WO2014002580A1 - 溶射材料及びその製造方法 - Google Patents
溶射材料及びその製造方法 Download PDFInfo
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- WO2014002580A1 WO2014002580A1 PCT/JP2013/061019 JP2013061019W WO2014002580A1 WO 2014002580 A1 WO2014002580 A1 WO 2014002580A1 JP 2013061019 W JP2013061019 W JP 2013061019W WO 2014002580 A1 WO2014002580 A1 WO 2014002580A1
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- yttrium
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
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- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
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- C04B35/62605—Treating the starting powders individually or as mixtures
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- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
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Definitions
- the present invention relates to a thermal spray material containing yttrium and a manufacturing method thereof.
- Halogen gas is used in the etching process in the manufacture of semiconductor devices.
- the inside of the etching apparatus is generally coated by spraying a material having high corrosion resistance.
- a material containing a rare earth element is often used.
- thermal spray materials containing rare earth elements include, for example, rare earth elements having an average primary particle diameter of 10 ⁇ m or less, an aspect ratio of 2 or less, an average particle diameter of 20 to 200 ⁇ m, and a bulkiness of 30% or less.
- a thermal spray material made of a granulated powder of fluoride is known (see Patent Document 1).
- spherical particles for thermal spraying which are formed from a compound containing rare earth elements (including yttrium) and have a fracture strength of 10 MPa or more and an average particle size of 10 to 80 ⁇ m are also known (see Patent Document 2).
- the thermal spray material described in Patent Document 1 is manufactured by granulating rare earth fluoride with a spray dryer using a binder and firing it at a temperature of 600 ° C. or lower.
- the thermal spray material described in this document has improved the flowability of particles compared to the non-granulated thermal spray material, but the flowability is still not fully satisfactory.
- the thermal spray film produced using the thermal spray material described in the same document has higher corrosion resistance against F-based plasma than conventional ceramic-based (for example, alumina) thermal spray film, but has a problem of low corrosion resistance against Cl-based plasma. There was also.
- the spherical particles for thermal spraying in Patent Document 2 are produced by granulating a fine powder slurry of a rare earth element-containing compound with a granulator, and then firing it at 1200 ° C. to 1800 ° C. when the compound is an oxide.
- firing conditions and the like for rare earth element-containing compounds other than oxides are not described in this document.
- an object of the present invention is to provide a thermal spray material capable of eliminating various drawbacks of the above-described conventional technology.
- the present invention has been made based on the above findings, and provides a thermal spray material having granules containing yttrium oxyfluoride (YOF).
- YOF yttrium oxyfluoride
- the present invention also provides a method for producing the thermal spray material, A first step of firing yttrium fluoride (YF 3 ) in an oxygen-containing atmosphere at 750 ° C. to 1100 ° C. to obtain yttrium oxyfluoride (YOF); A second step of pulverizing the yttrium oxyfluoride (YOF) obtained in the first step; A third step of mixing the crushed yttrium oxyfluoride (YOF) obtained in the second step with a solvent to obtain a slurry; A fourth step of granulating the slurry obtained in the third step with a spray dryer to obtain a granulated product; And a fifth step of obtaining granules of yttrium oxyfluoride (YOF) by baking the granulated product obtained in the fourth step at a temperature of 300 ° C. to 900 ° C. is there.
- YOF yttrium fluoride
- FIG. 1 is an X-ray diffraction pattern of a thermal spray material obtained in Example 4.
- the thermal spray material of the present invention contains yttrium oxyfluoride, that is, yttrium oxyfluoride represented by YOF.
- the yttrium oxyfluoride (YOF) in the present invention is a compound comprising yttrium (Y), oxygen (O), and fluorine (F).
- YOF may consist of only one of these compounds, or a combination of two or more.
- the thermal spray material of this invention may be comprised only from YOF, or may contain another substance in addition to YOF so that it may mention later.
- the thermal spray material of the present invention has granules containing YOF.
- the thermal spray material of this invention may consist only of the granule containing YOF, and may have particles of forms other than a granule. Examples of the particles having a form other than the granule include those in which the granule is partially pulverized into primary particles.
- the thermal spray material of the present invention has granules and particles other than granules, the composition of the granules and particles other than granules is generally the same.
- the granules referred to in the present invention are particles having an average particle diameter of preferably 20 ⁇ m to 200 ⁇ m. The average particle size is more preferably 25 ⁇ m to 100 ⁇ m.
- the sprayed material can be efficiently supplied into the frame during spraying.
- the average particle size of the granule is 200 ⁇ m or less, the sprayed material can be completely dissolved in the frame, thereby improving the smoothness of the sprayed film.
- a spray drying method described later may be employed and the granulation conditions may be set appropriately.
- the average particle size of the granules can be measured using, for example, a laser diffraction / scattering particle size / particle size distribution measuring apparatus.
- a laser diffraction / scattering particle size / particle size distribution measuring apparatus for example, a micro truck HRA manufactured by Nikkiso Co., Ltd. can be used.
- the sample is dispersed in a 0.2% by mass sodium hexametaphosphate aqueous solution at a concentration of 0.2 g / L to 2 g / L. Since there is a concern that the destruction of the granules may occur when the ultrasonic irradiation is performed during dispersion, it is preferable not to perform the ultrasonic irradiation.
- the particle diameter D 50 at which the integrated volume from the small particle diameter side is 50% is defined as the average particle diameter.
- the shape of the granule is not particularly limited.
- the shape is generally spherical.
- the thermal spray material made of granules preferably has a breaking strength of 0.3 MPa or more and less than 10 MPa, and more preferably 0.5 MPa or more and 9 MPa or less.
- the breaking strength of the granule is 0.3 MPa or more, it is possible to effectively prevent the granule from being damaged.
- Preventing the breakage of the granules is advantageous in that the flowability of the granules is prevented from being lowered, and the granules can be efficiently fed into the frame during spraying.
- the fracture strength of the granules is less than 10 MPa, the sprayed material is easily crushed in the frame, and the sprayed material is easily dissolved in the frame.
- the smoothness of the sprayed film can be enhanced.
- a spray drying method described later may be employed, and the firing conditions for firing the resulting granulated product may be appropriately set.
- Hiramatsu, Oka, Kiyama, Vol.81 No. 932, 1024-1030 (1965-12) “Rapid test of rock tensile strength with non-shaped specimen” (14 It can be measured based on -a) and (14-b). Specifically, the measurement is performed according to the following procedure. A test screen having a mesh size of 53 ⁇ m is placed on a test screen having a mesh size of 45 ⁇ m, and a sprayed material is put on the mesh screen having a mesh size of 53 ⁇ m. Granules that pass through a sieve having an aperture of 53 ⁇ m and that have not passed through a sieve having an aperture of 45 ⁇ m are collected and used as a sample for measurement.
- the compression load of the sample is measured with a flat indenter of ⁇ 50 ⁇ m.
- the measurement conditions are a test load of 9.8 mN (1 gf) and a load speed of 0.446 mN / sec.
- the compressive load of the sample is P (unit: N) and the particle size is d (unit: mm)
- the fracture strength St (unit: MPa) of the granule is calculated from the following equation (1).
- St 2.8P / ( ⁇ d 2 ) (1)
- the thermal spray material of the present invention contains YOF, and may further contain yttrium fluoride, that is, yttrium fluoride represented by YF 3 .
- the sprayed material of the present invention is preferably composed only of YOF.
- YF 3 is included.
- the degree to which YF 3 is contained in YOF can be controlled by the firing conditions in the first step in the method for producing a thermal spray material of the present invention described later. Note that it is not easy to accurately measure the amount of fluorine contained in the thermal spray material of the present invention. Therefore, in the present invention, the sprayed material is measured by X-ray diffraction, and the content of YF 3 is estimated from the value of the relative intensity of the main peak of YF 3 with respect to the main peak of YOF.
- the thermal spray material of the present invention contains oxygen.
- the amount of oxygen contained in the thermal spray material is preferably 0.3% by mass to 13.1% by mass, regardless of whether the thermal spray material contains YF 3 or not.
- the thermal spray material can be stably supplied at the time of thermal spraying, which makes it easier to obtain a smooth thermal spray film.
- the oxygen content 13.1% by mass or less it is effectively prevented that yttrium oxide, which is a substance that reduces the corrosion resistance of the sprayed film, is generated in the sprayed material. As a result, a decrease in the corrosion resistance of the sprayed film can be effectively prevented.
- the amount of oxygen contained in the thermal spray material is more preferably 0.4% by mass to 10.0% by mass, and further preferably 0.5% by mass to 5.0% by mass.
- the amount of oxygen contained in the thermal spray material may be appropriately set, for example, under conditions for firing YF 3 in an oxygen-containing atmosphere in the thermal spray material manufacturing method described later.
- the amount of oxygen contained in the thermal spray material can be measured by, for example, EMGA-920 which is an oxygen / nitrogen measuring device manufactured by Horiba, Ltd.
- the thermal spray material of the present invention may contain YF 3 in addition to YOF.
- the thermal spray material does not contain Y 2 O 3 which is an oxide of yttrium as much as possible. From the standpoint of corrosion resistance, etc., particularly from the viewpoint of corrosion resistance to chlorine-based gas.
- the conditions for firing YF 3 in an oxygen-containing atmosphere are set appropriately. That's fine.
- Y 2 O is determined from the intensity of the diffraction peak when the thermal spray material is measured by X-ray diffraction.
- the content of 3 is to be estimated.
- the relative intensity of the maximum diffraction peak derived from Y 2 O 3 is obtained.
- the relative strength is preferably 10 or less, more preferably 5 or less, and even more preferably 1 or less.
- part of yttrium (Y) may be substituted with at least one rare earth element (Ln) other than yttrium.
- Ln rare earth element
- various properties of the sprayed film such as heat resistance, wear resistance, and corrosion resistance, can be further enhanced.
- the rare earth element (Ln) other than yttrium at least one element selected from Sc, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu is used. Can be mentioned.
- the molar fraction of Ln with respect to the sum of Y and Ln in the thermal spray material may be 0.01 or more and 0.2 or less. Preferably, it is 0.02 or more and 0.1 or less.
- yttrium fluoride and a rare earth fluoride are used as raw materials used in the first step in the thermal spray material manufacturing method of the present invention described later. Can be used together.
- the YOF used in the thermal spray material of the present invention has the advantage that the fracture strength of the granules can be increased as compared with yttrium fluoride, which has been conventionally proposed as an yttrium-based thermal spray material. Can be efficiently supplied into the frame.
- YOF also has an advantage that it can form a more uniform sprayed film because it has a lower melting point than yttrium fluoride.
- the yttrium fluoride is easily attacked by oxygen radicals in the plasma by the cleaning gas, and is easily transformed into oxyfluoride by the attack. As a result, defects such as cracks are likely to occur in the sprayed film.
- YOF since YOF is not easily attacked by oxygen radicals in the plasma due to the cleaning gas, there is an advantage that defects are hardly generated in the sprayed film and particles are hardly generated.
- Yttrium fluoride (YF 3 ) is fired at 750 ° C. to 1100 ° C. in an oxygen-containing atmosphere to obtain yttrium oxyfluoride (YOF).
- Second step The yttrium oxyfluoride (YOF) obtained in the first step is pulverized.
- Step 5 The granulated product obtained in Step 4 is calcined at a temperature of 300 ° C. to 900 ° C. to obtain yttrium oxyfluoride (YOF) granules.
- YOF yttrium oxyfluoride
- yttrium fluoride which is a fluoride of yttrium
- YF 3 which is a fluoride of yttrium
- rare earth element-substituted yttrium fluoride in which a part of yttrium in yttrium fluoride is substituted with at least one rare earth element (Ln) other than yttrium can be used.
- these are collectively referred to as “yttrium fluoride and the like”.
- yttrium and rare earth elements (Ln) other than yttrium are collectively referred to as “yttrium and the like”.
- yttrium oxyfluoride and yttrium oxyfluoride in which a part of yttrium in yttrium oxyfluoride is substituted with at least one rare earth element (Ln) other than yttrium are collectively referred to as “yttrium oxyfluoride etc.” To tell.
- Yttrium fluoride and the like can be synthesized by various methods. In particular, wet synthesis is preferable from the viewpoint that a uniform high-purity product can be easily obtained.
- Yttrium fluoride is a solution obtained by dissolving a compound such as yttrium soluble in acid such as oxide, carbonate and hydroxide with nitric acid or hydrochloric acid, or nitrate and chloride such as yttrium.
- a solution obtained by dissolving a water-soluble compound with water or water and an acid and a fluorine-containing water-soluble compound such as hydrofluoric acid and ammonium fluoride are mixed to produce a precipitate such as yttrium fluoride.
- carbonate such as yttrium, oxalate, hydroxide or oxide is made into a slurry with water, and a fluorine-containing water-soluble compound is added to this slurry to produce a precipitate such as yttrium fluoride.
- the precipitate is washed and filtered, and further dried.
- yttrium fluoride or the like is baked, thereby generating yttrium oxyfluoride, which is an oxyfluoride such as yttrium.
- the degree of production of yttrium oxyfluoride and the like can be appropriately controlled by the firing conditions described below. Generally speaking, when the firing temperature is increased or the firing time is increased, the degree of generation of yttrium oxyfluoride and the like increases and the remaining amount of yttrium fluoride and the like decreases. If the firing temperature is further increased or the firing time is further increased, yttrium oxide or the like begins to be produced as a by-product.
- the firing temperature of yttrium fluoride or the like in this step is preferably 750 ° C. to 1100 ° C.
- the firing temperature of yttrium fluoride or the like is more preferably 800 ° C. to 1050 ° C., and further preferably 850 ° C. to 1000 ° C.
- the firing time is 1 hour to 48 hours, particularly 2 hours to 36 hours, provided that the firing temperature is within the above-mentioned range, in order to sufficiently produce yttrium oxyfluoride and the like. It is preferable from the viewpoint of suppressing excessive generation.
- the firing atmosphere is desirably an oxygen-containing atmosphere from the viewpoint of producing yttrium oxyfluoride or the like from yttrium fluoride or the like as a raw material.
- oxygen-containing atmosphere the use of air is simple because it does not require adjustment of the atmosphere.
- yttrium oxyfluoride or the like containing or not containing yttrium fluoride or the like is obtained depending on the degree of firing. Therefore, in the following description, yttrium oxyfluoride containing or not containing yttrium fluoride or the like is collectively referred to as “yttrium oxyfluoride”.
- the yttrium oxyfluoride obtained in the first step is pulverized.
- the pulverization either dry pulverization or wet pulverization can be used.
- the pulverization may be performed in one stage, or may be performed in two or more stages.
- crushing in two or more stages it is preferable to perform crushing in two stages from the viewpoint of cost and labor.
- the present step and the third step described below can be performed.
- dry pulverization various dry pulverizers such as a grinder, a jet mill, a ball mill, a hammer mill, and a pin mill can be used.
- wet pulverizers such as a ball mill and a bead mill can be used.
- the degree of pulverization of yttrium oxyfluoride in this step is preferably such that D 50 measured using a laser diffraction / scattering particle size / particle size distribution measuring device is 0.3 to 5 ⁇ m.
- D 50 is more preferably 0.5 to 3 ⁇ m.
- the pulverized yttrium oxyfluoride obtained in the second step is stirred and mixed in a solvent to obtain a slurry.
- a solvent for example, water and various organic solvents can be used.
- the concentration of yttrium oxyfluoride in the slurry is set to 100 g / L to 2000 g / L, particularly 200 g / L to 1500 g / L from the viewpoint that a granulated product can be successfully obtained by the spray dryer method performed after this step. preferable.
- the slurry obtained in the third step is granulated with a spray dryer to obtain a granulated product of yttrium oxyfluoride.
- the rotation speed of the atomizer when operating the spray dryer is preferably 5000 min ⁇ 1 to 30000 min ⁇ 1 .
- the rotational speed is set to 5000 min ⁇ 1 or more, the yttrium oxyfluoride can be sufficiently dispersed in the slurry, whereby a uniform granulated product can be obtained.
- the rotation speed is more preferably 6000 min ⁇ 1 to 25000 min ⁇ 1 .
- the inlet temperature when the spray dryer is operated is preferably 150 ° C to 300 ° C.
- the inlet temperature is preferably 150 ° C to 300 ° C.
- the solid content can be sufficiently dried, and it becomes easy to obtain granules with little remaining water.
- wasteful energy consumption can be suppressed by setting the inlet temperature to 300 ° C. or lower.
- the granulated product obtained in the fourth step is fired to obtain granulated granules of yttrium oxyfluoride.
- the breaking strength of the granules can be controlled.
- the firing temperature is preferably 300 ° C to 900 ° C. By setting the firing temperature to 300 ° C. or higher, the breaking strength of the granulated granule can be sufficiently increased. On the other hand, by setting the firing temperature to 900 ° C. or less, it is possible to prevent the fracture strength of the granulated granules from becoming excessively high. From these viewpoints, the firing temperature is more preferably 350 ° C. to 800 ° C., and further preferably 400 ° C. to 700 ° C.
- the firing time is more preferably 1 hour to 48 hours, more preferably 2 hours to 36 hours, provided that the firing temperature is within the above range. Firing is generally easy to perform in an air atmosphere, but the firing may be performed in other atmospheres, for example, in an inert atmosphere.
- the thermal spray material thus obtained is suitably used for various thermal sprays, for example, plasma spraying.
- the base material to be sprayed for example, various metals such as aluminum, various alloys such as an aluminum alloy, various ceramics such as alumina, quartz, and the like are used.
- the thermal spray material of the present invention can be suitably used not only as a thermal spray material but also as another material, for example, a material for ceramic parts.
- a ceramic part having excellent smoothness and particle resistance can be obtained. it can.
- Such ceramic parts are suitably used for electronic materials and jigs for firing them, for example.
- Example 1 a thermal spray material composed of granules of YOF and YF 3 was produced according to the following steps (a) to (d).
- (C) Fourth step The slurry obtained in the third step was granulated and dried using a spray dryer (Okawara Chemical Co., Ltd.) to obtain a granulated product.
- the operating conditions of the spray dryer were as follows. ⁇ Slurry supply speed: 300 mL / min ⁇ Atomizer speed: 9000 min -1 ⁇ Inlet temperature: 200 °C
- (D) Fifth Step The granulated product obtained in the fourth step was put in an alumina container and fired in an electric furnace in an air atmosphere to obtain granulated granules.
- the firing temperature was 600 ° C. and the firing time was 12 hours.
- the average particle diameter D 50 of the granules was measured by the above-mentioned method, and was about 50 ⁇ m (the values were almost the same in the examples and comparative examples described below).
- the shape was substantially spherical. Thus, the target thermal spray material was obtained.
- Examples 2 to 11 and Comparative Example 1 A thermal spray material was obtained in the same manner as in Example 1 except that yttrium fluoride was baked in the first step of Example 1 under the conditions shown in Table 1.
- Example 2 In this comparative example, a thermal spray material of yttrium oxide was manufactured. Using commercially available yttrium oxide, the same steps as the second to fourth steps in Example 1 were performed. Subsequently, the same process as the 5th process in Example 1 was performed. However, the firing temperature was 1300 ° C. Thus, the intended thermal spray material was obtained.
- Example 12 In this example, a thermal spray material in which a part of yttrium is substituted with a rare earth element (Ln) other than yttrium is manufactured.
- A 1st process
- i Wet synthesis of fluoride of yttrium and samarium
- yttrium oxide and samarium oxide was used instead of yttrium oxide used in the first step in Example 1, a mixture of yttrium oxide and samarium oxide was used. The amounts used of both were as shown in Table 2 below. This mixture was put into 40 L of stirred pure water to obtain a slurry. After adding 55 L of 15 mol / L nitric acid aqueous solution at a rate of 5 L / min, stirring was continued for 30 minutes.
- Example 13 to 16 This example is also an example in which a thermal spray material in which a part of yttrium is substituted with a rare earth element (Ln) other than yttrium is produced in the same manner as in Example 12.
- a thermal spray material in which a part of yttrium is substituted with a rare earth element (Ln) other than yttrium is produced in the same manner as in Example 12.
- the rare earth oxides shown in Table 2 below were used in the proportions shown in the same table. Except this, it carried out similarly to Example 12, and obtained the target thermal spray material.
- a 100 mm square aluminum alloy plate was used as the substrate.
- Plasma spraying was performed on the surface of the substrate.
- TWIN-SYSTEM 10-V manufactured by Plasma Technique was used as a spraying material supply device.
- F4 manufactured by Sulzer Metco was used as a plasma spraying apparatus. Plasma with a stirring speed of 50%, carrier gas flow rate of 2.5 L / min, supply scale of 10%, plasma gas Ar / H 2 , output of 35 kW, and apparatus-substrate distance of 150 mm so that the film thickness is about 100 ⁇ m.
- Thermal spraying was performed.
- the arithmetic average roughness (Ra) and the maximum height roughness (Rz) (JIS B 0601: 2001) of the surface of the sprayed coating thus obtained were measured with a stylus type surface roughness measuring instrument (JIS B0651: 2001). It was measured.
- Plasma etching was performed on the sprayed film of a 100 mm square aluminum alloy that was plasma sprayed.
- a silicon wafer having a diameter of 3 inches was placed in the chamber.
- the number of particles having a particle size of about 0.2 ⁇ m or more among particles adhering to the surface of the silicon wafer by being etched by the etching action was measured using a magnifying glass.
- the plasma etching conditions were F-based plasma as follows.
- the thermal spray material of each example has higher fluidity than the thermal spray material of the comparative example, and when thermal spraying is performed using the thermal spray material of each example, a thermal spray film having a low degree of unevenness on the surface can be obtained. . Furthermore, it can be seen that when the thermal spray material of each example is used, the degree of generation of particles is lower than when the thermal spray material of the comparative example is used. That is, it can be seen that the thermal spray film obtained using the thermal spray material of the example shows excellent corrosion resistance not only for the F-based plasma but also for the Cl-based plasma.
- the thermal spray material of the present invention has a higher granule fracture strength and better granule fluidity than a thermal spray material using yttrium fluoride.
- the thermal spray material of the present invention has a lower melting point than that of a thermal spray material using a yttrium fluoride.
- the thermal spray material of the present invention can easily obtain a uniform thermal spray film as compared with the thermal spray material using a yttrium fluoride.
- defects such as cracks are hardly generated in the sprayed film.
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Abstract
Description
イットリウムのフッ化物(YF3)を750℃~1100℃にて酸素含有雰囲気中で焼成してイットリウムのオキシフッ化物(YOF)を得る第1工程と、
第1工程で得られたイットリウムのオキシフッ化物(YOF)を粉砕する第2工程と、
第2工程で得られた粉砕されたイットリウムのオキシフッ化物(YOF)を溶媒と混合してスラリーを得る第3工程と、
第3工程で得られたスラリーをスプレードライヤーで造粒して造粒物を得る第4工程と、
第4工程で得られた造粒物を300℃~900℃の温度で焼成してイットリウムのオキシフッ化物(YOF)の顆粒を得る第5工程と、を含む溶射材料の製造方法を提供するものである。
St=2.8P/(πd2) (1)
・第1工程:イットリウムのフッ化物(YF3)を750℃~1100℃にて酸素含有雰囲気中で焼成してイットリウムのオキシフッ化物(YOF)を得る。
・第2工程:第1工程で得られたイットリウムのオキシフッ化物(YOF)を粉砕する。
・第3工程:第2工程で得られた粉砕されたイットリウムのオキシフッ化物(YOF)を溶媒と混合してスラリーを得る。
・第4工程:第3工程で得られたスラリーをスプレードライヤーで造粒して造粒物を得る。
・第5工程:第4工程で得られた造粒物を300℃~900℃の温度で焼成してイットリウムのオキシフッ化物(YOF)の顆粒を得る。
本工程においては、原料としてイットリウムのフッ化物であるフッ化イットリウム(YF3)を用いる。またフッ化イットリウムにおけるイットリウムの一部が、イットリウム以外の希土類元素(Ln)の少なくとも1種によって置換されている希土類元素置換フッ化イットリウムを用いることもできる。以下の説明においては、これらを総称して「フッ化イットリウム等」と言う。また、イットリウム及びイットリウム以外の希土類元素(Ln)を総称して「イットリウム等」と言う。更に、オキシフッ化イットリウム及びオキシフッ化イットリウムにおけるイットリウムの一部が、イットリウム以外の希土類元素(Ln)の少なくとも1種によって置換されている希土類元素置換オキシフッ化イットリウムを総称して「オキシフッ化イットリウム等」と言う。
本工程では、第1工程で得られたオキシフッ化イットリウム類を粉砕する。粉砕には、乾式粉砕及び湿式粉砕のいずれもが使用可能である。粉砕は1段階で実施してもよく、あるいは2段階以上で実施してもよい。特に、第1工程で得られたオキシフッ化イットリウム類が塊状になっている場合には、2段階以上の粉砕を行い、かつ各段階で適合した粉砕機を使用することが好ましい。2段階以上の粉砕を行う場合には、コストと手間の点から2段階での粉砕を行うことが好ましい。
本工程では、第2工程で得られた、粉砕されたオキシフッ化イットリウム類を溶媒に撹拌混合してスラリーを得る。溶媒の種類に特に制限はなく、例えば水や各種の有機溶媒を用いることができる。本工程の次に行うスプレードライヤー法で造粒物を首尾よく得る点から、スラリー中におけるオキシフッ化イットリウム類の濃度は100g/L~2000g/L、特に200g/L~1500g/Lとすることが好ましい。スラリーの濃度をこの範囲内に設定することで、エネルギーの過度の消費を抑制することができ、またスラリーの粘度が適切なものになって噴霧を安定させることができる。なお、上述した特許文献1においては、スラリー中に結合剤を添加することを必須としていたが、本製造方法によれば結合剤を使用しなくても十分な破壊強度を有する顆粒が得られる。尤も、本製造方法において結合剤を用いることは妨げられない。
本工程では、第3工程で得られたスラリーを、スプレードライヤーで造粒してオキシフッ化イットリウム類の造粒物を得る。スプレードライヤーを運転するときのアトマイザーの回転数は5000min-1~30000min-1とすることが好ましい。回転数を5000min-1以上とすることで、スラリー中でのオキシフッ化イットリウム類の分散を十分に行うことができ、それによって均一な造粒物を得ることができる。一方、回転数を30000min-1以下とすることで、目的とする粒径の顆粒が得られやすくなる。これらの観点から、アトマイザー回転数は6000min-1~25000min-1とすることが更に好ましい。
本工程では、第4工程で得られた造粒物を焼成してオキシフッ化イットリウム類の造粒顆粒を得る。この焼成の程度に応じて、顆粒の破壊強度を制御することができる。詳細には、焼成温度は300℃~900℃であることが好ましい。焼成温度を300℃以上とすることで、造粒された顆粒の破壊強度を十分に高くすることができる。一方、焼成温度を900℃以下とすることで、造粒された顆粒の破壊強度が過度に高くなることを防止することができる。これらの観点から、焼成温度は350℃~800℃とすることが更に好ましく、400℃~700℃とすることが一層好ましい。
本実施例ではYOF及びYF3からなる顆粒からなる溶射材料を、以下の(ア)~(エ)の工程にしたがい製造した。
(i)フッ化イットリウムの湿式合成
99.9%酸化イットリウム300kgを、撹拌した純水400L中に投入してスラリーを得た。そこへ15mol/Lの硝酸水溶液を5L/分の速度で550L添加した後、30分間撹拌を続けた。その後、真空ろ過を行い、Y2O3換算で270g/Lの溶解液1100Lを得た。
この溶解液を撹拌しながら、50%フッ化水素酸300Lを5L/分の速度で添加してフッ化イットリウムの沈殿を生成させた。沈殿の沈降、上澄液抜出、純水添加及びリパルプの各操作を2回実施した後、再度、沈降、上澄液抜出を行った。このようにして得られた泥状物を、ポリ四フッ化エチレン製のバットに入れて150℃で48時間乾燥させた。次いで、乾燥物を粉砕してフッ化イットリウムを得た。このフッ化イットリウムについてX線回折測定を行ったところ、YF3の回折ピークのみが観察され、オキシフッ化イットリウム(YOF)の回折ピークは観察されなかった。
(i)で得られたフッ化イットリウムをアルミナ製の容器に入れ、大気雰囲気下、電気炉中で焼成した。焼成温度及び焼成時間は表1に示すとおりとした。
第1工程で得られた焼成品を純水とともにビーズミルに入れて湿式粉砕した。マイクロトラックHRAにて測定したD50が1.0μm~2.0μmになるように粉砕を実施した。粉砕後、更に純水加えて濃度調整を行い500g/Lのスラリーとなした。
第3工程で得られたスラリーを、スプレードライヤー(大河原化工機(株)製)を用いて造粒・乾燥し、造粒物を得た。スプレードライヤーの操作条件は以下のとおりとした。
・スラリー供給速度:300mL/min
・アトマイザー回転数:9000min-1
・入口温度:200℃
第4工程で得られた造粒物をアルミナ製の容器に入れ、大気雰囲気下、電気炉中で焼成して造粒顆粒を得た。焼成温度は600℃、焼成時間は12時間とした。顆粒の平均粒径D50を上述の方法で測定したところ約50μmであった(以下に述べる実施例及び比較例でもほぼ同じ値であった。)。形状は略球状であった。このようにして、目的とする溶射材料を得た。
実施例1の第1工程におけるフッ化イットリウムの焼成を、表1に示す条件で行う以外は実施例1と同様にして溶射材料を得た。
本比較例では酸化イットリウムの溶射材料を製造した。市販の酸化イットリウムを用い、実施例1における第2工程~第4工程と同様の工程を行った。次いで、実施例1における第5工程と同様の工程を行った。ただし焼成温度を1300℃とした。このようにして目的とする溶射材料を得た。
本実施例は、イットリウムの一部がイットリウム以外の希土類元素(Ln)によって置換された溶射材料を製造した例である。
(ア)第1工程
(i)イットリウム及びサマリウムのフッ化物の湿式合成
実施例1における第1工程で用いた酸化イットリウムに代えて、酸化イットリウムと酸化サマリウムとの混合物を用いた。両者の使用量は以下の表2に示すとおりとした。この混合物を撹拌した純水40L中に投入してスラリーを得た。そこへ15mol/Lの硝酸水溶液を5L/分の速度で55L添加した後、30分間撹拌を続けた。この溶解液を撹拌しながら、50%フッ化水素酸30Lを5L/分の速度で添加して沈殿を生成させた。沈殿の沈降、上澄液抜出、純水添加及びリパルプの各操作を2回実施した後、再度、沈降、上澄液抜出を行った。このようにして得られた泥状物を、ポリ四フッ化エチレン製のバットに入れて150℃で48時間乾燥させた。次いで、乾燥物を粉砕してイットリウム及びサマリウムのフッ化物を得た。
(i)で得られたフッ化物をアルミナ製の容器に入れ、大気雰囲気下、電気炉中で焼成した。焼成温度は900℃、焼成時間は12時間とした。
実施例1と同様にした。これによって、目的とする溶射材料を得た。
本実施例も、実施例12と同様に、イットリウムの一部がイットリウム以外の希土類元素(Ln)のによって置換された溶射材料を製造した例である。実施例12において、第1工程で用いた酸化サマリウムに代えて、以下の表2に示す希土類酸化物を、同表に示す割合で用いた。これ以外は実施例12と同様にして、目的とする溶射材料を得た。
実施例及び比較例で得られた溶射材料について上述した方法で顆粒の破壊強度及び酸素含有量を測定した。また、以下に述べる方法でX線回折測定を行い、X線回折図を得た。得られたX線回折図に基づき、YF3、YFO及びY2O3の各メインピークについて相対強度を算出した。得られたX線回折図の代表例として、実施例4で得られた溶射材料のX線回折図を図1に示す。また、以下に述べる方法で、形成された溶射膜の表面粗さを測定した。更に、以下に述べる方法で、溶射時に顆粒を供給するときの流動性を評価し、パーティクルの発生数を測定した。それらの結果を以下の表3に示す。
・装置:UltimaIV(株式会社リガク製)
・線源:CuKα線
・管電圧:40kV
・管電流:40mA
・スキャン速度:2度/min
・ステップ:0.02度
・スキャン範囲:2θ=20度~40度
基材として100mm角のアルミニウム合金板を使用した。この基材の表面にプラズマ溶射を行った。溶射材料の供給装置として、プラズマテクニック製のTWIN-SYSTEM 10-Vを用いた。プラズマ溶射装置として、スルザーメテコ製のF4を用いた。撹拌回転数50%、キャリアガス流量2.5L/min、供給目盛10%、プラズマガスAr/H2、出力35kW、装置-基材間距離150mmの条件で、膜厚約100μmになるようにプラズマ溶射を行った。これによって得られた溶射膜の表面の算術平均粗さ(Ra)及び最大高さ粗さ(Rz)(JIS B 0601:2001)を、触針式表面粗さ測定器(JIS B0651:2001)で測定した。
上述した「溶射膜の表面粗さ」の測定を行うために行ったプラズマ溶射において、溶射材料の供給装置に顆粒を供給したときの流動性を目視観察し、以下の基準で評価した。
・“非常に良”:顆粒の流動に全く脈動がなく均一に流れている。
・“良”:顆粒の流動に脈動が若干あるが実用上問題がない。
・“不良”:顆粒の流動に脈動が大きく、場合によっては途中で掃除が必要である。
プラズマ溶射を行った100mm角のアルミニウム合金における溶射膜にプラズマエッチングを行った。プラズマエッチングを行うに際しては、チャンバー内には直径3インチのシリコンウエハーを載置しておいた。エッチング作用によって削られて飛散し、シリコンウエハーの表面に付着したパーティクルのうち、粒径が約0.2μm以上のものの数を、拡大鏡を用いて計測した。プラズマエッチング条件は以下のとおり、F系プラズマとした。
・雰囲気ガス CHF3:Ar:O2=80:160:100mL/min
・高周波電力:1300W
・圧力:4Pa
・温度:60℃
・エッチング時間:20時間
また、雰囲気ガスのCHF3をHClに変更してCl系プラズマとした場合についても同様の計測を実施した。
また、表3に示す結果から明らかなとおり、各実施例の溶射材料は比較例の溶射材料よりも破壊強度が高いことが判る。また、各実施例の溶射材料は比較例の溶射材料よりも流動性が高く、各実施例の溶射材料を用いて溶射を行うと、表面の凹凸の程度が低い溶射膜が得られることが判る。更に、各実施例の溶射材料を用いると、比較例の溶射材料を用いた場合よりもパーティクルの発生の程度が低くなることが判る。すなわち、実施例の溶射材料を用いて得られた溶射膜は、F系プラズマだけでなく、Cl系プラズマに対しても優れた耐食性を示すことが判る。
Claims (13)
- イットリウムのオキシフッ化物(YOF)を含む顆粒を有する溶射材料。
- 前記顆粒が更にイットリウムのフッ化物(YF3)を含む請求項1に記載の溶射材料。
- 酸素含有量が0.3質量%~13.1質量%である請求項1又は2に記載の溶射材料。
- 破壊強度が0.3MPa以上10MPa未満である請求項1ないし3のいずれか一項に記載の溶射材料。
- イットリウム(Y)の一部がイットリウム以外の希土類元素(Ln)の少なくとも1種によって置換されており、YとLnの合計に対するLnのモル分率が0.2以下である請求項1ないし4のいずれか一項に記載の溶射材料。
- イットリウム以外の希土類元素(Ln)が、サマリウム(Sm)、ガドリニウム(Gd)、ジスプロシウム(Dy)、エルビウム(Er)及びイッテルビウム(Yb)から選択される少なくとも1種である請求項5に記載の溶射材料。
- 請求項1ないし6のいずれか一項に記載の溶射材料の製造方法であって、
イットリウムのフッ化物(YF3)を750℃~1100℃にて酸素含有雰囲気中で焼成してイットリウムのオキシフッ化物(YOF)を得る第1工程と、
第1工程で得られたイットリウムのオキシフッ化物(YOF)を粉砕する第2工程と、
第2工程で得られた粉砕されたイットリウムのオキシフッ化物(YOF)を溶媒と混合してスラリーを得る第3工程と、
第3工程で得られたスラリーをスプレードライヤーで造粒して造粒物を得る第4工程と、
第4工程で得られた造粒物を300℃~900℃の温度で焼成してイットリウムのオキシフッ化物(YOF)の顆粒を得る第5工程と、を含む溶射材料の製造方法。 - 第1工程で用いるイットリウムのフッ化物(YF3)を湿式合成によって得る請求項7に記載の製造方法。
- 第1工程における酸素含有雰囲気が大気である請求項7又は8に記載の溶射材料の製造方法。
- 第1工程で得られたイットリウムのオキシフッ化物(YOF)を、第2工程において直接湿式粉砕するか又は乾式粉砕後に湿式粉砕して、イットリウムのオキシフッ化物(YOF)のスラリーを得る請求項7ないし9のいずれか一項に記載の溶射材料の製造方法。
- 第1工程において、イットリウムのフッ化物(YF3)を焼成して、イットリウムのフッ化物(YF3)を含むイットリウムのオキシフッ化物(YOF)を得る請求項7ないし10のいずれか一項に記載の溶射材料の製造方法。
- 第1工程で用いるイットリウムのフッ化物(YF3)として、イットリウム(Y)の一部がイットリウム以外の希土類元素(Ln)の少なくとも1種によって置換されたものを用いる請求項7ないし11のいずれか一項に記載の製造方法。
- イットリウム以外の希土類元素(Ln)が、サマリウム(Sm)、ガドリニウム(Gd)、ジスプロシウム(Dy)、エルビウム(Er)及びイッテルビウム(Yb)から選択される少なくとも1種である請求項12に記載の製造方法。
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EP2868766B1 (en) | 2019-01-09 |
JP5396672B2 (ja) | 2014-01-22 |
US9388485B2 (en) | 2016-07-12 |
EP2868766A1 (en) | 2015-05-06 |
KR101591891B1 (ko) | 2016-02-04 |
EP2868766A4 (en) | 2016-02-24 |
US20150096462A1 (en) | 2015-04-09 |
JP2014009361A (ja) | 2014-01-20 |
KR20150005931A (ko) | 2015-01-15 |
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