Method of manufacturing titania and alumina ceramic sintered bodies

Abstract: A sintered oxide ceramics constituted of a single component in which the number of black spots on a mirror surface, which surface is formed by polishing said sintered ceramics and pressing the polished surface to slide on a buff having carbon black sprayed thereon, amounts to 100 or under per 1 mm² when observed under an optical microscope; and a method of making sintered oxide ceramics having a small number of black spots as set forth in Claim 1, characterized in that oxide ceramic particles being 1 micron or under in average particle size and 99 % or above in purity are formed into a body and then sintered in the atmosphere of air, inert gas, or reducing gas at a temperature ranging from 1000 to 1500 °C.

Description: Technical Field This invention relates to a method of manufacturing a titania or alumina ceramic body for fabrication into vacuum chucks, vacuum tweezers, remotely controlled hands, and other products which are used in handling Si wafers in the semiconductor industry, as in cleaning, transferring, and surface-treating the wafers, and which therefore should be protected against the deposition or adsorption of dirt and other impurities ; titania or alumina ceramic bodies for various industrial mirrors and other devices in which the existence of pores is to be avoided; titania or alumina ceramic bodies and materials for pieces in the field of personal ornaments, including tie-pins, earrings, and pendants, that are required to be lustrous and not easily soiled. Background Art In the manufacture of the vacuum chucks, vacuum tweezers, and the like employed in the operations for transfer, cleaning, and surface treatment of Si wafers in the semiconductor industry, ceramic materials have been used with the view of avoiding the intrusion of metallic elements into the wafers or the contamination with such elements. The ceramic materials used are in many cases alumina and infrequently silicon carbide. The products fabricated from the ceramic materials usually are used after their portions to come in contact with Si wafers have been ground and lapped. At times pores that the ceramic-material itself has remain exposed on the lapped surface and attract dirt and dust. With the tendency toward higher density and larger-scale integration of semiconductor elements, the possibility of the dirt and dust in the pores of the ceramic material gaining entrance into the process of fabrication has posed a problem. To settle this problem, various less porous ceramic materials have been studied. However, even the least porous material has about 300 pores per square millimeter, and it is not fully satisfactory yet to meet the requirement of the semiconductor industry that is directed toward much larger-scale integration. Disclosure of the Invention The present inventor, in an effort to solve the problem, has found that a titania and an alumina ceramic material of a single component sintered at a relatively low temperature has an unusually small number of pores and has now perfected the present invention. The invention as defined in the appended claims will be described in detail below. The essence of the invention resides in the fact that when a fine, high-purity titania or alumina ceramic powder is chosen as a raw material and fired below the usual firing temperature for oxide ceramics, the product attains an adequate sintered density while an increase in size of the pores is avoided by inhibiting the particle growth. The reason is yet to be clarified theoretically, but it is presumed that, whereas the progress of sintering usually causes pores to collect and grow to an appreciable degree in the grain boundary phase, a quite fine, high-purity oxide ceramic powder used as a material allows the pores to remain in the crystal grains as pores of almost microscopically unobservable size (known as "ghost pores"), precluding the possibility of pore growth in the crystalline grain boundary. A HIP treatment (hot isostatic pressing treatment) is performed in the same temperature range as the firing temperature but below the firing temperature to reduce the number of microscopically observable pores to almost nil. The expression "fired below the usual firing temperature for oxide ceramics" as used herein means, in general terms, being fired in the temperature range between 1000 and 1500°C. Within this temperature range the temperature used varies with the particular oxide ceramic material. For example, the temperature for alumina ceramics ranges from 1200 to 1500°C and that for titania ceramics from 1000 to 1300°C. In both cases the firing temperatures are lower than ordinary firing temperatures. A lower temperature below the firing temperature specified under the invention does not allow the sintering itself to proceed, while a higher temperature causes rapid particle growth, resulting in the migration of pores to the grain boundary phase and an increase in the size of pores due to the particle growth. If the raw powder does not have a purity of at least 99,8 or 99,9%, respectively, or if its average particle diameter is larger than 0.5 micrometer, the powder loses the property of being easily sintered at low temperature and does not attain an adequate sintered density. If it is sintered at elevated temperature to increase the sintered density, attendant particle growth makes the pores coarser. For these reasons the purity of the raw powder is specified to be at least about 99.8%, and the average particle diameter of the powder is no more than about 0.5 micrometer. The raw oxide ceramic powder is compacted in a variety of ways. For example, for the fabrication of such thin-sheet products as vacuum chucks or vacuum tweezers, the powder is compacted into sheets by the doctor blade method or by extrusion. For the quantity production of tiepins, earrings, or other personal ornaments, mechanical press compacting is used. Mirrors and other large-area flat sheets are made from the powder compacted by CIP (cold isostatic pressing), casting, or other similar technique. Whatever compacting method is resorted to, an organic binder suited for the particular method is used as a compacting assistant. The resulting compact is fired at a temperature in the optimum firing temperature range of 1000 to 1500°C, and an oxide ceramic material with an unusually small number of pores is obtained. To eliminate almost all pores, HIP treatment is performed. The HIP treatment is carried out below the firing temperature in order to suppress an increase in the size of pores due to particle growth. The atmosphere for firing may be either air or a non-air surrounding gas such as argon. So far as pores are concerned, the HIP treatment temperature and pressure are important considerations. The titania or alumina ceramic sintered body thus obtained is machined, e.g., by surface grinding, joining, or lapping, to a finished product. The most important of the properties the product is to possess is low porosity, and the present inventors have had to exert their ingenuity to evaluate that particular property of the product. This is because, as is common with oxide ceramics, the ceramic product appears to become increasingly transparent, tending to defy focusing, as the pores decrease in size and number. Thus the pores become difficult to observe in the microscopic structural study. It has been customary in such a case to polish the surface to a mirror finish and deposit gold or the like by evaporation on it for easier observation. The present invention uses a technique of improving pore visibility by filling the pores with fine black powder of carbon black and increasing the contrast in the visual field of the microscope. First, an oxide sintered body is polished using a diamond disk, buff or the like to a mirror surface, as in ordinary structural observation. Then, carbon black rather than diamond powder is sprinkled over a polishing buff, and the buff is pressed against the mirror surface and moved in sliding contact with it to force the carbon black into the pores. The mirror surface is inspected under the microscope and the number of black spots, or the pores filled with carbon black, per square millimeter is counted. A HIP-treated oxide ceramic blackens and looks less transparent, but the number of black spots on it was counted in the same manner as described above. When evaluated in the foregoing way, the oxide ceramics according to the present invention were found to have unusually small numbers of pores, all less than 100/mm 2 . Best Mode for Carrying Out the Invention Examples of the invention will now be described. (Example 1) To a titania powder having an average particle diameter of 0.25 micrometer and a purity of 99.8% (a titania powder made by Ishihara Sangyo Kaisha under the trade name "CREL") was added 2% polyvinyl alcohol as a compacting assistant. The mixture was mixed in a mortar, dried, and sieved for particle size regulation. The mixture was compacted by CIP at a pressure not lower than 10 MPa (100 kg/cm 2 ) and sintered at ordinary pressure in air at 1000 to 1300°C. Part of the sintered body was additionally treated by HIP in an argon atmosphere at 800 to 1300°C and at a pressure of at least 50 MPa (500 kg/cm 2 ). The ordinary-pressure sintered body and the HIP-treated body were both ground and polished and then forced against a buff sprinkled with carbon black and moved in sliding contact with the buff, and inspected under an optical microscope. The results are given under Nos. 1 and 2 in Table 1, No. 1 not falling within the definition of claim 1. (Example 2) An alumina powder having an average particle diameter of 0.4 micrometers and a purity of 99.9% (a product of Taimei Chemical Co., trade-named "Taimicron") was used as a raw material and compacted in the same way as described in Example 1, and the compact was sintered in air at ordinary pressure and at 1200 to 1500°C. Part of it was additionally HIP-treated in a nitrogen atmosphere at 1000 to 1500°C and at no less than 50 MPa (500 kg/cm 2 ). The ordinary-pressure sintered body and the HIP-treated body were polished and observed under an optical microscope in the manner described in Example 1. The results are represented by Nos. 3 and 4 in Table 1, No. 3 not falling within the definition of claim 4. (Comparative Example 1) CIP compacts were made by the same procedures as those used in Examples 1 and 2 and then sintered at ordinary firing temperatures or HIP-treated at elevated temperatures. The results are given in Nos. 5 to 10 in Table 1. Industrial Applicability As described above, firing a high-purity, fine titania and alumina ceramic powder below ordinary firing temperatures makes it possible for the sintered product to have pores in a state not observable under a microscope (called "ghost pores"). The product is treated by HIP. In this way oxide ceramic sintered bodies having unusually small numbers of pores, gloss, and excellent surface smoothness have been obtained. They are useful for the articles of the semiconductor industry which must be protected against dirt and dust for the sake of large-scale integration; for industrial mirrors; and for personal ornamental pieces.

Claims: A method of manufacturing a titania ceramic body with no more than 100 pores/mm 2 , comprising compacting a titania (TIO 2 ) powder having a purity of at least 99.8 % and an average particle diameter of no more than 0.5 µ m at a pressure not lower than 10 MPa (100 kg/cm 2 ), sintering the thus obtained compact in air or in an inert atmosphere or in an inert reducing atmosphere at a temperature of 1000°C to 1300°C under ordinary pressure, to produce a sintered body, treating the sintered body by hot isostatic pressing (HIP) in an inert gas at a temperature from 800°C and below the firing temperature and at a pressure of at least 50 MPa (500 kg/cm 2 ), grinding and polishing the HIP treated sintered body to a mirror surface until the number of pores, visible under an optical microscope, is no more than 100/mm 2 . Method of claim 1, wherein the sintered body is treated by hot isostatic pressing in argon. Method of claim 1 or 2, wherein the average particle diameter of the titania powder is less than 0.3 µ m. A method of manufacturing an alumina ceramic body with no more than 100 pores/mm 2 , comprising compacting an alumina (Al 2 O 3 ) powder having a purity of at least 99.9 % and an average particle diameter of no more than 0.5 µ m at a pressure not lower than 10 MPa (100 kg/cm 2 ), sintering the thus obtained compact in air or in an inert atmosphere or in an inert reducing atmosphere at a temperature of 1200°C to 1500°C under ordinary pressure, to produce a sintered body, treating the sintered body by hot isostatic pressing (HIP) in an inert gas at a temperature from 1000°C and below the firing temperature and at a pressure of at least 50 MPa (500 kg/cm 2 ), grinding and polishing the HIP treated sintered to a mirror surface until the number of pores, visible under an optical microscope, is no more than 100/mm 2 . Method of claim 4, wherein the average particle diameter of the alumina powder is no more than 0.4 µ n. Method of claim 4 or 5, wherein the sintered body is treated by hot isostatic pressing in nitrogen gas. Method according to any of claims 1 to 6, wherein compacting is carried out as cold isostatic pressing (CIP). Method according to any of claims 1 to 7 wherein the number of pores is determined by forcing the surface of the mirror against a buff sprinkled with carbon black and moved i sliding contact with the buff, and the number of resulting black spots on the surface is counted under observation with optical microscope.

Inventors: KISHI YUKIO, KISHI, YUKIO, KISHI, Yukio, 101, Izumigaoka Park Hill
Applicants: NIHON CEMENT, NIHON CEMENT CO., LTD.
Application year: 1992
Main classification: C04B41
IPC codes: C04B35