CN100348349C - 浇注粗晶粒硅化碳化硅制品的方法及用来浇注该制品的预浇注混合物 - Google Patents
浇注粗晶粒硅化碳化硅制品的方法及用来浇注该制品的预浇注混合物 Download PDFInfo
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical group [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 title claims abstract description 55
- 238000000034 method Methods 0.000 title claims abstract description 37
- 238000005266 casting Methods 0.000 title abstract description 5
- 239000000203 mixture Substances 0.000 claims abstract description 62
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 38
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 30
- 239000002245 particle Substances 0.000 claims abstract description 24
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- 229910010271 silicon carbide Inorganic materials 0.000 claims description 45
- 229910052710 silicon Inorganic materials 0.000 claims description 34
- 239000010703 silicon Substances 0.000 claims description 34
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 17
- 229910052799 carbon Inorganic materials 0.000 claims description 17
- 238000006243 chemical reaction Methods 0.000 claims description 13
- 239000000375 suspending agent Substances 0.000 claims description 8
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- 239000004115 Sodium Silicate Substances 0.000 claims description 3
- 235000019795 sodium metasilicate Nutrition 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical group [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 3
- 238000002844 melting Methods 0.000 abstract description 2
- 230000008018 melting Effects 0.000 abstract description 2
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- 235000013339 cereals Nutrition 0.000 description 11
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
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- 229910021641 deionized water Inorganic materials 0.000 description 3
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- XJKVPKYVPCWHFO-UHFFFAOYSA-N silicon;hydrate Chemical compound O.[Si] XJKVPKYVPCWHFO-UHFFFAOYSA-N 0.000 description 1
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Abstract
本发明涉及浇注硅化碳化硅制品的方法。该方法包括提供一种预浇注混合物，该混合物由颗粒最大粒度在1000至2000微米之间的碳化硅粉末及在混合物中的重量百分含量不超过9.5%的水组成。将由混合物形成的浆料倒入模具中。接着，在规定时间内从模具中除去水，形成多孔固体生坯。用金属硅包围生坯，加热生坯至金属硅熔点以上的预定温度。金属硅就将生坯硅化形成硅化碳化硅制品。
Description
技术领域
本发明涉及浇注碳化硅制品。更具体的，本发明涉及浇注粗粒度硅化碳化硅制品的方法及设备。
背景技术
碳化硅材料常用于铸件中用来设计复杂造型制品，这些制品能经受极端条件，例如在半导体、矿物加工、陶瓷加工或油类工业中常遇到的条件。而且，一般优选在烧制过程中使碳化硅制品硅化，以便进一步提高成品中材料的结合强度。硅化碳化硅制品由于具有较好的抗磨或经受严酷化学环境的能力而优于碳化硅制品。
硅化碳化硅制品的一个示例性浇注过程从预浇注混合物开始，该混合物一般由细颗粒碳化硅粉末、蒸馏水及分散助剂或其它化学品组成。将预浇注混合物放入磨机中研磨并彻底混合得到含水浆料。接着将浆料倒入石膏模具中，模具除去大部分水留下近似网状结构的生坯。干燥生坯，再在高温下硅化并增密和强化制品。接着将制品冷却并进行修整，例如机加工或抛光从而得到最终产品。
然而，早期的生产方法中，碳化硅粉末非常细小，碳化硅的总表面积能吸收很多水。也就是说，早期工艺中，碳化硅混合物的颗粒最大粒度一般为250-300微米，颗粒粒度随分布不同而降至亚微米级。全部颗粒具有能吸多量水的大表面积，因此要求约11％至15％的水含量来形成浆料。
问题是，形成浆料所需的水越多，为了形成固体生坯就必须除去更多的水。对于具有大截面厚度的注件，这种过程耗时耗力，从而严重降低了最终产品的产率。例如，利用早期工艺生产截面厚度大于等于0.75英寸的硅化碳化硅制品要求长达24小时的时间来除去足够水以便形成固体生坯。
另外，碳化硅颗粒必须充分填满由水留下的孔隙，否则最终产品中就会形成裂纹及孔隙。因此，目前硅化碳化硅注件的实际截面厚度只能限制在1英寸或更小。
然而，对于更大、更复杂浇注硅化碳化硅产品的要求超出了早期工艺的生产能力。越来越需要截面厚度大于1英寸的注件，有些情况下，要求截面厚度为8英寸甚至更大。
为了满足具有更大截面厚度的复杂形状制品的要求，早期的工艺试图在预浇注混合物中减少水含量或加大碳化硅的粒度。然而，配制粗粒度预浇注混合物及开发一种浇注混合物的方法十分困难，因为有几个因素会影响最终的产品。这些因素包括但不限于，选择合适的颗粒粒度及其分布的组合，合适的材料纯度，混合物中正确的水含量以及其它使用的化学品。而且，调节一个因素通常会影响其它因素从而进一步使问题复杂化。因此，通过早期工艺生产的截面宽度大于等于1英寸的硅化碳化硅制品还不能避免诸如裂纹或孔隙等无法接受的缺陷。
发明内容
基于前述说明，本发明的总体目标是提供一种配制预浇注混合物以及一种能克服早期工艺中存在的问题及缺陷的生产方法。
本发明提供预浇注混合物并提供一种由预浇注混合物有效浇注硅化碳化硅制品的方法，从而能使注件的截面厚度大于1英寸，因此本发明优于早期工艺并提供了另一种可选途径。最终的注件能制成具有复杂形状，并具有8英寸以上厚度而不会出现无法接受的缺陷。另外，对大多数截面厚度在3/4英寸至2英寸的制品，从模具中除去水形成固体生坯的时间不超过4小时，而利用早期工艺则需要24小时甚至更长时间。
本发明的一个实例由于提供浇注硅化碳化硅制品的方法，实现了本发明的优点。该方法包括提供由碳化硅粉末及水组成的预浇注混合物，碳化硅粉末的颗粒最大粒度在1000至2000微米之间，水的重量百分含量不超过混合物的9.5％。由混合物形成浆料，然后倒入模具中。在规定时间内从模具中除去水形成多孔生坯。用金属硅包围生坯，加热生坯至金属硅熔点以上的预定温度。金属硅对生坯形成硅化硅化碳化硅制品。
本发明的一个可选实例中，浇注的方法还包括用碳和金属硅包围生坯。接着将生坯、金属硅及碳加热至金属硅熔点以上的预定温度。在高温下，生坯、金属硅以及碳通过反应粘合在一起，形成反应粘合碳化硅制品。
另外，预浇注混合物还可以含有碳粉。接着生坯(内部含有碳粉)以及金属硅通过反应粘合在一起形成反应粘合碳化硅制品。
附图说明
图1是根据本发明制备硅化碳化硅制品的流程图示例；
图2是根据本发明制备反应粘合碳化硅制品的流程图示例；
图3是制备反应粘合碳化硅制品的可选流程图示例；
图4是根据本发明优选的预浇注混合物示例。
图1中，10所示是制备硅化碳化硅制品的常用流程图。将碳化硅(SiC)粗粉末和细粉末与去离子水混合形成预浇注混合物20。粗碳化硅粉末最大粒度约在1000微米至2000微米之间，优选不超过1500微米。
具体实施方式
粉末一般是将碳化硅原料通过具有预定最大筛目即孔眼尺寸的筛网设备，从粗颗粒中分离出较细颗粒而得到的。这样，粉末中粒度一般从最大粒度连续分布至亚微米级大小。另外，下面将详细讨论的是，混合物中可以掺入具有多个最大粒度及粒度分布的多种粉末。
与早期工艺中最大粒度在250至300微米的细粉末相比，预浇注混合物中的上述粗粉末具有更大的最大粒度及平均粒度。相应的，对于给定体积，粗粉末颗粒的总表面积要比细粉末总表面积小得多，因此能吸收更少的水。粗颗粒混合物所需水的重量百分含量一般不超过9.5％，优选在4.5％至8.5％之间。
一旦预浇注混合物20形成后，将混合物放入磨机22中通过其翻动彻底混合形成浆料24。浆料24是不可溶物质，例如硅粉在水中的悬浮液，其稠度相当于泥浆或粘土。
浆料24形成后，将材料从磨机中取出倒入石膏模具中。从模具26中移除大部分水28形成近似网状结构的生坯39。
在浇注过程结束时，近似网状结构的生坯30密度一般为理论密度的60％至90％，生坯相当多孔。有利的是，主要由于预浇注混合物具有合适的粒度分布以及含水量，模具中所有被水占据的空间基本上都被固体材料取代，因此生坯中不会形成无法接受的缺陷。
接着干燥生坯32，用金属硅粉34覆盖生坯。尽管该步骤披露了采用金属硅粉，也可以使用其它物理构型的金属硅来包围生坯，例如可以将生坯包含在金属硅容器中。
接着将生坯及包围的硅粉放到炉子36中，例如感应电炉中。将生坯加热38至金属硅熔点以上的温度，一般加热到1500至2200摄氏度左右，硅化并使制品增密40。
硅化碳化硅还称作硅渗透碳化硅，因为硅化是一种渗透形式。渗透可以说明成任何通过反应或由液体或蒸汽沉积填充孔隙的工艺。液体反应的情况中，该工艺称作熔体渗透；蒸汽相的情况中，该工艺称作化学蒸汽渗透即CVI。
目前的例子中，因为生坯不是完全致密的，即有孔隙，金属硅会熔融渗透到孔隙中形成基质包围生坯的碳化硅晶体。这一过程得到了几乎为零孔隙率的完全致密的结构。
硅化完成后，将制品冷却42再经过修整过程44，例如对关键尺寸进行最后机械加工。接着检查制品46，得到最终的粗粒硅化碳化硅浇注制品48。
上述浇注方法能有效生产截面厚度大于等于1英寸的碳化硅浇注制品，某些情况下，截面厚度能达到8英寸以上。另外，上述方法还大大减少了从模具中除去水形成固体生坯的时间。例如，对于截面厚度在3/4英寸至2英寸的大部分制品，采用上述方法除去足够水所需时间小于4小时，而用早期的浇注方法则需要24小时或者更长。
图2中，60所示是根据本发明制备反应粘合碳化硅制品的典型的生产过程流程图。反应粘合碳化硅(RBSC)制品由均匀混合的碳化硅及碳的细粒混合物制备，碳化硅和碳同时硅化并反应粘合在一起。具体是将从该混合物得到的制品在高温下暴露在液体硅或蒸汽硅中，硅与碳反应又形成碳化硅，形成的碳化硅将原来的颗粒粘合在一起。硅还填充任何残余的孔隙，也就是硅化。RBSC制品在致密化过程中尺寸几乎不变，RBSC产品随温度升至硅的熔点时强度基本不变。根据本发明生产的一种优选的RBSC材料可以从Worcester，Massachusetts的Saint-GobainCeramics & Plastics公司购买，商品名为CRYSTARRB。
在图2中，形成粗品粒RBSC的示例性方法类似于图1中形成粗晶粒硅化碳化硅的方法。因此，与图1中基本相同的步骤采用同样的数字标明。
因此，步骤20-32基本相同，将碳化硅(SiC)粗粉末与去离子水混合形成预浇注混合物20。粗碳化硅粉末最大粒度在1000微米至2000微米之间，优选不超过1500微米。粗粒混合物所需水量一般不超过混合物总重量的9.5％，优选在4.5％至8.5％之间。
预浇注混合物形成20后，放入磨机22中，通过翻滚混合形成浆料24，将浆料倒入石膏模具26中。从模具28中除去水形成近似网状结构的生坯30，接着干燥生坯32。
将金属硅粉和碳粉混合物覆盖生坯62。将生坯及周围的硅粉及碳粉放到炉子中36。加热至金属硅熔点以上温度38，一般在1500至2200摄氏度之间，硅化并反应粘合制品64。
步骤64中，一些硅与碳反应形成新的碳化硅，新形成的碳化硅通过反应粘合将生坯原来的颗粒粘合在一起。同时，剩余的硅填充任何残余开放的孔隙产生致密化并在生坯的碳化硅结构周围形成金属硅基质，也就是硅化。
反应粘合和硅化完成后，将制品冷却42并经过修整过程44。检查制品46得到最终的粗晶粒RBSC浇注品66。
由于反应粘合提高了粘合强度，粗晶粒又具有较大的粒度，二者组合使得最终的产品66具有多种优良性能。其中一个性能就是耐磨性提高。有些情况下，粗晶粒RBSC的耐磨性可能要比细晶粒RBSC的耐磨性高25％。而且，RBSC产品即使是温度升至硅的熔点温度，粘合强度也几乎不变。
图3中，80所示是制品粗晶粒RBSC制品的另一种可选实例。该过程与图2中所描述的过程基本相同，不同的是碳粉在步骤82中与预浇注混合物混合。在该实例中，生坯30仅在步骤84中被金属硅包围，因为附加的碳已经掺入到生坯中。得到的粗晶粒RBSC制品相同。
图4中，100以表格形式显示了预浇注混合物的优选实例。预浇注混合物100包括两种类型的碳化硅粉末102及104，两种粉末分别具有两种粒度分布。第一种碳化硅粉末102在混合物100中的重量百分含量为37.36％±10％，最大粒度不超过15微米。第一种粉末102的纯度在97.5％至100％之间。第二种碳化硅粉末104在混合物100中的重量百分含量为56.04％±10％，最大粒度不超过1400微米。第二种粉末104的纯度在98.40％至100％之间。
去离子水106在混合物中的重量百分含量约为6.54％±2.0％。采用悬浮剂或分散剂108，例如硅酸钠来防止碳化硅颗粒在浆料中的凝结或聚集。悬浮剂108在混合物100中的重量百分含量约为0.058％±0.05％。
上述混合物有时以干燥粉末组分的方式说明。也就是说，混合物中总的碳化硅粉末包括第一种102及第二种104粉末两种组分。第一种粉末102在整体粉末中的重量百分含量为40％±10％，第二种粉末104在整体粉末中的重量百分含量为60％±10％，第一种及第二种粉末的组合基本上组成混合物中100％的碳化硅粉末。
上述预浇注混合物100用于前述在流程图10，60及80中说明的示例方法中时，能有效生产具有大截面宽度的复杂硅化碳化硅制品。这类复杂形状制品的例子包括矿物加工行业用的细研磨机或锥体，食品加工行业用的螺旋输送机以及航空工业用的文丘里喷嘴。
尽管说明了一些优选的实例，在不背离本发明主旨和范围的条件下可以修改和替换这些实例。因此，要理解的是，已进行的描述只是说明本发明而不是限制本发明。
Claims (15)
1.浇注硅化碳化硅制品的制造方法，包括：
提供由下列组分组成的预浇注混合物：
最大粒度在1000至2000微米之间的碳化硅粉末，水，水在混合物中的重量百分含量不超过9.5％；
由混合物形成浆料；
将浆料倒入模具中；
在预定时间内从模具中除去水，形成固体多孔生坯；
用金属硅包围生坯；
加热生坯及金属硅至金属硅熔点以上的预定温度；
硅化生坯形成硅化碳化硅制品。
2.如权利要求1所述的方法，包括：
还用碳包围生坯；
加热生坯、金属硅及碳至金属硅熔点以上的预定温度；
反应粘合生坯、金属硅及碳，形成反应粘合碳化硅制品。
3.如权利要求1所述的方法，包括：
预浇注混合物进一步含有碳粉；
反应粘合生坯及整个包含在生坯内的碳粉以及金属硅，形成反应粘合碳化硅制品。
4.如权利要求1所述的方法，包括形成截面厚度大于1.0英寸的硅化碳化硅制品。
5.如权利要求1所述的方法，包括：
在小于等于4小时的时间内从模具中除去水，形成多孔固体生坯；
形成截面厚度为3/4英寸至2英寸的硅化碳化硅制品。
6.如权利要求1所述的方法，包括在1500至2200摄氏度之间加热生坯及金属硅。
7.如权利要求1所述的方法，其中，混合物中的碳化硅粉末最大粒度不超过1500微米。
8.如权利要求1所述的方法，预浇注混合物含有悬浮剂，悬浮剂在混合物中的重量百分含量为0.058％±0.05％。
9.如权利要求8所述的方法，悬浮剂是硅酸钠。
10.如权利要求1所述的方法，成品是一种CRYSTAR RB。
11.用来浇注硅化碳化硅制品的预浇注混合物，包含：
最大粒度在1000至2000微米的碳化硅粉末，
水，水在混合物中的重量百分含量不超过9.5％；
12.如权利要求11所述的预浇注混合物，混合物中的碳化硅粉末最大粒度不超过1500微米。
13.如权利要求11所述的预浇注混合物含有悬浮剂，悬浮剂在混合物中的重量百分含量为0.058％±0.05％。
14.如权利要求13所述的预浇注混合物，悬浮剂是硅酸钠。
15.如权利要求11所述的预浇注混合物，混合物用于浇注一种类型的CRYSTARRB。
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| US10/292,099 US6591892B1 (en) | 2002-11-12 | 2002-11-12 | Method and apparatus for casting coarse grain siliconized silicon carbide parts |
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| US7678458B2 (en) | 2007-01-24 | 2010-03-16 | Asml Holding N.V. | Bonding silicon silicon carbide to glass ceramics |
| EP2695740B1 (en) * | 2012-08-08 | 2017-09-06 | Canon Kabushiki Kaisha | Recording medium |
| US10058746B1 (en) * | 2017-04-26 | 2018-08-28 | Hung-Tao Peng | Manufacturing method of golf strike pad and the components of the golf strike pad made by the same manufacturing method |
| US20200198007A1 (en) * | 2018-12-25 | 2020-06-25 | Canon Kabushiki Kaisha | Article including silicon carbide and method of manufacturing same |
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| US3459566A (en) * | 1967-01-03 | 1969-08-05 | Carborundum Co | Process for producing silicon carbide articles employing pyromellitic dianhydride-limonene dioxide mixture |
| US4019913A (en) * | 1975-07-18 | 1977-04-26 | Norton Company | Process for fabricating silicon carbide articles |
| US5334675A (en) * | 1992-12-09 | 1994-08-02 | Borden, Inc. | Latent acid curable compositions |
| CN1232440A (zh) * | 1996-10-04 | 1999-10-20 | 圣戈本工业陶瓷股份有限公司 | 制造无裂纹碳化硅扩散元件的方法 |
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| CA1328347C (en) * | 1986-11-07 | 1994-04-12 | Martin R. Kasprzyk | Tubular ceramic articles, methods and apparatus for their manufacture |
| EP0560902A1 (en) * | 1990-12-04 | 1993-09-22 | United Technologies Corporation | Composite monolithic lap and a method of making the same |
| US6503572B1 (en) * | 1999-07-23 | 2003-01-07 | M Cubed Technologies, Inc. | Silicon carbide composites and methods for making same |
| JP2001351961A (ja) * | 2000-06-07 | 2001-12-21 | Taiheiyo Cement Corp | Ｓｉウェハ搬送治具及びその製造方法 |
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2002
- 2002-11-12 US US10/292,099 patent/US6591892B1/en not_active Expired - Lifetime
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- 2003-10-21 CN CNB2003801062823A patent/CN100348349C/zh not_active Expired - Lifetime
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- 2003-10-21 EP EP03811237A patent/EP1560672B1/en not_active Expired - Lifetime
- 2003-10-21 AT AT03811237T patent/ATE433355T1/de not_active IP Right Cessation
- 2003-10-21 DE DE60327938T patent/DE60327938D1/de not_active Expired - Lifetime
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3459566A (en) * | 1967-01-03 | 1969-08-05 | Carborundum Co | Process for producing silicon carbide articles employing pyromellitic dianhydride-limonene dioxide mixture |
| US4019913A (en) * | 1975-07-18 | 1977-04-26 | Norton Company | Process for fabricating silicon carbide articles |
| US5334675A (en) * | 1992-12-09 | 1994-08-02 | Borden, Inc. | Latent acid curable compositions |
| CN1232440A (zh) * | 1996-10-04 | 1999-10-20 | 圣戈本工业陶瓷股份有限公司 | 制造无裂纹碳化硅扩散元件的方法 |
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| WO2004043630A2 (en) | 2004-05-27 |
| EP1560672B1 (en) | 2009-06-10 |
| EP1560672A4 (en) | 2006-12-06 |
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| EP1560672A2 (en) | 2005-08-10 |
| ATE433355T1 (de) | 2009-06-15 |
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| US6591892B1 (en) | 2003-07-15 |
| DE60327938D1 (de) | 2009-07-23 |
| AU2003301911A8 (en) | 2004-06-03 |
| CN1726105A (zh) | 2006-01-25 |
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