursor of a ceramic, which comprises reacting a compound containing silicon or aluminum with a supercritical fluid which contains, for the production of a nitrogenous ceramic, a nitrogen atom in its molecule and maintaining the reactants under conditions to form the precursor and removing the by-products formed. A process of making a polymeric precursor of a ceramic, which comprises reacting a silicon-containing reagent selected from silicon tetrachloride, trichlorosilanes, alkyltrichlorosilanes, trialkylsilanes, trialkylchlorosilanes, dialkyldichlorosilanes and dialkylsilanes with a nitrogen-containing supercritical fluid and maintaining the reactants under conditions to form the precursor and removing the by-products formed. A process of making a polymeric precursor of a carbide ceramic, which comprises reacting a compound selected from an organometallic compound containing silicon, a silicon salt, a silane and mixtures thereof with a hydrocarbon supercritical fluid; and maintaining the reactants under conditions to form the precursor and removing the by-products formed. A process as claimed in Claim 1, 2 or 3, wherein the supercritical fluid comprises methane, ethane, propane, butane, C₅-C₂₅ hydrocarbons, hydrogen or mixtures thereof. A process as claimed in Claim 3 or 4, wherein said compound consists of an organometallic compound and a salt and/or a hydride. A process as claimed in Claim 2, wherein said reagent is of the formula R n SiCl 4-n or R n SiH 4-n' wherein R is an aliphatic group containing 1 to 10 carbon atoms or an amyl group containing alkyl substitution, and n is 1, 2 or 3 in the case of the halosilanes and n is 2 in the case of the silane. A process as claimed in any of Claims 1 to 3 or 6, comprising: 1) exposing a compacted ceramic powder selected from a nitride, an oxynitride and a carbonitride to a supercritical fluid comprising an organometallic compound, a metal halide and mixtures thereof; 2) adding a nitrogenous compound which has been pressurized and heated until it reaches the supercritical region; 3) isolating the green-form ceramic produced; and 4) sintering the green-form ceramic. A process as claimed in any of Claims 1 to 3, 6 or 7, comprising reacting a compound selected from an alkylhalosilane, an aluminium oxychloride, a boehmite, and a dialkylsilane with a nitrogen derivative selected from ammonia and an organic amine under conditions of supercritical pressure and supercritical temperature. A process for the production of a polymeric nitride precursor, comprising conducting the reaction of any of Claims 1 to 4 under conditions of supercritical pressure and supercritical temperature. A process as claimed in Claim 2, wherein the silane reagent is an alkylhalosilane and the nitrogen-containing material is ammonia. A process as claimed in Claim 9, for the production of a ceramic polymer precursor useful for making a nitride, an oxynitride and/or a carbonitride, comprising reacting an organometallic halide selected from R n SiCl 4-n , R n SiH₂, AlOCl and boehmite wherein R is an aliphatic saturated or unsaturated residue containing one to 20 carbon atoms in the presence of a reactant selected from nitrogen, ammonia, hydrazine, primary and secondary amines, hydrogen and mixtures thereof and where n is 1, 2 or 3, said process being conducted under conditions of supercritical pressure and supercritical temperature. A process as claimed in Claim 11, wherein the pressure of nitrogen is 3.378 x 10⁶Pa to 4.482 x 10⁶Pa. A process as claimed in Claim 10 or 11, wherein the pressure of hydrogen is 1.296 x 10⁶Pa to 1.689 x 10⁶Pa. A process as claimed in Claim 11, 12 or 13, wherein the pressure of ammonia is 1.140 x 10⁷Pa to 1.482 x 10⁷Pa. A process as claimed in any of Claims 11 to 14, wherein the temperature is room temperature to 160°C and may be increased at a rate of 5°C/hr to 50°C/hr or reduced at a rate of 20°C/hr to 100°C/hr. A process as claimed in Claim 11, wherein the pressure is increased at a rate of 50 pa/hr to 1000 pa/hr or decreased from peak pressure at a rate of 50 pa to 300 pa per hour. A process as claimed in any of Claims 11 to 16, wherein a metal halide is added to form an oxynitride second phase and preferably the metal in the metal halide is selected from Y, Al, Mg, Be, Ce, Ca, Fe, Ti, Zr, Hf, Co., and/or Ni. A process as claimed in any of Claims 11 to 16, wherein a metal hydride is added to form an oxynitride second phase and preferably the metal in the metal hydride is selected from Y, Mg, Be, Ca, Ti, Zr and Hf. A process as claimed in any of Claims 11 to 16, wherein a metal oxide, hydroxide or oxygen-containing organometallic compound is added to form an oxynitride second phase and preferably the metal in the metal oxide, hydroxide or oxygen-containing organometallic compound is selected from Y, Mg, Be, Ce, Ca, Fe, Ti, Zr, Hf, Co and Ni. A process as claimed in Claim 4 as dependent on Claim 3, wherein the pressure of methane is 4.620 x 10⁶Pa to 6.033 x 10⁶Pa, of ethane is 4.882 x 10⁶Pa to 6.387 x 10⁶Pa, of propane is 4.240 x 10⁶Pa to 5.55 x 10⁶Pa, of butane is 3.792 x 10⁶Pa to 4.964 x 10⁶Pa, of pentane is 3.378 x 10⁶Pa to 4.413 x 10⁶Pa, of hexane is 3.033 x 10⁶Pa to 3.965 x 10⁶Pa, and of hydrogen is 1.275 x 10⁶Pa to 1.689 x 10⁶Pa. A process as claimed in Claim 20, wherein the temperature is room temperature to 285°C. A process as claimed in Claim 20 or 21 wherein the pressure is increased at a rate of 1.379 x 10⁵Pa/hr to 1.379 x 10⁶Pa or decreased at a rate of 1.379 x 10⁵Pa/hr to 6.895 x 10⁵Pa/hr. A process as claimed in any of Claims 19 to 21, wherein a metal halide is added to form a sintering aid and preferably the metal in the metal halides or organometallic halide is selected from B, Al, Ti, Ni, Fe, Be and Mg. A process as claimed in any of Claims 20 to 22, wherein a metal hydride or organometallic compound is added to form a sintering aid and preferably the metal in the metal hydride or organometallic compound is selected from B, Ti, Be, Mg. A process as claimed in any of the preceding claims, wherein a catalyst is used to activate Si-H, Si-N, Si-Si or Si-C bonds and preferably the catalyst is a homogenous catalyst which may be a metal complex or cluster preferably selected from H₄Ru₄(CO)₁₂, Ru₃(CO)₁₂, Fe₃(CO)₁₂, Rh₆(CO)₁₂, Co₂(CO)₈(Ph₃P)₂Rh(CO)H, H₂PtCl₆, nickel cyclooctadiene, Os₃(CO)₁₂, Ir₄(CO)₁₂, (Ph₃P)₂Ir(CO)H, Pd(OAc)₂, TiCl₂, (Ph₃P)₃RhCl, H₂Os₃(CO)₁₀, and Pd(Ph₃P)₄ and Fe₃(CO)₁₂/Ru₃(CO)₁₂ mixtures, where Ph represents phenyl, or a heterogenous catalyst, preferably selected from Pt/C, Pt/BaSO₄, Cr, Pd/C, CO/C, Pt black, Co black, Pd black, Ir/Al₂O₃, Pt/SiO₂, Rh/TiO2, Rh/La₂O₃, Pd/Ag alloy, LaNi₅ and PtO₂. A process as claimed in any of Claims 11 to 25, wherein magnetism is used to orient paramagnetic phases in the polymer during supercritical fluid extraction, pyrolysis and/or sintering. A process as claimed in Claim 26, wherein the paramagnetic phase contains iron. A process as claimed in any of Claims 12 to 27, wherein fibers are formed by educting the polymer through a spinneret and magnet while heating the fiber to pyrolysis and finally heat treating in nitrogen or ammonia. A process of producing a ceramic material, which comprises maintaining a precursor, obtained by a process as claimed in any preceding claim, in the supercritical fluid so as to polymerize the precursor to form a sintered product, after final sintering.

Inventors: SULLIVAN THOMAS MILTON, SULLIVAN, THOMAS MILTON
Applicants: SULLIVAN THOMAS MILTON, SULLIVAN, THOMAS MILTON
Application year: 1989
Main classification: C04B35
IPC codes: C04B35