Patent ID: 8273291

Claim:
A controlled combustion synthesis process comprising: introducing, into a reaction container within an apparatus forming an enclosure, a starting material comprising a mixture including silicon powder, aluminum, and one or more substances from the group consisting of alumina and silica; exhausting air from said apparatus; supplying nitrogen to said apparatus from the exterior thereof by means of a nitrogen feed system including a gas pressure control valve; detecting the internal pressure within said apparatus by means of a pressure sensor, and thereby determining the quantity of nitrogen in said apparatus; initiating a reaction in said starting material by igniting said starting material, by means of at least one ignition system, when a predetermined quantity of nitrogen has been introduced into said apparatus as determined by said pressure sensor; detecting the internal temperature of the reaction container by temperature detection means; and controlling said reaction by: regulating the pressure within said apparatus by introducing nitrogen into the reaction container and exhausting reactant gas therefrom by means of said pressure control valve in response to said pressure sensor; controlling the temperature of said reaction container by regulating the flow of cooling water through a cooling system comprising a water-cooled jacket covering substantially the entire apparatus in response to the temperature as detected by said temperature detection means; and controlling the temperature of said cooling plate by regulating the flow of cooling water through said cooling plate in response to the temperature as detected by said temperature detection means; whereby combustion synthesis of a silicon alloy is carried out while maintaining the internal pressure within said apparatus and the temperature of said reaction container at specified values.