JP2013075777A - Alumina sintered compact and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an alumina sintered compact capable of improving electrical characteristics, improving processing easiness and intending uniformity of color, and a method for producing the same.SOLUTION: The raw material of this sintered compact is prepared by adding 0.1-2.0 pts.wt. of a Ti compound as an auxiliary raw material in terms of TiOto 100 pts.wt. of AlOas a main raw material. A compact made of the raw materials is sintered at 1,400-1,600°C for at least 3 hours in an atmosphere in which air is supplied while controlled at 8-25 L/min per 1 m, and the sintered compact is cooled while the cooling speed of the atmospheric temperature of the sintered compact is controlled at 5-30°C/h.

Description

  The present invention relates to an alumina sintered body and a method for producing the same.

Al ₂ O _3, which is a typical fine ceramic, has excellent mechanical strength, heat resistance, chemical resistance, and low dielectric loss tangent, so it is often used for semiconductors and high-frequency plasma device members for liquid crystals. Yes.

However, since there are impurities such as Na and K ions in the general-purpose Al ₂ O ₃ raw material (standard purity 90.0 to 99.9%), desired electrical characteristics (dielectric loss) are realized. However, the electrical characteristics in the sintered body are locally different, and the electrical characteristics become unstable. Furthermore, Al ₂ O ₃ is a difficult-to-work material, and the processing cost of the sintered body is increased. Moreover, when the color of alumina ceramics is not uniform (there is uneven color), it cannot be handled as a product.

Regarding the problem of electrical characteristics, according to the prior art 1, by adding CaTiO ₃ and SiO ₂ to Al ₂ O ₃ , a grain boundary phase made of glass is formed in the sintered body, and is derived from the raw material It has been proposed to stabilize the electrical characteristics (lower dielectric loss) by trapping the impurities in the grain boundary phase (see Patent Document 1). Similarly, according to the prior art 2, Si and M (at least one of Mg, Ca, Sr, and Ba) are contained as other elements in Al ₂ O ₃ to stabilize electrical characteristics. (See Patent Document 2).

Regarding the problem of workability, according to Prior Art 3, by adding TiO ₂ to Al ₂ O ₃ and promoting grain growth, Al ₂ O ₃ ceramics can be given free-cutting properties (workability). It has been proposed (see Patent Document 3).

  Regarding the problem of coloration, according to the prior art 3, the final color of the ceramics is such that when the alumina ceramics mainly composed of alumina and dispersed with Ti and Ti oxide are heat-treated in a reducing atmosphere, the color becomes blue. The coloration is adjusted by adjusting the heat treatment atmosphere.

JP 2006-124217 A JP 2011-116615 A JP 2004-352572 A

  However, according to the prior art 1 or 2, since the Si component is very small, the proportion of the grain boundary phase is small, it is difficult to form a liquid phase uniformly over the entire grain boundary, and the stable electric power as a whole in the sintered body. Unable to get characteristics. Moreover, according to the prior art 2, since the Si component exists as an agglomerated grain at the grain boundary, it is difficult to obtain stable electrical characteristics. Furthermore, in a plasma irradiation environment, the aggregated grains composed of fine crystals are likely to fall off selectively, making it difficult to use.

On the other hand, according to the prior art 3, the structure is only controlled, and when a grindstone load is applied, the processing proceeds while particles are dropped. Since the Al ₂ O ₃ particles themselves are not modified, intragranular fracture is unlikely to occur, and the processing cost is not drastically reduced. Moreover, the color adjustment of the surface layer portion of the alumina ceramic is only adjusted by adjusting the atmosphere, and color unevenness may be confirmed when the cut surface is viewed.

  Then, this invention makes it a subject to provide the alumina sintered compact which can aim at the improvement of an electrical property, the improvement of workability, and the uniformity of coloring, and its manufacturing method.

In the alumina sintered body of the present invention for solving the above problems, the Ti compound as an auxiliary material is 0.1 to 2.0 in terms of TiO _{2 with} respect to 100 parts by weight of Al ₂ O _{3 as} the main material. The dielectric loss tan δ at a frequency of 1 MHz to 5 GHz is 10 ⁻⁴ units, the grinding resistance is 20 [kgf] or less, and there is no color unevenness in an arbitrary cut surface.

In the method for producing an alumina sintered body of the present invention for solving the above-mentioned problems, a Ti compound as an auxiliary material is added in an amount of 0.1 in terms of TiO ₂ with respect to 100 parts by weight of Al ₂ O ₃ as a main material. A raw material is prepared by adding ~ 2.0 parts by weight, a molded body is produced by molding the raw material, and an air supply amount per 1 [m ³ ] atmosphere of the molded body is 8-25 [L / The molded body is fired at 1400 to 1600 [° C.] for 3 hours or more while being controlled at min], and then the molded body is controlled while the temperature drop rate of the ambient temperature of the molded body is controlled to 5 to 30 [° C./hr]. The alumina sintered body is manufactured by cooling the substrate. In this manufacturing method, the ratio of the air supply amount per atmosphere 1 [m ³ ] of the molded body to the TiO ₂ equivalent addition amount of the auxiliary raw material with respect to 100 parts by weight of the main raw material is controlled to 8 to 93.75. Is preferred.

The 1st explanatory view about the manufacturing conditions of the alumina ceramics of the present invention. 2nd explanatory drawing regarding the manufacturing conditions of the alumina ceramics of this invention. Explanatory drawing regarding the ceramic sintering process. Explanatory drawing regarding the coloration of a sintered compact.

The alumina sintered body of the present invention is manufactured by the following procedure. First, a raw material is prepared by mixing Al ₂ O ₃ having a purity of 95% or more as a main raw material and a Ti compound as an auxiliary raw material.

The auxiliary material is added in an amount of 0.1 to 2.0 parts by weight in terms of TiO _{2 with} respect to 100 parts by weight of the main material. For simplicity of description, the addition amount (parts by weight) of the auxiliary material to 100 parts by weight of the main material is described as “p”. In addition to TiO ₂ , the auxiliary material may be a chloride that generates an oxide after firing, an organic Ti compound, or the like. Preferably, the raw material is adjusted after adjusting the particle size of the auxiliary raw material to 0.05 to 2.5 [μm].

  When the raw material slurry is prepared, a known one such as a polycarboxylic acid type is used as the dispersant. The solvent is preferably water, particularly ion-exchanged water with few impurities, but a known solvent such as alcohol may be used. As the binder, known materials such as polyvinyl alcohol and acrylic emulsion are used. Moreover, additives, such as a pH adjuster and an antifoamer, may be added as needed. As the mixing method, a known method such as ball mill mixing may be employed.

  Furthermore, a molded object is produced by shape | molding a raw material. As a forming method of the raw material powder, various forming methods such as uniaxial press forming, CIP forming, wet forming, pressure casting forming, or sludge casting forming may be employed.

In addition, the compact is fired at 1400 to 1600 [° C.] for 3 hours or more while the air supply amount per 1 [m ³ ] of the compact is controlled to 8 to 25 [L / min]. Thereafter, the compact is cooled while the rate of temperature drop to the ambient temperature of 700 [° C.] is controlled to 5 to 30 [° C./hr], whereby an alumina sintered body is manufactured. For simplicity of description, the air supply amount is described as “f”, and the temperature drop rate is described as “v”.

(Example)
Example 1
The addition amount p of “TiO ₂ ” as an auxiliary material to 95% pure Al ₂ O ₃ as the main material was adjusted to “0.1”. A cylindrical molded body having a diameter of 90 [mm] and a thickness of 50 [mm] was produced. The alumina sintered body of Example 1 is sintered by controlling the air supply amount f to the sintering atmosphere to “8” and controlling the subsequent temperature drop rate v to “5”. Was manufactured.

(Example 2)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “2.0”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “25” and the subsequent cooling rate v was controlled to “10”. Otherwise, the alumina sintered body of Example 2 was produced under the same conditions as in Example 1.

(Example 3)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.2”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “15” and the subsequent cooling rate v was controlled to “30”. Otherwise, the alumina sintered body of Example 3 was produced under the same conditions as in Example 1.

Example 4
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.3”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “10” and the subsequent cooling rate v was controlled to “5”. Otherwise, the alumina sintered body of Example 4 was produced under the same conditions as in Example 1.

(Example 5)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “1.0”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “8” and the subsequent cooling rate v was controlled to “30”. Otherwise, the alumina sintered body of Example 5 was produced under the same conditions as in Example 1.

(Example 6)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “1.8”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “25” and the subsequent cooling rate v was controlled to “5”. Otherwise, the alumina sintered body of Example 6 was produced under the same conditions as in Example 1.

(Example 7)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “1.2”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “18” and the subsequent cooling rate v was controlled to “18”. Otherwise, the alumina sintered body of Example 7 was manufactured under the same conditions as in Example 1.

(Example 8)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.8”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “25” and the subsequent cooling rate v was controlled to “30”. Otherwise, the alumina sintered body of Example 8 was manufactured under the same conditions as in Example 1.

Example 9
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.2”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “15.0” and the subsequent cooling rate v was controlled to “12.5”. Otherwise, the alumina sintered body of Example 9 was produced under the same conditions as in Example 1.

(Example 10)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.2”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “18.75” and the subsequent cooling rate v was controlled to “12.5”. Otherwise, the alumina sintered body of Example 10 was produced under the same conditions as in Example 1.

(Evaluation of physical properties of sintered body)
The dielectric loss of the sintered body was measured by a Q meter MQ-1601 manufactured by Meguro Radio Instruments Co., Ltd. and an AGILMT network analyzer 8719ES.

  For the workability of the sintered body, measured values were obtained by plunge processing 2 pass up cut of a surface grinder (processing machine: Nagase ultra-precision surface grinder, grindstone: Allied resin bond φ350, rotation speed: 1300 rpm, feed rate: 2. 5 m / min cutting depth: 0.06 mm / pass).

  As for the average sintered particle diameter of the sintered body, 20 sites are arbitrarily selected from one sintered body, and the polished surface is thermally corroded to precipitate grain boundaries, and then each site is observed by SEM. It was calculated according to If the average particle diameter is in the range of 10 to 50 [μm], the result of grain growth is evaluated as good (◯), and if the average particle diameter is out of the range, the result of grain growth is not good Not rated (x).

For the density unevenness of the sintered body, the cylindrical sintered body was cut at three different heights, and it was judged whether there was any density unevenness in the cut surface. With the same sintered body, the presence or absence of density unevenness was evaluated depending on whether the difference in density was 0.03 [g / cm ³ ] or more.

  The coloration of the sintered body was evaluated by visually observing the outside and inside of the sintered body on the cut surface after the sintered body was cut. As represented by the uniformity of brightness in FIG. 4A, the color is uniform when the outer color and the inner color (for example, blue, yellow) in the cross section of the sintered body are the same. (○). On the other hand, as represented by uneven brightness in FIG. 4B, when the outer color (for example, blue) and the inner color (for example, yellow) in the cross section of the sintered body are different, there is color unevenness ( X).

  The physical property measurement results of the sintered bodies of Examples 1 to 10 are shown in Table 1 together with the manufacturing conditions.

  In FIG. 1, the combination of the additive amount p of the auxiliary material in each sintered body of Examples 1 to 10, the air supply amount f with respect to the sintering atmosphere of the molded body, and the temperature drop rate v is a white sphere numbered. Indicated by position. The sintered bodies of Examples 1 to 10 are adjusted to be included in a cubic range defined by p = 0.10 to 2.0, f = 8 to 25, and v = 5 to 30. .

  In FIG. 2, the combinations of v and f / p in the respective sintered bodies of Examples 1 to 10 are indicated by the positions of white circles with numerals. The sintered bodies of Examples 1 to 10 are adjusted so as to be included in the rectangular range defined by (f / p) = 8 to 93.75 and v = 5 to 30.

As can be seen from Table 1, the dielectric loss tan δ at 1 [MHz] to 5 [GHz] of the sintered bodies of Examples 1 to 10 is a value of 10 ⁻⁴ units. Moreover, the grinding resistance of the sintered bodies of Examples 1 to 10 is 20 [kgf] or less. The main raw material particles constituting the sintered bodies of Examples 1 to 10 were columnar, and the average sintered particle diameter in the major axis direction of the columns was 10 to 50 [μm]. Furthermore, no color unevenness was observed in the sintered bodies of Examples 1 to 10.

(Comparative example)
(Comparative Example 1)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.2”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “18.75” and the subsequent cooling rate v was controlled to “60”. Otherwise, the alumina sintered body of Comparative Example 1 was produced under the same conditions as in Example 1.

(Comparative Example 2)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “1.0”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “5” and the subsequent cooling rate v was controlled to “20”. Otherwise, the alumina sintered body of Comparative Example 2 was produced under the same conditions as in Example 1.

(Comparative Example 3)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “1.0”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “0” and the subsequent temperature drop rate v was controlled to “40”. Otherwise, the alumina sintered body of Comparative Example 3 was produced under the same conditions as in Example 1.

(Comparative Example 4)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.2”. The molded body was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “15.0” and the subsequent cooling rate v was controlled to “80”. Otherwise, the alumina sintered body of Comparative Example 4 was produced under the same conditions as in Example 1.

(Comparative Example 5)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.3”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “18.75” and the subsequent cooling rate v was controlled to “60”. Otherwise, the alumina sintered body of Comparative Example 5 was produced under the same conditions as in Example 1.

(Comparative Example 6)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “10.0”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “25.0” and the subsequent cooling rate v was controlled to “15”. Otherwise, the alumina sintered body of Comparative Example 6 was produced under the same conditions as in Example 1.

(Comparative Example 7)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “10.0”. The molded body was sintered while the air supply amount f to the sintering atmosphere was controlled to “20.0” and the subsequent temperature drop rate v was controlled to “70”. Otherwise, the alumina sintered body of Comparative Example 7 was produced under the same conditions as in Example 1.

(Comparative Example 8)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.05”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “18.5” and the subsequent cooling rate v was controlled to “20”. Other than that, the alumina sintered body of Comparative Example 8 was produced under the same conditions as in Example 1.

(Comparative Example 9)
The addition amount p of “TiO ₂ ” as an auxiliary material was adjusted to “0.01”. The compact was sintered while the air supply amount f with respect to the sintering atmosphere was controlled to “5.0” and the subsequent cooling rate v was controlled to “50”. Otherwise, the alumina sintered body of Comparative Example 9 was produced under the same conditions as in Example 1.

  The physical property measurement results of the sintered bodies of Comparative Examples 1 to 9 are shown in Table 2 together with the manufacturing conditions.

  In FIG. 1, black spheres with numbers indicating the combinations of the additive amount p of the auxiliary material, the air supply amount f with respect to the sintering atmosphere of the molded body, and the cooling rate v in each of the sintered bodies of Comparative Examples 1-9 Is indicated by the position of. The sintered bodies of Comparative Examples 1 to 9 are adjusted so as to be out of the cubic range.

  In FIG. 2, the combinations of v and f / p in the respective sintered bodies of Comparative Examples 1 to 10 are indicated by the positions of black circles with numerals. The sintered bodies of Comparative Examples 1 to 9 are adjusted so as to be out of the rectangular range.

As can be seen from Table 2, the dielectric loss tan δ exhibits a value of 10 ⁻³ units at 1 [MHz] to 5 [GHz] of the sintered bodies of Comparative Examples 1 to 9. The grinding resistance of the sintered bodies of Comparative Examples 1 to 9 is 25 to 35 [kgf], and the grinding resistance is larger than that of the sintered bodies of Examples 1 to 10. Although the main raw material particles constituting the sintered bodies of Comparative Examples 1 to 9 are columnar, the average sintered particle diameter in the major axis direction of the columns is less than 10 [μm], and the sintering of Examples 1 to 10 is performed. Small compared to union. Moreover, the uneven color was seen by the sintered compact of Comparative Examples 1-7.

According to the method for producing an alumina sintered body of the present invention, as air is supplied to the firing atmosphere, as shown schematically in FIG. , Ti of TiO ₂ (subsidiary raw material) enters Al ₂ O ₃ in the form of Ti ⁴⁺ to promote a solid solution reaction. Particles coarsened by a solid solution reaction can contribute to the promotion of the processing by intragranular fracture during the processing of the sintered body. Therefore, the processability of the alumina sintered body of the present invention is improved and the processing cost is increased. Reduction.

Since the volume of the grain boundary phase decreases with the growth of Al ₂ O ₃ grains, ions such as Na ⁺ and K ⁺ derived from impurities inevitably contained in the raw material are difficult to perform ion jumping or grain boundary movement. Is realized. This stabilizes the dielectric loss tan δ of the alumina sintered body of the present invention (see Tables 1 and 2).

However, there is a limit to the amount that Ti ⁴⁺ can dissolve in Al ₂ O ₃ (solid solution limit). For this reason, when an auxiliary material is added excessively with respect to the main material, TiO _{2 that} is not solid-solution partitioned reacts with Al ₂ O ₃ to form Al ₂ TiO ₅ (aluminum titanate) at the grain boundary. Once formed, Al ₂ TiO ₅ decomposes into Al ₂ O ₃ and TiO ₂ during firing and cooling as schematically shown in FIG. 3B.

  Due to the effect of this decomposition, the sintered body changes its color to blue or dark blue. Furthermore, the coloration is not constant inside and outside the sintered body, and color unevenness such as a difference in hue or a difference in brightness is likely to occur (see Table 2 Comparative Examples 1 to 9 and FIG. 4B).

Therefore, after the molded body is fired at 1400 to 1600 [° C.] for 3 hours or more, the temperature lowering rate to the ambient temperature 700 [° C.] of the molded body is controlled to 5 to 30 [° C./hr]. Thereby, it is inferred that the decomposition reaction of Al ₂ TiO ₅ is made uniform and the coloration of the sintered body is stabilized (see Table 1 Examples 1 to 10 and FIG. 4A).

Claims (3)

A Ti compound as an auxiliary material is contained in an amount of 0.1 to 2.0 parts by weight in terms of TiO _{2 with} respect to 100 parts by weight of Al ₂ O ₃ as a main material, and a dielectric loss tan δ at a frequency of 1 MHz to 5 GHz is 10 ^−4. An alumina-based sintered body, which is a table, has a grinding resistance of 20 [kgf] or less, and has no color unevenness in an arbitrary cut surface. A method for producing the alumina sintered body according to claim 1,
A raw material is prepared by adding 0.1 to 2.0 parts by weight of a Ti compound as an auxiliary raw material in terms of TiO ₂ with respect to 100 parts by weight of Al ₂ O ₃ as a main raw material,
Create a molded body by molding the raw material,
The molded body is fired at 1400 to 1600 [° C.] for 3 hours or more while controlling the air supply amount per 1 [m ³ ] of the molded body at 8 to 25 [L / min], and then the molded body. The said alumina sintered body is manufactured by cooling the said molded object, controlling the temperature-fall rate of the atmospheric temperature of 5-30 [degreeC / hr]. The method of claim 2, wherein
A method of controlling a ratio of an air supply amount per atmosphere 1 [m ³ ] of the molded body to a TiO ₂ equivalent addition amount of the auxiliary raw material with respect to 100 parts by weight of the main raw material to 8 to 93.75. .