Method of forming ceramic materials and ceramic products, and ceramic materials and ceramic products formed thereby

摘要

A method of producing a dense ceramic product comprises the steps of mixing a ceramic powder containing a major proportion of an alpha-phase substituted silicon nitride obeying the formula M_x(Si,Al)₁₂ (O.N)₁₆, where x is not greater than 2 and M is a modifying cation (e.g. yttrium, calcium, lithium, magnesium, cerium) with at least one nitride of silicon and/or alumina wherein the alumina represents not more than 10% by weight of the mixture; and sintering the mixture in a non-oxidising atmosphere at a temperature of 1700°C to 1900°C so as to produce (1) a dense ceramic product consisting essentially of beta-phase substituted silicon nitride having the general formula Si_6-2Al₂-N_8-2O₂, where z is greater than zero and not greater than 1.5, and 0.05% wt to 20% wt of a further phase containing said modifying cation M, or (2) a dense ceramic product consisting essentially of said beta-phase substituted silicon nitride a 0.05% wt to 90% wt of an alpha-phase substituted silicon nitride obeying said formula M_x(Si,Al)₁₂(O,N)₁₆ and a minor amount of a further phase containing said modifying cation M.;The ceramic powder is preferably produced by effecting a first stage nitriding by heating a powder mixture comprising silicon, aluminium alumina and an oxide or nitride of a modifying cation in a nitriding atmosphere at a temperature below the melting point of aluminium until said first stage nitriding is substantially complete; effecting a second stage nitriding by heating the first stage nitrided mixture at a temperature below the melting point of silicon whilst maintaining a nitriding atmosphere until the second stage nitriding is substantially complete whereby a friable material is produced; and subsequently sintering the comminuted friable product at a temperature between 1650°C and 1900°C whilst maintaining a non-oxidising atmosphere to obtain a friable ceramic material including more than 50% by weight of an alpha-phase substituted silicon nitride obeying the formula M_x(Si,Al)₁₂(O,N)₁₆. where x is not greater than 1 and M is the modifying cation, or a friable ceramic material including greater than 50% by weight of a mixture of said alpha-phase substituted silicon nitride and a beta-phase substituted silicon nitride of the formula Si_6-2Al,N_{8 2}O₂, where z is greater than zero and not greater than 1.5.