JPWO2006057232A1 - 窒化珪素質焼結体およびその製造方法、並びに金属溶湯用部材、熱間加工用部材、掘削用部材 - Google Patents
窒化珪素質焼結体およびその製造方法、並びに金属溶湯用部材、熱間加工用部材、掘削用部材 Download PDFInfo
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Abstract
Description
本発明の窒化珪素質焼結体は、組成式Si6-ZAlZOZN8-Zにおける固溶量z値が0.1〜1である低固溶量β−サイアロンを主相とし、残部がRE−Al−Si−Oを含む粒界相とFe珪化物粒子で構成されている。上記粒界相のAl,Si,REの構成比率は、Al2O3、SiO2、RE2O3換算としたときにAl2O35〜50質量%、SiO25〜20質量%、残部RE2O3であり、上記粒界相が焼結体中の20体積%以下である。Fe珪化物粒子の含有量は、Fe換算で焼結体中の0.02〜3質量%である。この窒化珪素質焼結体の熱伝導は、主相である低固溶量β−サイアロン粒子内のフォノンの伝搬と、粒界相内のフォノンの伝搬で決定される。
(第1の製造方法)
次に、本発明の窒化珪素質焼結体の製造方法について説明する。先ず第1の方法として、β化率40%以下の窒化珪素質粉末であって、含有するβ型窒化珪素質部のz値が0.5以下である粉末、すなわち組成式をSi6-ZAlZOZN8-Zとしたときの固溶量z値が0.5以下であるβ化率40%以下の窒化珪素質粉末と、添加物成分としてRE2O3粉末と、Al2O3粉末と、Fe2O3粉末と、あるいはWO3粉末とを混合、成形し、窒素分圧50〜300kPa、温度1800℃以下において開気孔率5%以下となるまで焼成し、その後相対密度96%以上となるまで緻密化させる。
上記のような製造方法によって窒化珪素質焼結体を得ることができるが、本発明の窒化珪素質焼結体では、以下のような第2の製造方法を用いることが好ましい。
この製造方法は、先ず、上述と同様の窒化珪素質粉末と、上記添加物粉末と、金属シリコン粉末とを、(金属シリコン粉末)/(窒化珪素質粉末)の重量比で1〜10となるように混合して成形し、成形体を調製する。ついで、この成形体を、窒素分圧50kPa〜1.1MPa、1000〜1400℃の温度範囲で焼成し、金属シリコン粉末を窒化珪素に変換した多孔質窒化体を調製する、ついで、この窒化体を窒素分圧50〜300kPa、温度1800℃以下において開気孔率5%以下となるまで焼成し、その後相対密度96%以上となるまで緻密化させて、窒化珪素質焼結体を得る。
掘削部材用の耐摩耗シールリング(掘削用部材)、揚水用部品の大型縦軸受け、高温用のボールバルブなどの、ポンプ部品用部材として好適に用いることができる。
火力発電バーナー部品のバーナーリング、保炎リング、高温耐磨耗部品のライニング材、ノズルなどの、エネルギー用部材として好適に用いることができる。
[実施例1]
β化率10%(β―Si6-ZAlZOZN8-Zとしたときのz≦0.1)の窒化珪素質粉末(平均粒径D50=3μm、Al含有量200ppm、酸素含有量0.9質量%)と、Y2O3粉末(平均粒径D50=0.9μm)、Er2O3粉末(平均粒径D50=0.9μm)、Yb2O3粉末(平均粒径D50=2.3μm)、Lu2O3粉末(平均粒径D50=0.6μm)、Al2O3粉末(平均粒径D50=0.5μm)、SiO2粉末(平均粒径D50=1.9μm)、Fe2O3粉末(平均粒径D50=0.6μm)の所定量を、水中にて振動ミルで72時間かけて粉砕混合し、D90=1.5μmとした混合粉末スラリーを作製した。
これらの結果を、表1に併せて示す。
β化率25%(β―Si6-ZAlZOZN8-Zとしたときのz=0.5)の窒化珪素質粉末(平均粒径D50=4.5μm、酸素含有量0.7質量%)と、実施例1記載のY2O3粉末、Al2O3粉末、Fe2O3粉末と、平均粒径5.3μmのWO3粉末をIPA中にて回転ミルで120時間かけて粉砕混合し、D90=1.5μmとした混合粉末スラリーを作製した。
これらの結果を、表2に併せて示す。
実施例2における試料28(B判定)のY−Al−Si−Oを含む粒界相は、粉末X線回折法でメリライト相であることが確認された。同一試料を実施例2と同一セット方法にて1840℃に昇温し、1時間当たり200℃で冷却した(試料28A)。試料は実施例1,2と同様の方法で各種分析し、z値、粒界相の構成比率、Fe,Wの含有量、珪化物種が実施例2の試料28と同一であることを確認した。さらには、JIS R 1607、SEPB法に準じる方法で破壊靱性値を測定した。その結果を、表3に示す。
実施例2における試料31(B判定)は、粒界相中のAl2O3成分が15質量%以下であったため、Y−Al−Si−Oを含む粒界相は、粉末X線回折法で非晶質であることが確認された。同一試料を実施例2と同一セット方法にて1300℃にて3時間保持して熱処理を行った(試料31A)。試料は実施例1、2、3と同様の方法で各種分析し、z値、粒界相の構成比率、Fe,Wの含有量、珪化物種が実施例2の試料31と同一であることを確認した。これらの結果を、表4に併せて示す。
実施例1記載のY2O3粉末8質量%、Al2O3粉末5質量%、SiO2粉末2質量%、Fe2O3粉末1質量%、WO3粉末1質量%と、残部が表5に示す各種窒化珪素粉末とを、水中にてバレルミルで60時間かけて粉砕混合し、D90≦1.5μmとした混合粉末スラリーを作製した。
これらの結果を、表5に併せて示す。
実施例1記載のY2O3粉末10質量%、Al2O3粉末4質量%、Fe2O3粉末1質量%、WO3粉末2質量%と、残部が窒化珪素成分となるように秤量した。窒化珪素成分は、実施例1記載の窒化珪素質粉末(β化率10%、β―Si6-ZAlZOZN8-Zとしたときのz≦0.1、平均粒径D50=3μm、Al含有量200ppm、酸素含有量0.9質量%)と金属シリコン粉末(平均粒径D50=30μm、Al含有量300ppm、Fe含有量5000ppm、酸素含有量0.7質量%)を表6記載の重量比(Si/Si3N4)となるように秤量した。
これらの結果を、表6に併せて示す。
Claims (13)
- 組成式Si6-ZAlZOZN8-Zで表され、固溶量z値が0.1〜1であるβ−サイアロンを主相とし、粒界相およびFe珪化物粒子を含有する窒化珪素質焼結体であり、
前記粒界相は、RE(周期律表第3族元素)−Al−Si−Oを含有し、かつAl、Si、REの構成比率がAl2O3、SiO2、RE2O3換算でAl2O35〜50質量%、SiO25〜20質量%、残部がRE2O3であり、該粒界相を焼結体100体積%に対して20体積%以下の範囲で含有し、前記Fe珪化物粒子をFe換算で焼結体100質量%に対して0.02〜3質量%含有する窒化珪素質焼結体。 - 800℃における熱伝導率が10W/(m・K)以上であり、800℃における四点曲げ強度が500MPa以上である請求項1記載の窒化珪素質焼結体。
- 前記REがYである請求項1記載の窒化珪素質焼結体。
- さらにW珪化物粒子をW換算で焼結体100質量%に対して0.1〜5質量%含有する請求項1記載の窒化珪素質焼結体。
- 前記粒界相が非晶質である請求項1記載の窒化珪素質焼結体。
- 前記粒界相の一部が、ボラステナイト相、アパタイト相、ダイシリケート相およびモノシリケート相から選ばれる少なくとも1種に結晶化している請求項1記載の窒化珪素質焼結体。
- 組成式をSi6-ZAlZOZN8-Zとしたときの固溶量z値が0.5以下であるβ化率40%以下の窒化珪素質粉末と、添加物成分としてRE2O3粉末、Al2O3粉末およびFe2O3粉末とを混合して混合物を調製する工程と、
該混合物を成形して得られる成形体を窒素分圧50〜300kPa、温度1800℃以下で開気孔率5%以下となるまで焼成し、その後相対密度96%以上となるまで緻密化させる工程とを含む請求項1記載の窒化珪素質焼結体の製造方法。 - 組成式をSi6-ZAlZOZN8-Zとしたときの固溶量z値が0.5以下であるβ化率40%以下の窒化珪素質粉末と、金属シリコン粉末とを、重量比[(金属シリコン粉末)/(窒化珪素質粉末)]が1〜10となる割合で混合し、さらに添加物成分としてY2O3粉末、Al2O3粉末およびFe2O3粉末を混合して混合物を調製する工程と、
該混合物を成形して得られる成形体を窒素分圧50kPa〜1.1MPa、1000〜1400℃の温度範囲で焼成し、前記金属シリコン粉末を窒化珪素に変換した多孔質窒化体を調製する工程と、
該多孔質窒化体を窒素分圧50〜300kPa、温度1800℃以下で開気孔率5%以下となるまで焼成し、その後相対密度96%以上となるまで緻密化させる工程とを含む請求項1記載の窒化珪素質焼結体の製造方法。 - 前記多孔質窒化体中の窒化珪素部のβ化率が40%以下、z値が0.5以下である請求項8記載の窒化珪素質焼結体の製造方法。
- 前記混合物に、添加物成分としてさらにWO3粉末を混合する請求項7または8記載の窒化珪素質焼結体の製造方法。
- 請求項1記載の窒化珪素質焼結体からなる金属溶湯用部材。
- 請求項1記載の窒化珪素質焼結体からなる熱間加工用部材。
- 請求項1記載の窒化珪素質焼結体からなる掘削用部材。
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