Joined articles, corrosion-resistant joining materials and process for producing joined articles

Abstract: A joined article having a first member (8) made of aluminium nitride joined to a second member (7) through a joining layer (9), wherein a second member (7) is made of a material selected from a ceramic material or a metal, and the joining layer includes a continuous phase (22) made of a metal selected from the group consisting of copper, aluminum and nickel as a main component and 10 % by weight of at least one active metal selected from the group consisting of magnesium, titanium, zirconium and hafnium relative to the joining layer.

Description: Background of the Invention (1) Field of the Invention The present invention relates to a joined article made of an aluminum nitride member and a ceramic member, a joined article made of such an aluminum nitride member and a metallic member, and a producing process thereof. (2) Related Art Statement Heretofore, joined articles made of aluminum nitride members and ceramic members as well as joined articles made of aluminum nitride members and metallic members have been constructed in various manners, and used in various applications. For example, in the case of ceramic heaters, electrostatic chucks, high frequency electrodes, etc. used in semiconductor-producing apparatuses, aluminum nitride members vs. various ceramic members, aluminum nitride members vs. metallic fittings for thermocouple sets, aluminum nitride members vs. electrodes, etc. need to be joined to each other. Having noted a brazing process among various joining processes, the present inventors tried to join an aluminum nitride member to a ceramic member or an aluminum member to a metallic member through a brazing material arranged therebetween by heating the brazing material. However, the inventors discovered that although most of the brazing materials were satisfactorily joined to the metals they were unsatisfactory in wetting the aluminum nitride member, so that the brazing material was not satisfactorily joined to the aluminum nitride member or a very small gap was formed therebetween reducing the joining strength. Further, when such a joined article is arranged in a semiconductor-producing apparatus, the joined article including the aluminum nitride member is arranged in and exposed to an atmosphere of a halogen-based corrosive gas, particularly containing plasma. However, the inventors discovered that in such a use, the corrosive atmosphere entered the joined interface through the brazed portion causing deterioration of the joined layer and consequently reducing the joining strength of the aluminum nitride joined article. EP0455229 discloses a joined article comprising an aluminum or aluminum alloy body brazed to an aluminum oxide layer on a surface of an aluminum nitride body using aluminum alloy brazing alloy. Summary of the Invention The present invention is directed to a joined article made of an aluminum nitride member and a metallic member or a ceramic member joined through a brazing material, and is aimed at improving wettability of the aluminum nitride, consequently enhancing joining strength, and improving corrosion-resistance of the joined article against the halogen-based corrosive gas. The present invention provides a joined article as set out in claim 1. The present invention also provides a process for producing a joined article as set out in claim 8 The present inventors tried to find a brazing material for firmly joining aluminum nitride members to opponent members, and discovered that when a brazing material comprising a metal selected from the group consisting of copper, aluminum and nickel as a main component and 0.3 % by weight to 10 % by weight of at least one active metal selected from magnesium, titanium, zirconium and hafnium relative to the joining layer is used, a joined portion between the aluminum nitride member and the opponent member exhibits improved corrosion resistance against the halogen-based corrosive gas and wettability of the aluminum nitride member with the brazing material is improved. If a metal other than those above was used as the main component of the brazing material the corrosion resistance against the halogen-based corrosive gas, particularly such a halogen-based corrosive gas containing plasma, was poor, corrosion of the joining interface proceeded, and joining strength largely decreased. However, if the brazing material was made of the above main component alone, it exhibited poor wettability upon the aluminum nitride member. However, when at least one of magnesium, titanium, zirconium and hafnium was incorporated into the brazing material, the wettability upon the aluminum nitride member with the brazing material was conspicuously enhanced. Further, it was also confirmed that if the content of at least one of these active metals is not less than 0.3 % by weight in the brazing material, the wettability upon the aluminum nitride member with the brazing material is conspicuously improved. When the content of at least one of the active metals was not less than 1.0 % by weight of the brazing material, the wettability was further enhanced. When the content of at least one of these active metals was not more than 10 % by weight, corrosion resistance of the brazing material against the halogen-based corrosive gas was largely improved. It is more preferable that the content of at least one of the active metals is set at not more than 5.0 % by weight. However, in the case of magnesium, since a part of magnesium is evaporated off during joining, the actual content of magnesium may be less than 0.3 % by weight, ordinarily for example 0.1 % by weight, even if not less than 0.3 wt% of magnesium was incorporated. The main component of the brazing material is aluminum, nickel or copper. The brazing material containing aluminum as its main component is preferably used, because this brazing material permits joining at a lower temperature and the exhibition of reduced thermal stress after the joining, as compared with those containing nickel or copper. A third component may be incorporated in the brazing material. When the main component is aluminum, silicon or boron is preferably used as the third component because such elements give no adverse effect upon the main component. When the main component is nickel or copper, at least one element selected from silicon, boron and aluminum is preferably used as the third component because such elements give no adverse effect upon the main component. The above third component functions to lower the melting point. The addition of the third component makes the fluidability of the brazing material greater even at the same temperature. If the content of the third component is over 20 % by weight, the corrosion resistance of the joining layer is reduced. Therefore, the content of the third component is preferably not more than 20 % by weight, and more preferably 1 to 12 % by weight. As the ceramic material constituting the second member to be joined to the first member made of aluminum nitride, a ceramic material having corrosion resistance against the halogen-based corrosive gas is preferable, and particularly aluminum nitride or dense alumina is more preferable. As the metal constituting said second member, a metal having corrosion resistance against the halogen-based corrosive gas is preferable, and particularly a metal selected from nickel, copper, aluminum and an alloy made of any two or three of these metals is more preferable. As to the aluminum alloy-based brazing material, 1 to 2 % by weight of magnesium and 9-12 % by weight of silicon are preferably contained so as to improve wettability. Furthermore, it is preferable that a film made of at least one metal selected from copper, aluminum and nickel is formed, before the joining, on at least one of a surface of said first member made of aluminum nitride which is to be joined to said second member and a surface of said brazing material which is to be joined to the aluminum nitride member by sputtering, vapor deposition, friction press contacting, plating or the like. This film enhances the wettability to the brazing material. The thickness of this film is preferably is 0.1 to 20 µm. Moreover, it is preferable that a film made of at least one metal selected from magnesium, titanium, zirconium and hafnium is formed, before the joining, on at least one of a surface of said first member made of aluminum nitride which is to be joined to said second member and a surface of said brazing material which is to be joined to the aluminum nitride member by sputtering, vapor deposition, friction press contacting, plating or the like. This film enhances the reaction between the brazing material and said first member. The thickness of this film is preferably is 0.1 to 5 µm. The present inventors produced various joined articles according to the above-mentioned joining process, examined the structure of the joining portion or the joining layer in detail, and observed corrosion resistance against the halogen-based corrosive gas. The present invention will now be explained in more detail with reference to the accompanying drawings. Figs. 1(a), 1(b) and 1(c) are front views for illustrating aluminum nitride members 8 and opponent members 7 before joining. In an embodiment of Fig. 1(a), a joining surface 8a of the aluminum nitride member is opposed to a joining surface 7a of the opponent member 7, and a sheet-shaped brazing material 9 is held between the joining surfaces. When the sheet 9 is contacted with both the joining surfaces, brazing is effected by heating. In an embodiment of Fig. 1(b), a metallic film 10 is formed at a joining surface 8a of the aluminum nitride member 8. When a joining surface 7a of the opponent member and the metallic film 10 are brought into contact with the sheet 9, brazing is effected by heating. In an embodiment of Fig. 1(c), a metallic film 22 is formed on a surface of a brazing material sheet on the side of the aluminium nitride member 8. When the joining surface 7a is contacted with the sheet 9 and the metallic film 22 is contacted with the joining surface 8a, brazing is effected by heating. As mentioned above, the material of each of the metallic films 10 and 22 is at least one metal selected from copper, aluminum, nickel, magnesium, titanium, zirconium and hafnium. Figs. 2(a) and 2(b), Figs. 3(a) and 3(b), and Figs. 4(a) and 4(b) are schematic, enlarged, sectional views for illustrating joining layers formed according to the present invention, respectively. In Fig. 2(a), a joining layer 23A is formed between an aluminum nitride member 8 and an opponent member 7. This joining layer 23A includes a continuous phase 24 composed of a metal selected from the group consisting of copper, aluminum and nickel as a main component. The opponent member 7 is composed of a ceramic material or a metal of copper or aluminum excluding nickel. An active metal layer 25 is formed on the joining layer 23A on the side of the aluminium nitride member 8, and this active metal layer is made of at least one active metal selected from titanium, zirconium and hafnium. Since these active metals do not easily form a solid solution in the above main component, and yet easily wet the surface of the aluminum nitride member, it is considered that such an active metal forms a layer as shown. The construction of the continuous phase 24 and the active metal layer 25 in the joining layer 23B shown in Fig. 2(b) is the same as that in the joining layer 23A of Fig. 2(a). However, in Fig. 2(b), particles of a dispersed phase 27 are formed in the continuous phase 24. These particles are made of the third component contained in the brazing material. Also in a joining layer 23C shown in Fig. 3(a), particles of a dispersed phase 27 are formed in a continuous phase 26. The dispersed particles 27 are composed of the third component in the brazing material. The continuous phase 26 is joined to a surface of the opponent member 7, and also firmly joined to a surface 8a of the aluminum nitride member 8. The present inventors discovered that when the main component and the second component of the brazing material are aluminum and magnesium, respectively, a continuous phase is produced through magnesium being in solid solution in this continuous phase. In this case, different from the microstructures shown in Figs. 2(a) and 2(b), no active metal layer is formed along the surface of the aluminum nitride member 8. As a result, the main component of the continuous phase 26 shown in Fig. 3(b) is aluminum and magnesium in solid solution in the continuous phase 26. In the joining layer 23D shown in Fig. 3(b), the main component and the second component (active component) of the brazing material are aluminum and magnesium, respectively. A nickel member 28 is used as an opponent member. A reaction phase 29 composed of the nickel-aluminum intermetallic compound is formed along the surface 28a of the nickel member 28 through the reaction between the nickel member 28 and aluminum in the brazing material during the joining. In a joining layer 23E in Fig. 4(a), a number of dispersion phases 27 composed of particles of a third component and a number of dispersion phases 30 composed of the nickel-aluminum intermetallic compound are dispersed together in a continuous phase 26. In order to produce such a microstructure, the main component and the active component of the brazing material are aluminum and magnesium respectively, and the third component is incorporated into the brazing material. As shown in Fig. 1(b), a nickel film 10 is preliminarily formed on a surface 8a of the aluminum nitride member 8 or alternatively as shown in Fig. 1(c), a nickel film 22 is preliminarily formed on a surface of the sheet-shaped brazing material 9 on the side of the aluminum nitride member 8. When brazing is then effected, a continuous phase 26 in which magnesium is in solid solution with aluminium is produced, and the nickel-aluminun intermetallic compound is produced through the reaction between the component of the thin nickel film and aluminum, which produces the dispersed phases 30 in the continuous phase 26 through dispersion of the intermetallic compound. When a brazing material and producing process similar to those mentioned above are employed and a nickel member 28 is used as an opponent member, a joining layer 23F having a microstructure shown in Fig. 4(b) is produced. A continuous phase 26 and dispersion phases 27 and 30 in the joining layer 23F are the same as those in the joining layer 23E shown in Fig. 4(a), respectively. Further, a reaction layer 29 composed of the nickel-aluminum intermetallic compound is produced along the surface 28a of the nickel member 28. Among the above-exemplified joining layers having the respective microstructures, it is preferable that the main component of the continuous phase is aluminum and magnesium in solid solution in this continuous phase. The embodiments shown in Figs. 3(a), 3(b), 4(a) and 4(b) correspond to this. When titanium, zirconium or hafnium is used as an active metal, as shown in Fig. 2(a) and 2(b), the active metal tends to collect and form the active metal layer 25 on the surface of the aluminum nitride member, so that the wettability of the aluminum nitride with the brazing material is enhanced. For example, when a halogen-based corrosive gas is brought into contact with the joined article along arrows A as shown in Fig. 5(a), the joining layer is successively corroded from the surface side, whereby surfaces of the metallic particles in the continuous phase 24 are corroded. A reference numeral 37 denotes a corroded area 37, "L" being the width of the corroded area 37 as viewed from the front side of the joining layer. At that time, since the third component such as Si is more likely to be corroded as compared with the metals as the main component of the dispersing phase, pores 36 are formed at the dispersing phases of the third component. These pores 36 are formed in an area far deeper than the corroded area 37. The present inventors have discovered that the active metal layer 25 was also more likely to be corroded with the halogen-based corrosive gas, and that a corroded area 38 occurred in a layer-shaped form along the above layer 25 between the continuous phase 24 and the aluminum nitride member 8. The width of the corroded layer 38 was far greater than L of the corroded area 37 in the continuous phase 24. The slender layer-shaped corroded area 38 may also conspicuously reduce the joining strength between the members 7 and 8. To the contrary, when the main component of the continuous phase is aluminum and magnesium in solid solution in the continuous phase, such a layer-shaped corroded area 38 does not occur and therefore, the corrosion resistance against the halogen-based corrosive gas may be further enhanced. The present inventors further discovered that the nickel-aluminum intermetallic compound has a conspicuous corrosion resistance against the halogen-based corrosive gas. For example, when the halogen-based corrosive gas is brought into contact with the joining layer having the microstructure shown in Fig. 4(a) or 4(b) along the arrows A in Fig. 5(b), the continuous phase 26 is corroded, and pores 36 are formed through the dispersion phases made of the third component being simultaneously corroded. However, no corrosion is seen in the reaction layer 29 composed of the nickel-aluminum intermetallic compound. Further, no corrosion is seen in the dispersion phases 30 composed of the nickel-aluminum intermetallic compound, including the dispersion phases 30 in the corroded area 37. As mentioned above, the nickel-aluminum intermetallic compound exhibited high corrosion resistance, whether it was present in the form of the dispersion phase or contained in the continuous phase. Particularly, when a number of the dispersion phases exist in the continuous phase composed mainly of aluminum, propagation of the corrosion progressing in the continuous phase is stopped with the dispersion phases 30 dispersed in the continuous phase. Therefore, this is particularly advantageous, because the corrosion resistance of the continuous phase itself is enhanced. The nickel-aluminum intermetallic compound includes Al 3 Ni, Al 3 Ni 2 , AlNi and AlNi 3 . The particle diameter of the dispersion phase composed of the nickel-aluminum intermetallic compound is ordinarily 2 to 500 µm, and particularly preferably 10 to 100 µm. The dispersion phases have unspecified shapes. As the halogen-based corrosive gas, CF 4 , NF 3 , ClF 3 , HF, HCl and HBr may be recited by way of example. Among CF 4 , NF 3 and ClF 3 , ClF 3 has a particularly high F radial-dissociating degree and the highest corrosion resistance when compared at the same temperature and plasma output. The thickness of the joining layer is preferably not less than 1 µm, and preferably not more than 500 µm. The aluminum nitride member constituting the joined article according to the present invention is a member to be exposed mainly to the halogen-based corrosive gas, and is to be favorably installed in a semiconductor-producing apparatus which uses the halogen-based corrosive gas as a film-forming gas or an etching gas. As such aluminum nitride members, mention may be made, for example, of positive type devices such as ceramic heaters in which a resistive heating element is buried in an aluminum nitride substrate, electrostatic ceramic chucks in which an electrostatically chucking electrode is buried in an aluminum nitride substrate, electrostatic chuck-provided heaters in which a resistive heating element and an electrostatically chucking electrode are buried in an aluminum nitride substrate, and a high frequency wave-generating electrode device in which a plasma generating electrode is buried in a aluminum nitride substrate. In addition, mention may be made, for example, of devices such as dummy wafers, shadow rings, tubes for generating a high frequency plasma, a doom for generating a high frequency plasma, a high frequency wave-permeating windows, infrared beam-permeating windows, lift pins for supporting semiconductor wafers, showers, etc. In the following, various embodiments to which the present invention is applied will be explained. Fig. 6 is a view illustrating an example of a structure of an electrostatic chuck device. In Fig. 6, a reference numeral 1 denotes an electrostatically chucking main body, and reference numerals 4 and 5 denote an electrode-joining portion and a thermocouple-joining portion, respectively. The detailed structures of the electrode-joining section 4 and the thermocouple-joining portion 5 are shown in Fig. 6. As shown in Fig. 6, a mesh 12 is buried in the electrostatically chucking main body 1 near its surface 1a. This mesh may be employed as a resistive heating element of the aluminum nitride heater. Further, in the electrostatically chucking main body 1 is formed a hole 13, which is opened to a rear surface 1b of the main body 1. A part of the mesh 12 is exposed from a bottom surface 13a of the hole 13. A terminal 14 is made of a corrosion resistant metal such as nickel, and has a cylindrical tip portion 14a having a diameter greater than the remaining portion of the terminal 14. A sheet 15A made of the brazing material in the present invention, a residual stress-mitigating insert material 16 and another sheet 15B made of the brazing material in the present invention are inserted between the tip end face 14a of the tip portion 14b and the bottom surface 13a of the hole 13. The electrode-joining section is formed by brazing. Fig. 6 shows the electrostatic chuck in a non-joined state. In the electrostatically chucking main body 1 a hole 17 is also formed which opens to a rear surface 1b of the main body and has a bottom surface 17a formed by exposed aluminum nitride. The hole 17 is shallower than the hole 13. A pair of electrodes 18 constituting a thermocouple are received in the hole 17. A cap made of nickel is provided around the tip portion 18a of the thermocouple 18. The outer diameter of the cap 19 is slightly smaller than the inner diameter of the hole 17, which enables the cap 19 to be easily inserted into the hole 17 at a given interval therebetween. Between the tip end face of the cap 19 and the bottom portion 17a of the hole 17 is inserted a sheet 15C made of a brazing material according to the present invention, an insert material 21 and another sheet 15D of the brazing material according to the present invention. A thermocouple-joining section 5 is formed by brazing. In the electrostatic chuck shown in Fig. 6, the present invention is applied to the following. (a) Joining between the terminal 14 and the aluminum nitride member 1 (b) Joining between the cap 19 and the aluminum nitride member 1 In the electrode-joining section 4 in the electrostatic chuck shown in Fig. 6, according to the present invention, the brazing material joins the terminal 14 to the electrostatically chucking main body 1 made of aluminum nitride as well as to the metallic mesh 12 buried in the main body 1. In the following, more detailed examples will be explained. Experiment 1 Joined articles each composed of an aluminum nitride member and another aluminum nitride member were produced, and strength and corrosion-resistance of their aluminum nitride joined articles was examined. First, two aluminum nitride members and were prepared, and then, as shown in Fig. 7(a), a sheet 9A made of a brazing material having a composition given in Table 1 was sandwiched between the two aluminum nitride members 7A and 8A, which was heated at given temperature shown in Table 1 in vacuum, thereby obtaining a joined article. As a result, joined aluminum nitride articles in Example Nos. 1-28 using brazing materials falling in the scope of the present invention and those in Comparative Example Nos. 1-13 using brazing materials falling outside the scope of the present invention were obtained. In Example Nos. 25 and 26, a titanium film was formed on a surface of each of the aluminum nitride member in thickness of 3 µm or 1 µm, respectively, by sputtering, before the joining. In Example No. 27, a titanium film was formed on a surface of the brazing material in thickness of 1 µm by sputtering, before the joining. In Example No. 28, an aluminum film was formed on a surface of each of the aluminum nitride member in thickness of 1 µm by sputtering, before the joining. Plural four-point bending test pieces having a dimension of 3 mm x 4 mm x 40 mm as shaped as shown in Fig. 7(b) were prepared from each of the joined aluminum nitride articles in Examples and Comparative Examples. Among them, four-point bending strength of the test piece of each of Examples and Comparative Examples was determined as shown in Fig. 7(c) according to JIS (Japanese Industrial Standard) R 1601. Thereafter, the remaining test pieces were each subjected to a plasma exposure test at an atmosphere temperature of 400°C and a plasma output of 1 kW in a CF 4 gas for 160 hours. After the plasma exposure test, tensile strength was measured, and a section of a joined portion was observed through a microscope as shown in Fig. 7(d). At that time, the length of a color-changed area 37 in the joining layer 32 was measured as a corroded distance "L". These results are shown in Table 1. As seen from the results in Table 1, Example Nos. 1 to 28 suffered no great change in their four-point bending strength between before and after the plasma exposure test, possessed sufficient four-point bending strength even after the plasma exposure test, and exhibited shorter corroded distances and satisfactory corrosion resistance, as compared with Comparative Example Nos. 1 to 13. Among these Examples, the copper-based brazing materials in Example Nos. 1 to 7 and the nickel-based brazing material in Example Nos. 8 to 14 turned out to be preferable, because they exhibited particularly satisfactory corrosion resistance. Further, the joined articles in Examples using the aluminum-based brazing materials, Example Nos. 25 to 28 in which a given film was provided at a joining interface turned out to exhibit greater bending strength as compared with Example No. 19 in which no such a film was provided. Test No. Brazing material Joining temperature °C 4-point bending strength MPa Corroded distance µm before test after test Example A1 Cu-0.3Ti-3Si-2Al 1050 190 185 130 Example A2 Cu-1.0Ti-3Si-2Al 1050 220 218 30 Example A3 Cu-2.25Ti-3Si-2Al 1050 242 232 15 Example A4 Cu-5.05Ti-3Si-2Al 1050 250 242 25 Example A5 Cu-10Ti-3Si-2Al 1050 255 220 100 Example A6 Cu-2.25Ti-8Si-4Al 1050 245 233 30 Example A7 Cu-2.25Ti-10Si-10Al 1050 212 200 120 Example A8 Cu-2.25Zr-3Si-2Al 1050 230 244 25 Example A9 Cu-2.25Hf-3Si-2Al 1050 211 202 30 Example A10 Cu-1.5Mg-3Si-2Al 1050 195 180 50 Example A11 Ni-0.3Ti-3.5Si-1.8B 1085 185 160 120 Example A12 Ni-2.25Ti-3.5Si-1.8B 1085 204 195 20 Example A13 Ni-10Ti-3.5Si-1.8B 1085 246 200 80 Example A14 Ni-2.25Ti-16Si-4B 1085 185 150 100 Example A15 Ni-2.25Zr-3.5Si-1.8B 1085 198 191 30 Example A16 Ni-2.25Hf-3.5Si-1.8B 1085 205 210 35 Example A17 Ni-1.5Mg-3.5Si-1.8B 1085 188 185 30 Example A18 Al-0.3Mg-10Si 610 95 88 150 Example A19 Al-1.5Mg-10Si 610 110 65 100 Example A20 Al-10Mg-10Si 610 112 50 140 Example A21 Al-1.5Mg-20Si 610 105 52 150 Example A22 Al-2.5Ti-10Si 610 125 70 100 Example A23 Al-2.5Zr-10Si 610 118 72 110 Example A24 Al-2.5Hf-10Si 610 124 68 100 Example A25 Al-1.5Mg-20Si 610 177 175 120 Example A26 Al-1.5Mg-10Si 610 188 151 150 Example A27 Al-1.5Mg-10Si 610 252 242 100 Example A28 Al-1.5Mg-10Si 610 314 303 90 Comparative Example A1 Cu-0.1Ti-3Si-2Al 1050 not joined Comparative Example A2 Cu-12Ti-3Si-2Al 1050 222 48 800 Comparative Example A3 Cu-2.25Ti-15Si-10Al 1050 200 52 750 Comparative Example A4 Ni-0.1Ti-3.5Si-1.8B 1085 not joined Comparative Example A5 Ni-12Ti-3.5Si-1.8B 1085 196 32 700 Comparative Example A6 Ni-2.25Ti-20Si-8B 1085 188 22 700 Comparative Example A7 Al-0.1Mg-10Si 610 not joined Comparative Example A8 Al-12Mg-10Si 610 95 31 700 Comparative Example A9 Al-1.5Mg-25Si 610 105 22 750 Comparative Example A10 99.9Al 680 not joined Comparative Example A11 Al-12Si-3Cu 600 not joined Comparative Example A12 Ag-Cu-In-Ti 750 250 20 1100 Comparative Example A13 Ag-35Cu-2.5Ti 850 270 30 1200 Experiment 2 Joined articles each composed of an aluminum nitride member and one selected from various metallic members were produced, and strength and corrosion-resistance of their aluminum nitride joined articles were examined. First, aluminum nitride members and metallic members shown in the following Table 2 were prepared. Then, as shown in Fig. 8(a), a sheet 43A made of a brazing material having a composition given in Table 2, an insert member 44 and another sheet 43B made of the brazing material were sandwiched between the aluminum nitride member 41 and the metallic member 42, which was heated at given temperature shown in Table 2. The insert member 44 was provided to mitigate residual stress. By the above heating, a joining layer 50 was formed. As a result, plural joined bodies each in Example Nos. 1-31 using brazing materials falling in the scope of the present invention and plural ones each in Comparative Example Nos. 1-8 using brazing materials falling outside the scope of the present invention were obtained. In Example Nos. 27 and 28, a titanium film was formed on a surface of the aluminum nitride member in thickness of 3 µm or 1 µm, respectively, by sputtering, before the joining. In Example No. 29, a titanium film was formed on a surface of the brazing material in thickness of 1 µm by sputtering, before the joining. In Example No. 30, an aluminum film was formed on a surface of the aluminum nitride member in thickness of 1 µm by sputtering, before the joining. With respect to Example Nos. 1 to 30 and Comparative Example Nos. 1 to 8, a load of 0.6 g/mm 2 was applied, whereas a load of 26.5 g/mm 2 was applied to Example No. 31 only. As shown in Fig. 8(c), some of thus obtained test pieces in Examples and comparative Examples were subjected to the four-point bending strength test, and tensile strength was determined. The remaining test pieces were subjected to the same plasma exposure test as in Experiment 1. After the plasma exposure test, tensile strength was measured, and the corroded distance was determined in the same way as in Experiment 1. The thus obtained results are shown in Table 2. As seen from the results in Table 1, Example Nos. 1 to 31 suffered no great change in their four-point bending strength between before and after the plasma exposure test, possessed sufficient four-point bending strength even after the plasma exposure test, and exhibited shorter corroded distances and satisfactory corrosion resistance as compared with Comparative Example Nos. 1 to 13. Among these Examples using the aluminum-based brazing materials, Example Nos. 27 to 30 in which a given film was provided at a joining interface turned out to exhibit greater bending strength as compared with Example No. 2 in which no such a film was provided. Further, the joined body in Example 31 in which a greater load was applied during the joining turned out to give greater tensile strength as compared with Example No. 2 in which a smaller load was applied during the joining. Metal Brazing material Insert material Thickness µm Tensile strength (MPa) Corroded distance before test after test Example B1 Ni Al-0.3Mg-10Si Al 0.55 5.3 5.0 120 Example B2 Al-1.5Mg-10Si Al 0.55 5.1 5.0 100 Example B3 Al-10Mg-10Si Al 0.55 4.8 4.6 115 Example B4 Al-1.5Mg-20Si Al 0.55 4.8 4.5 150 Example B5 Al-1.5Mg-10Si Cu 0.5 5.5 5.3 110 Example B6 Al-2.5Ti-10Si Al 0.55 6.7 6.3 100 Example B7 Al-2.5Zr-10Si Al 0.55 6.5 6.0 100 Example B8 Al-2.5Hf-10Si Al 0.55 6.7 6.2 95 Example B9 Ni Cu-0.3Ti-3Si-2Al Cu 0.5 10.2 9.4 55 Example B10 Cu-2.25Ti-3Si-2Al Cu 0.5 13.2 12.5 25 Example B11 Cu-10Ti-3Si-2Al Cu 0.5 12.2 9.4 85 Example B12 Cu-2.25Ti-10Si-10Al Cu 0.5 12.5 9.6 80 Example 1B3 Cu-2.25Ti-3Si-2Al Cu 2 14.0 13.0 20 Example B14 Cu-2.25Zr-3Si-2Al Cu 0.5 12.5 12.0 22 Example B15 Cu-2.25Hf-3Si-2Al Cu 0.5 11.0 10.6 20 Example B16 Cu-1.5Mg-3Si-2Al Cu 0.5 11.5 10.5 30 Example B17 Ni Ni-0.3Ti-3.5Si-1.8B Cu 0.5 10.3 8.5 60 Example 1B8 Ni-2.25Ti-3.5Si-1.8B Cu 0.5 12.3 11.3 20 Example B19 Ni-10Ti-3.5Si-1.8B Cu 0.5 10.5 8.6 65 Example B20 Ni-2.25Zr-16Si-4B Cu 0.5 10.4 8.7 90 Example B21 Ni-2.25Hf-3.5Si-1.8B Cu 0.5 12.5 11.5 30 Example B22 Ni-1.5Mg-3.5Si-1.8B Cu 0.5 12.8 11.5 30 Example B23 Cu Al-1.5Mg-10Si Al 0.55 6.0 5.5 100 Example B24 Cu-2.25Ti-3Si-2Al Cu 0.5 11.5 10.5 20 Example B25 Ni-2.25Ti-3.5Si-1.8B Cu 0.5 12.5 11.5 30 Example B26 Al Al-1.5Mg-10Si Al 0.55 5.4 5.2 110 Example B27 Ni Al-1.5Mg-10Si Al 0.55 10.8 8.0 120 Example B28 Al-1.5Mg-10Si Al 0.55 12.5 9.8 115 Example B29 Al-1.5Mg-10Si Al 0.55 15.7 12.7 150 Example B30 Al-1.5Mg-10Si Al 0.55 17.4 13.3 100 Example B31 Al-1.5Mg-10Si Al 0.55 40.2 37.5 100 Comparative Example B1 Ni Cu-0.1Ti-3Si-2Al Cu 0.5 9.5 3.3 800 Comparative Example B2 Cu-2.25Ti-15Si-10Al Cu 0.5 9.5 2.2 850 Comparative Example B3 Ni Al-12Mg-10Si Al 0.55 4.1 2.2 900 Comparative Example B4 Al-0.1Mg-10Si Al 0.55 4.5 2.5 900 Comparative Example B5 Al-1.5Mg-25Si Al 0.55 4.2 2.0 1000 Comparative Example B6 Ni Ni-12Ti-3.5Si-1.8B Cu 0.5 9.4 3.0 1000 Comparative Example B7 Ni-0.1Ti-3.5Si-1.8B Cu 0.5 8.5 2.5 900 Comparative Example B8 Ni-2.25Ti-20Si-8B Cu 0.5 7.8 2.7 900 Experiment 3 Joined articles each composed of an aluminum nitride member and a nickel member were produced, and their corrosion-resistance was examined. First, an aluminum nitride member 51 having a dimension of 10 mm x 10 mm x 10 mm and a nickel member 52 having a dimension of 10 mm x 10 mm x 0.5 mm were prepared. Then, as shown in Fig. 8(c), a sheet 53 made of a brazing material having a composition given in Table 3 with a dimension of 10 mm x 10 mm x 0.1 mm was inserted between the aluminum nitride member 51 and the nickel member 52, which was heated at given temperature shown in Table 3 in vacuum. Before joining, the nickel member was softened by annealing at 1000°C in vacuum for 1 hour, thereby reducing residual stress after the joining. Each of the thus obtained test pieces was subjected to the four-point bending strength measurement before and after the plasma exposure test in the same manner as in Experiment 2. In the plasma exposure test, ClF 3 which has a high fluorine-dissociation degree and stronger corrosive force at the same temperature and plasma output than CF 4 was used, and the plasma output was 1 kW, the temperature was 450°C and the exposure time was 200 hours. The corroded distance M of the layer-shaped corrosion area along the interface between the joining layer and the aluminum nitride member was measured. Thus obtained results are shown in Table 3. Example Nos. C1-C7 used the aluminum alloy-based brazing materials, Example Nos. C8-C11 used the copper alloy-based brazing materials, and Example Nos. C12-C15 used the nickel-based brazing materials, and their results are shown in Table 3. Comparison of those results revealed that the aluminum alloy-based brazing materials added with magnesium exhibited the most favorable corrosion resistance. The reason is considered that magnesium among the active metals exhibits better corrosion resistance against the halogen gas as compared with titanium, zirconium and hafnium, and that magnesium is solid-solved in the aluminum alloy, whereas each of titanium, hafnium and zirconium is segregated at the joining interface so that the corroding speed is high. Further, Example No. C7 in which the brazing material was plated with nickel before the joining exhibited extremely good corrosion resistance. The reason is considered that plating the surface of the brazing material with nickel improves wettability and reduces very small non-joined portions at the joining interface, and the nickel-aluminum intermetallic compound phases having good corrosion resistance are dispersed in the brazing material layer after the joining. Fig. 9 is an electron microscope photograph showing a ceramic texture of a part of a test sample in Example No. C7 given in Table 3 before the plasma exposure test, and Fig. 10 is a view for schematically explaining Fig. 9. It is seen that an aluminum layer 26 (a gray portion in the photograph) in which magnesium is solid-solved exists in the joining layer between the aluminum nitride member 8 and the nickel member 28, and that a number of the dispersion phases 30 (white portions in the photograph) composed of the nickel-aluminum intermetallic compound are formed in the aluminum layer 26. Further, a number of slender dispersion phases 27 (portions slightly brighter than the aluminum layer 26 in the photograph) composed mainly of a third component are formed. In addition, the formation of the reaction phase 29 is also observed. Fig. 11 is an electron microscope photograph showing a ceramic texture of a part of a test sample in Example No. C7 given in Table 3 after the plasma exposure test, and Fig. 12 is a view for schematically explaining Fig. 11. In Figs. 11 and 12, the same microstructure as shown in Figs. 9 and 10 is recognized, but pores are seen along the dispersion phases 27. The pores 36 appear as slender black portions along the thin gray dispersion phases 27 in the photograph. The present invention is not limited to the above-mentioned experiments only, but various modifications, variations and changes thereof are possible. For example, although only the aluminum nitride members have been recited in the above experiments as examples of the ceramic members to be joined to the aluminum nitride members, similar results were obtained with respect to other ceramic members (for example, dense alumina). As having been described above, according to the present invention, the wettability of the alumina nitride member can be enhanced, the joining strength can be increased, and the corrosion resistance of the joined article against the halogen-based corrosive gas can be improved in the case of the production of the joined article of the aluminum nitride and the metallic member or the ceramic member. Brazing material Joining temperature °C Corroded distance µm Example C1 Al-0.9Mg-10Si 610 1.8 Example C2 Al-1.5Mg-10Si 610 1.5 Example C3 Al-2.0Mg-10Si 610 1.7 Example C4 Al-2.5Ti-12Si 610 3.6 Example C5 Al-2.5Zr-10Si 610 3.4 Example C6 Al-2.5Hf-10Si 610 3.8 Example C7 Al-1.5Mg-10Si 2 µm thick Ni plated on Al alloy 610 0.3 Example C8 Cu-2.25Ti-3Si-2Al 1050 2.5 Example C9 Cu-2.25Zr-3Si-2Al 1050 2.2 Example C10 Cu-2.25Hf-3Si-2Al 1050 2.5 Example C11 Cu-1.5Mg-3Si-2Al 1050 3.5 Example C12 Ni-2.25Ti-3.5Si-1.8B 1085 2.2 Example C13 Ni-2.25Zr-3.5Si-1.8B 1085 2.5 Example C14 Ni-2.25Hf-3.5Si-1.8B 1085 2.7 Example C15 Ni-1.5Mg-3.5Si-1.8B 1085 3.8

Claims: A joined article comprising a first member (1,8,41) made of aluminum nitride and a second member (7,14,18,28, 42) made of a material selected from a ceramic material and a metal, said members being joined to each other through a joining layer (23,50), wherein said joining layer has a continuous phase (24,26) comprising a metal selected from copper, aluminum and nickel as a main component and 0.3 to 10% by weight in total relative to the weight of the joining layer of at least one active metal selected from magnesium, titanium, zirconium and hafnium, said joining layer having the continuous phase being formed directly on the surface of said aluminium nitride member or with the interposition of an active metal layer made from copper, aluminium, nickel, magnesium, titanium, zirconium or hafnium. The joined article set forth in claim 1, wherein the material of said second member is a ceramic selected from aluminum nitride or dense alumina. The joined article set forth in claim 1, wherein the material of said second member is selected from the nickel, copper, aluminum and an alloy made of any two or all three of these. The joined article set forth in any one of claims 1 to 3, wherein said joining layer includes said continuous phase and an active metal layer located on said first member made of aluminum nitride, said active metal layer (25) comprising at least one active metal selected from titanium, zirconium and hafnium. The joined article set forth in any one of claims 1 to 3, wherein said continuous phase contains aluminum as a main component, and magnesium is in solid solution in said continuous phase. The joined article set forth in any one of claims 1 to 3, wherein a dispersed phase (27) composed of a nickel-aluminum intermetallic compound is formed in said continuous phase (24,26). The joined article set forth in claim 3, wherein the metal of said second member is nickel, and a reaction layer (29) made of a nickel-aluminum intermetallic compound is formed on the surface of said second member to which said joining layer is joined. A process for producing a joined article of a first member (1,8,41) made of aluminum nitride and a second member (7,14,18,28,42) made of a material selected from a ceramic material and a metal, said process comprising the steps of: (1) separately preparing said first and second members; (2) arranging a brazing material (9,15A) between said first and second members, said brazing material comprising a metal selected from copper, aluminum and nickel as a main component and 0.3 to 10% by weight in total, relative to the joining layer, of at least one active metal selected from magnesium, titanium, zirconium and hafnium; and (3) brazing said first member to said second member by heating said brazing material, with said brazing metal directly contacting the surface of the aluminium nitride member (1,8,41) or with the interposition of an active metal layer made from copper, aluminium, nickel, magnesium, titanium, zirconium or hafnium. The process set forth in claim 8, wherein the content of said active metal or metals is 1 to 5% by weight. The joined article-producing process set forth in claim 8 or 9, wherein said brazing material contains 1 to 20% by weight of a third component. The process set forth in any one of claims 8 to 10, wherein a film (25,29) made of a metal selected from copper, aluminum, nickel, magnesium, titanium, zirconium and hafnium is formed on at least one of (i) the surface of said first member which is to be joined to said second member via said brazing material and (ii) the surface of said brazing material which is to be joined to said first member. The process set forth in claim 11, wherein said film (25,29) is a nickel film. The process set forth in any one of claims 8 to 12, wherein said material of said second member is a ceramic selected from aluminum nitride and dense alumina. The process set forth in any one of claims 8 to 12, wherein the material of said second member is a metal selected from nickel, copper, aluminum and an alloy made of any two or all three of these.

Inventors: FUJI TOMOYUKI, USHIKOSHI RYUSUKE, FUJI, TOMOYUKI, USHIKOSHI, RYUSUKE
Applicants: NGK INSULATORS LTD, NGK INSULATORS, LTD.
Application year: 1996
Main classification: C04B37
IPC codes: C04B37, B23K35, B23K1