WO2019194240A1 - 複合セラミックス積層体、及び製造方法 - Google Patents
複合セラミックス積層体、及び製造方法 Download PDFInfo
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- WO2019194240A1 WO2019194240A1 PCT/JP2019/014860 JP2019014860W WO2019194240A1 WO 2019194240 A1 WO2019194240 A1 WO 2019194240A1 JP 2019014860 W JP2019014860 W JP 2019014860W WO 2019194240 A1 WO2019194240 A1 WO 2019194240A1
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Definitions
- the present disclosure relates to a composite ceramic laminate and a manufacturing method.
- Ceramic laminates obtained by laminating a base material and ceramics are used in various fields as structural materials (rolling, conveying rolls, furnace walls, etc.) and functional materials (ceramic insulation circuit boards, etc.).
- the ceramics used vary depending on the application. In each application, in order to obtain excellent strength, fracture toughness, wear resistance, thermal conductivity, heat dissipation, insulation, etc., fine ceramics with particularly high purity and component management standards are used. Examples of fine ceramics include alumina (Al 2 O 3 ), aluminum nitride (AlN), silicon nitride (Si 3 N 4 ), zirconia (ZrO 2 ), and the like.
- Non-Patent Document 1 describes silicon nitride as fine ceramics.
- a composite structure is also adopted in ceramic materials.
- a composite ceramic having a two-phase structure by mixing alumina and zirconia is known (see Patent Document 1 and Patent Document 2).
- Non-Patent Document 2 and Non-Patent Document 3 describe examples in which silicon nitride and zirconia are sintered.
- the composite ceramics described in Patent Document 1 and Patent Document 2 have a structure in which a second phase having a low volume ratio is dispersed in a first phase having a high volume ratio.
- a representative of these composite ceramics is a combination of alumina and zirconia, and is called alumina-dispersed zirconia, zirconia-dispersed alumina, zirconia-reinforced alumina, or alumina-reinforced zirconia.
- combinations of ceramic materials that can be combined are limited.
- a heating step is indispensable for densification.
- a combination system in which an oxide and a nitride react with each other by heat from the heating process, it is difficult to make a composite of ceramic materials. For this reason, ceramic materials cannot be freely combined.
- nitrides and oxides have various mechanical characteristics, electrical characteristics, and thermal characteristics.
- a high temperature of at least 1300 ° C. is required. For this reason, even if the nitride and oxide raw materials are fine crystals, grain growth occurs, and the oxide and nitride react to form an oxynitride.
- a composite ceramic that is a material in which a nitride phase and an oxide phase are combined microscopically as a material has not been realized so far.
- a composite ceramic laminate in which such a composite ceramic is bonded to a base material causes, for example, a reaction between the composite ceramic and the base material in the process for forming the laminate, and a melting of the base material. It is not embodied until.
- Non-Patent Document 2 In an example in which silicon nitride and zirconia are sintered as a composite ceramic, as described in Non-Patent Document 2, a reaction phase such as Si 2 N 2 O is formed by heating for densification. Therefore, it is shown that the structure of the raw material silicon nitride and zirconia is not maintained. Further, as described in Non-Patent Document 3, it is shown that zirconium oxynitride which is easily oxidized is formed and induces cracks.
- a ceramic material using a combination of a nitride and an oxide having physical properties separated from each other in particular, a ceramic material obtained by sintering a combination of a nitride and an oxide is a nitride and an oxide. Since physical properties would react, excellent physical properties could not be obtained.
- the present disclosure is intended to provide a composite ceramic laminate that is a laminate of a composite ceramic having excellent fracture toughness and a base material, and a method for producing the composite ceramic laminate.
- This disclosure includes the following aspects.
- a substrate; A composite ceramic coating the substrate; With The composite ceramic is a composite material including a nitride phase and an oxide phase having an elastic modulus different from the elastic modulus of the nitride phase by 10% or more, and the balance being impurities.
- the phase occupying the largest area ratio is the first phase, the area ratio is 1% or more, and the elastic modulus has the largest difference from the elastic modulus of the first phase.
- the phase is a toughening phase
- the toughening phase is the oxide phase
- the toughening phase is the nitride phase.
- Composite ceramic laminate [2] In the cross section perpendicular to the joint surface between the composite ceramic and the base material, the composite ceramic has a void having a major axis of 0.1 ⁇ m or more in an area ratio of 0% or more and 3% or less.
- Composite ceramic laminate In the cross section perpendicular to the joint surface between the composite ceramic and the base material, the composite ceramic has a void having a major axis of 0.1 ⁇ m or more in an area ratio of 0% or more and 3% or less.
- a composite ceramic laminate that is a laminate of a composite ceramic having excellent fracture toughness and a base material, and a method for manufacturing the composite ceramic laminate are provided.
- the composite ceramic laminate of the present disclosure is a ceramic laminate that is hard to break against thermal and mechanical loads by laminating composite ceramics with high fracture toughness (that is, highly reliable) A ceramic laminate) can be realized.
- the composite ceramic laminate of the present disclosure includes a base material and a composite ceramic that covers the base material.
- the composite ceramic is a composite material including a nitride phase and an oxide phase having an elastic modulus different from the elastic modulus of the nitride phase by 10% or more, with the balance being impurities.
- the phase occupying the largest area ratio of the nitride phase or the oxide phase is the first phase, and the area ratio is 1% or more.
- the phase having the largest difference from the elastic modulus of the first phase is defined as the toughening phase.
- the first phase and the toughening phase are when the first phase is the nitride phase, the toughening phase is the oxide phase, and the first phase is the oxide phase.
- the toughening phase is the nitride phase.
- the “composite ceramic laminate” refers to a structure including a form in which a composite ceramic is coated on a base material.
- “composite ceramics” refers to a state in which nitrides and oxides are microscopically double-phased by being mixed and bonded with a particle diameter of approximately 100 ⁇ m or less.
- the “joint surface” represents a coating interface between the base material and the composite ceramic coated on the base material.
- the nitride phase and the oxide phase having an elastic modulus different from that of the nitride phase by 10% or more are the difference between the elastic modulus of the first phase and the elastic modulus of the toughening phase. Is divided by the elastic modulus of the low-modulus phase of the first phase and the toughening phase, and the 100 fraction is 10% or more. In other words, this term refers to a nitride phase (or oxide phase) and an oxide phase (or nitride phase) having an elastic modulus different from that of the nitride phase (or oxide phase) by 10% or more. It represents that there is, and that the following formula 1 is satisfied.
- the maximum area ratio of the first phase is 99%.
- the “elastic modulus” represents a longitudinal elastic modulus (that is, Young's modulus) of a polycrystal.
- the “impurity” represents a small phase derived from impurities inevitably present, an amorphous phase formed thinly at a crystal grain boundary, and an oxynitride phase.
- the toughening phase when the first phase is a nitride phase, the toughening phase is an oxide phase.
- the first phase is an oxide phase
- the toughening phase is a nitride phase.
- the “second phase” represents a phase occupying the next largest area ratio after the first phase in the composite ceramic. That is, they are referred to as “first phase”, “second phase”, and “third phase” in descending order of area ratio.
- the “particle diameter” represents the diameter of each phase obtained by the intercept method described later, and is distinguished from the crystallographic crystal particle diameter.
- a numerical range expressed using “to” means a range including numerical values described before and after “to” as a lower limit value and an upper limit value.
- the term “process” is not limited to an independent process, and is included in the term if the intended purpose of the process is achieved even when it cannot be clearly distinguished from other processes.
- the term “room temperature” or “room temperature” means a temperature in the range of 20 ° C. ⁇ 15 ° C. (ie, 5 ° C. to 35 ° C.). This temperature is the average temperature of the substrate during film formation. At the moment when the raw material powder collides, it cannot be denied that the temperature of the substrate has risen beyond this microscopically due to the impact of the collision. However, heat generated in a very fine region of the base material is dissipated at that moment, and the temperature of the entire substrate is kept at room temperature (that is, a temperature in the above range).
- the composite ceramic laminate of the present disclosure includes, for example, the following aspects.
- the composite ceramics may be coated on one surface of one surface of the surface facing the thickness direction of the substrate.
- the composite ceramic may be entirely covered on one side of one side (see FIG. 1A).
- the composite ceramic may be partially coated on one surface (see FIG. 1B).
- the composite ceramics may be coated on both surfaces of the one surface and the other surface on the surface facing the thickness direction of the substrate.
- another material (metal or the like) other than the composite ceramic material may be formed on the composite ceramic material (see FIG. 1B).
- the substrate may be a flat plate or may have a curved surface such as a column or cylinder.
- the composite ceramics may be coated on the outer peripheral surface of the cylinder (see FIG.
- the composite ceramic may be coated on the side surface (surface in the thickness direction) of the base material.
- the surface on each substrate may be entirely covered or partially covered.
- different composite ceramics may be coated at different locations on the substrate. Different composite ceramics may be coated in multiple layers.
- 1A to 1D are diagrams showing another example of the form of the composite ceramic laminate according to the present disclosure.
- 1A to 1D show cross sections of the composite ceramic laminate 10 perpendicular to the bonding surface 14 between the composite ceramic 11 and the substrate 12.
- the composite ceramic laminate 10 ⁇ / b> A one surface of a flat substrate 12 is coated with the composite ceramic 11.
- the composite ceramic 11 is entirely covered on one surface of the substrate 12.
- the composite ceramic laminate 10 ⁇ / b> B one surface of a flat substrate 12 is coated with a composite ceramic 11, and a material 13 different from the composite ceramic 11 is coated on the composite ceramic 11.
- materials, such as copper and aluminum, are mentioned, for example.
- the composite ceramic laminate 10 ⁇ / b> B the composite ceramic 11 is partially covered on one surface of the substrate 12.
- the composite ceramic laminate 10 ⁇ / b> C the composite ceramic 11 is coated on the entire outer peripheral surface of the columnar substrate 12.
- the composite ceramic laminate 10D the composite ceramic 11 is coated on the entire inner peripheral surface of the cylindrical substrate 12.
- the composite ceramic laminate of the present disclosure is not limited to the embodiment illustrated in FIGS. 1A to 1D.
- the observation surface for evaluating the structure of the composite ceramic in the composite ceramic laminate of the present disclosure is a cross section perpendicular to the joint surface between the base material and the composite ceramic.
- the composite ceramic laminate is a ceramic laminate in which a composite ceramic is coated on the circumferential surface of a columnar or cylindrical structure as a substrate (for example, conveyance, rolling roll, etc.)
- An arbitrary cross section on a plane perpendicular to the central axis of the cylinder is evaluated as an observation plane.
- the reason for defining the observation surface is that when the composite ceramic structure has anisotropy, the evaluation result may vary depending on the observation cross section.
- the anisotropy of the structure may have a favorable effect on the mechanical and thermal reliability of the composite ceramic laminate.
- the arbitrary cross section refers to a cross section on the inner side of 1 mm or more from the outer edge of the composite ceramic coated on the base material (the coated end perpendicular to the bonding surface). That is, the arbitrary cross section represents a cross section that is 1 mm or more on the inner side from the outer edge of the composite ceramic provided on the base in the cross section orthogonal to the bonding surface between the base and the composite ceramic. A portion near the center in the thickness direction of the composite ceramic in this cross section is observed.
- FIGS. 2A and 2B are diagrams illustrating an example of a composite ceramic observation surface in the composite ceramic laminate of the present disclosure and an example of a direction of a line for evaluating a particle diameter by a section method within the observation surface.
- FIG. 2A shows the observation surface of the composite ceramic laminate 10A
- FIG. 2B shows the observation surface of the composite ceramic laminate 10C. Specifically, as shown in FIGS.
- the intercept method is first performed in a direction perpendicular to the bonding surface 14 in a cross section orthogonal to the bonding surface 14 between the composite ceramic 11 and the substrate 12.
- a line 23 and a line 33 in a direction parallel to the joint surface 14 are drawn.
- it is defined by the average of the length of the intersection between each line 23 or 33 and the crystal grain boundary.
- the line 23 perpendicular to the bonding surface 14 is a straight line regardless of whether the composite ceramic laminate 10 is a flat plate, a cylinder, or a cylinder. If the base material of the composite ceramic laminate is a cylinder or a cylinder and the peripheral surface thereof is coated, the line 33 parallel to the bonding surface 14 becomes an arc as shown by the solid line in FIG. 2B.
- the structure of the composite ceramic is fine, and the size of the observation surface is smaller than the size of the composite ceramic laminate 10. For this reason, a straight line may be drawn approximately in the observation plane to be evaluated.
- the composite ceramic laminate of the present disclosure has excellent toughness (that is, mechanically and thermally highly reliable) as a whole laminate. Therefore, in the composite ceramic constituting the composite ceramic laminate of the present disclosure, a nitride and an oxide are microscopically combined.
- “microscopic” means a state in which the particle diameter is double-phased to a size of approximately 100 ⁇ m or less.
- the laminated body of the ceramic and the base material that are microscopically composited has a form in which the length at the joint surface is approximately 1 mm or more.
- nitride and oxide are expressed as a nitride phase and an oxide phase, respectively.
- a phase in which two or more phases of a nitride phase and an oxide phase are made into a multiphase is expressed as a composite ceramic phase.
- the above-mentioned microscopically composite ceramic composite is coated on the base material, external stress and internal stress caused by the difference in the thermal expansion coefficient between the base material and the composite ceramic due to the temperature rise and fall. Realization of a composite ceramic laminate having high reliability that is difficult to break against a certain thermal stress (that is, against a thermal load) is expected.
- nitrides and oxides are often excellent in strength. Since nitrides and oxides have a wide distribution of Young's modulus and thermal expansion coefficient, a composite ceramic laminate having excellent fracture toughness is realized by microscopically forming a double phase. Many metal nitrides and metal oxides containing a semimetal such as silicon have high insulating properties, and for example, an excellent laminate used as an insulating heat dissipation substrate can be manufactured. Furthermore, these materials can produce a composite ceramic laminate that is chemically stable and excellent in corrosion resistance, and there are also materials having catalytic properties. For example, in the composite ceramic phase, a nitride phase is used as a catalyst carrier and an oxide. Production of a ceramic laminate using the phase as a catalyst can be expected. In addition, by selecting an appropriate combination of nitride and oxide, it is expected to realize a composite ceramic laminate having high mechanical and thermal reliability.
- Nitride and oxide are not particularly limited.
- nitrides and oxides used in engineering ceramics that require mechanical properties are suitable as the materials constituting the composite ceramics.
- the nitride include silicon nitride (Si 3 N 4 ) and aluminum nitride (AlN).
- oxides include zirconium oxide (ZrO 2 ), aluminum oxide (Al 2 O 3 ), magnesia (MgO), silica (SiO 2 ), titania (TiO 2 ), calcia (CaO), and rare earth oxides.
- rare earth oxides include yttria (Y 2 O 3 ) and ceria (CeO 2 ).
- the combination of the nitride and the oxide is not limited to one type each, and a plurality of types may be selected from each of the nitride and the oxide as necessary.
- rare earth oxides such as Y 2 O 3 and CeO 2 have plasma resistance and catalytic properties and are useful as oxides constituting composite ceramics.
- a composite ceramic laminate including a composite ceramic composed of CeO 2 and Si 3 N 4 can be used as a polishing member such as a dresser.
- the elastic modulus of the nitride and the oxide constituting the composite ceramic is different, and the elastic modulus represented by the above-described formula 1 is based on the smaller phase of the constituent phases.
- the ratio is 10% or more.
- the ratio of elastic moduli is desirably different by 20% or more. Considering that there is a concern that the elastic modulus ratio may be destroyed by internal stress if the ratio is too large, it may be 1000% or less.
- the elastic modulus is a three-dimensional one that is expressed as a longitudinal elastic modulus, a transverse elastic modulus, a Poisson's ratio, or originally a tensor.
- the elastic modulus is defined by the longitudinal elastic modulus (that is, Young's modulus) of the polycrystalline body. Young's modulus varies depending on the density of the same substance. In the present disclosure, a value of a polycrystal having a density of 97% or more with respect to the theoretical density is used as the Young's modulus.
- Young's modulus of Al 2 O 3 , ZrO 2 , Y 2 O 3 , CeO 2 , MgO, SiO 2 , TiO 2 , ⁇ -Si 3 N 4 , and AlN are as shown below. is there. Representative values of Young's modulus are 370 GPa (Al 2 O 3 ), 220 GPa (ZrO 2 ), 160 PGa (Y 2 O 3 ), 170 GPa (CeO 2 ), 240 GPa (MgO), 80 GPa (SiO 2 ), 300 GPa (TiO 2 ). ) 290 GPa ( ⁇ -Si 3 N 4 ) and 310 GPa (AlN).
- ⁇ -Si 3 N 4 is 338 GPa, which is a calculated value calculated from Non-Patent Document 1, because it is difficult to manufacture a dense material by a general method.
- the Young's modulus of ⁇ -Si 3 N 4 according to this document is 288 GPa.
- Zirconia can include zirconia in the form of cubic, tetragonal, monoclinic and the like by default in the present disclosure. Zirconia can apply the above Young's modulus in any form.
- the composite ceramic laminate of the present disclosure it is preferable that the composite ceramic is a composite material of a nitride and an oxide, but the void having a major axis of 0.1 ⁇ m or more does not exist or is small. That is, in the composite ceramic, it is preferable that the ratio of voids having a major axis of 0.1 ⁇ m or more that has an effect of reducing fracture toughness on the observation surface defined in the present disclosure is 0% or more and 3% or less.
- the composite ceramic of the present disclosure is dense enough to satisfy the above porosity.
- the fine voids may be slightly contained at 3% or less.
- the voids having a major axis of 0.1 ⁇ m or more may be included in an area ratio of more than 0% and 3% or less.
- a void having a major axis of 0.1 ⁇ m or more may be included in an area ratio of 0.05% or more, or may be included in 0.1% or more.
- a void having a major axis of 0.1 ⁇ m or more may be included in an area ratio of 2% or less, 1% or less, 0.5% or less, or 0.1% or less. May be included.
- the major axis of the gap refers to the largest scissor diameter (that is, caliper diameter) measured by sandwiching the gap from various directions.
- FIG. 3B is an explanatory diagram showing the scissor diameter of the void when the void is present in the composite ceramic of the present disclosure.
- the major axis L is the length of the longest portion in the gap 17 and is expressed as the largest scissor diameter.
- the scissor diameter is obtained from the length between which the gap 17 existing in the structure of the composite ceramic 11 is selected and the longest portion is sandwiched.
- the reason for adopting the major axis is that sharp voids with a large aspect ratio have an effect of lowering the toughness of the composite ceramic. For this reason, it is preferable that a void having a major axis of 0.1 ⁇ m or more enters the measurement.
- the size of the void is determined by the mirror-polished observation surface in the concave portion when observed at a magnification of 20,000 times with a scanning electron microscope having a resolution of 0.1 ⁇ m or more. The part which becomes is judged as a space
- the area ratio of voids having a major axis of 0.1 ⁇ m or more, which is the largest scissor diameter of the recess, is preferably 0% or more and 3% or less as a ratio to the observation field. The larger the area to be evaluated, the closer to the average value of the ceramic material. It is desirable to increase the number of observation fields until it converges to a certain value.
- the area ratio of voids having a major axis of 0.1 ⁇ m or more is an average when 20,000 times scanning electron microscope images are observed for five or more fields.
- the nitrides and oxides constituting the composite ceramic are selected to enhance the properties of the laminate by utilizing each excellent characteristic and microscopically compositing. It is what is done. Therefore, it is not preferable that the nitride and the oxide react with each other.
- the strength depends on the physical properties of the oxynitride phase. And often reduces toughness. For this reason, in the present disclosure, there is no phase different from these phases at a typical interface between the nitride phase and the oxide phase. Alternatively, even if a phase different from the nitride phase and the oxide phase exists, the thickness existing at the interface between the oxide phase and the nitride phase is 0.1 ⁇ m or less.
- a reaction phase that grows by reacting when nitrides and oxides are thermally densified at a high temperature as in a sintering method to form a multiphase is unacceptable.
- a newly generated reaction phase that is not intentionally added as a raw material is unacceptable.
- the oxynitride phase is thin and not very large (generally impurities are at most less than 3% by volume).
- the area ratio of the evaluation surface to be defined is used as the volume ratio, so that the impurity is less than 3% in terms of the area ratio of the cross section defined in the present disclosure. Impurities are allowed because they do not significantly affect the properties of the composite ceramic laminate.
- the impurity evaluation method is as follows. First, the observation surface specified in the present disclosure is mirror-polished. Next, the interface between the nitride phase and the oxide phase is observed with a scanning electron microscope having a resolution of 0.1 ⁇ m or less or a transmission electron microscope at a magnification of 10,000 times or more. As a result of observing the interface between the nitride phase and the oxide phase, if a phase different from the nitride phase and the oxide phase has a thickness of 0.1 ⁇ m or less at 9 interfaces out of 10 interfaces. Good.
- a small phase derived from impurities inevitably existed on the surface and inside of the raw material nitride and on the surface and inside of the raw material oxide, and a thin amorphous formed at the grain boundary.
- the thickness of the phase and the oxynitride phase should be 0.1 ⁇ m or less.
- the impurities that is, the small phase derived from impurities inevitably present, the amorphous phase formed thinly at the crystal grain boundary, and the oxynitride phase
- the impurities include metal oxides, nitrides, and oxynitrides that are different from the raw materials inevitably included in the raw materials.
- the ratio of the oxide phase and the nitride phase in the composite ceramic of the present disclosure should be determined according to the intended use and is not particularly limited. It is preferable that the ratio is such that the composite effect can be effectively exhibited by utilizing the difference in the physical property values of the nitride and the oxide constituting each of the oxide phase and the nitride phase.
- the ratio of the oxide phase and the nitride phase is desirably a volume ratio, and the oxide phase / nitride phase is preferably 1% / 99% to 99% / 1%.
- the volume ratio of the oxide phase / nitride phase represents the ratio between the entire nitride phase and the entire oxide phase.
- the area ratio of the specified evaluation surface is used as the volume ratio.
- the area ratio is measured by extracting a target phase by image processing using a luminance difference obtained by a scanning electron microscope and calculating the area ratio.
- observation is performed at a magnification of 5000 to 50000 times with a scanning electron microscope having a resolution of 0.1 ⁇ m or more, and an average of 5 or more images having different fields of view is used. What is necessary is just to determine the magnification to observe in consideration of the magnitude
- Each of the oxide phase and the nitride phase is confirmed by using an EDS (energy dispersive X-ray analyzer).
- a transmission electron microscope may be used.
- the microscopic form of the nitride phase and oxide phase of the composite ceramic of the present disclosure is not limited.
- the smaller phase is usually dispersed using the larger phase as a matrix.
- the other phase is disposed so as to fill the gap between the particles constituting one phase. Actually, for example, it takes a complicated form as shown in FIG. 3A.
- FIG. 3A is an explanatory diagram of an example of a structure of the composite ceramic according to the present disclosure and a crystal grain evaluation method using a section method.
- FIG. 3A shows the structure of the composite ceramic 11 when a cross section perpendicular to the joint surface 14 between the composite ceramic 11 and the substrate 12 is observed.
- the composite ceramic 11 has a nitride phase 15, an oxide phase 16, and a void 17.
- the structure of the composite ceramic 11 shown in FIG. 3A is a two-component system including one type of nitride phase and one type of oxide phase.
- the nitride phase 15 occupies the largest area ratio among the nitride phase 15 and the oxide phase 16.
- the area ratio of the oxide phase 16 is smaller than the area ratio of the nitride phase 15.
- the phase occupying the largest area ratio in the composite ceramic is defined as the first phase.
- the phase occupying the next largest area ratio after the first phase is defined as the second phase.
- the third phase and the fourth phase are referred to in descending order of area ratio. Therefore, the nitride phase 15 is the first phase. Since the oxide phase 16 is smaller than the area ratio of the nitride phase 15, it becomes the second phase. Further, the oxide phase 16 occupies an area ratio of 1% or more, and exhibits an elastic modulus having the largest difference with respect to the elastic modulus of the first phase. Therefore, the oxide phase 16 is a toughening phase. That is, the oxide phase 16 as the second phase is also a toughening phase. Thus, in the present disclosure, in the composite ceramic, the second phase may be the same phase as the toughening phase.
- the structure of the composite ceramic is not limited to the structure shown in FIG. 3A described above.
- the composite ceramic used in the present disclosure only needs to be densely composited in a system composed of a nitride phase and an oxide phase that has not been realized so far. In order to obtain excellent fracture toughness, which is an effect obtained by combining these, it is desirable that they are combined microscopically.
- the average particle size of the composite ceramic phase is preferably 1 ⁇ m or less, more preferably 0.5 ⁇ m or less in each of the direction perpendicular to and parallel to the joint surface between the composite ceramic and the substrate. desirable.
- the average particle size of the composite ceramic phase may be 0.1 ⁇ m or less, and may contain crystal grains of 0.005 ⁇ m or less that can be observed with a transmission electron microscope.
- the average particle size of the composite ceramic phase is the average particle size of the entire oxide phase and nitride phase.
- the lower limit value of the average particle diameter may be 0.005 ⁇ m or more, which is a size of about 1000 nitride or oxide unit cells.
- the average particle diameter of the oxide phase and the average particle diameter of the nitride phase may be 1 ⁇ m or less, 0.5 ⁇ m or less, or 0.1 ⁇ m or less, respectively.
- 0.005 micrometer or more may be sufficient. As described above, in the present disclosure, it is more desirable to make finer in all phases constituting the composite ceramic.
- the toughening of the composite ceramics which is the object of the present disclosure, can be achieved mainly by the presence of the toughening phase, it is preferable that at least the toughening phase is refined.
- the suitable range of the average particle diameter of an oxide phase and the average particle diameter of a nitride phase may change with the combination of an oxide phase and a nitride phase, the volume ratio (area ratio) of a toughening phase, etc. Is.
- the average particle diameter of the toughening phase in a direction perpendicular to the joint surface is 1 ⁇ m or less in a cross section orthogonal to the joint surface between the composite ceramic and the base material.
- the average particle diameter of each phase (each phase other than the toughening phase such as the first phase) in the direction parallel to the bonding surface is 1 ⁇ m or less.
- the average particle diameter of the toughening phase may be 0.5 ⁇ m or less, or 0.1 ⁇ m or less.
- the average particle diameter of each phase may be 0.5 ⁇ m or less, or 0.1 ⁇ m or less.
- the lower limit of the average particle diameter of the toughening phase and the particle diameter of the second phase defined here may be 0.005 ⁇ m or more.
- the intercept method is adopted as a method for obtaining the average particle diameter of each phase including the toughening phase.
- the average particle diameter is determined as follows (see FIG. 3A). As shown in FIG. 3A, an arbitrary cross section orthogonal to the joint surface between the composite ceramic and the base material is taken as an observation surface. Then, the observation surface is mirror-polished so that the crystal grain boundary can be identified. Next, lines are drawn on both the straight line 28 perpendicular to the joint surface and the straight line 38 parallel to the joint surface. Next, at the intersection 29 where the drawn straight line 28 and the crystal grain boundary intersect, the length between the adjacent intersections 29 is measured.
- the length between the adjacent intersections 39 is measured.
- the average value of the measured length is defined as the average particle diameter.
- the average particle diameter is obtained by distinguishing between a direction perpendicular to the joint surface and a direction parallel to the joint surface.
- the arbitrary cross section refers to a cross section on the inner side of 1 mm or more from the outer edge of the composite ceramic coated on the substrate.
- the average particle diameter in the toughening phase in the direction perpendicular to the joint surface can be obtained as follows. In the composite ceramic structure shown in FIG. 3A, the oxide phase 16 corresponds to the toughening phase as described above.
- the average particle diameter in the toughening phase in the direction perpendicular to the joint surface is the average in the length between the adjacent intersections 39 in the oxide phase 16 with respect to the intersection 39 between the straight line 38 and the oxide phase 16. It is obtained from the value.
- the particle size is measured with a scanning electron microscope having a resolution of 0.1 ⁇ m or more at a magnification of 5000 to 50000 times, and at least 20 particles (preferably 30 or more) are used to calculate the average particle size. Measure. What is necessary is just to set an observation magnification to the magnification which can measure at least 20 or more particles.
- the crystal grain boundary should be determined by confirming the orientation difference between adjacent crystal grains using a transmission electron microscope or the like.
- the crystal grain interface with a large misorientation is usually a slight difference caused by the difference in contrast between crystal grains and the presence of crystal grain boundaries.
- the determination is easily made by the edge effect caused by unevenness. Therefore, the determination of the crystal grain boundary may be performed using the contrast generated in the secondary electron image and the reflected electron image of the scanning electron microscope without confirming the orientation difference.
- a crystal grain boundary determined in this way is defined as a particle boundary, and a particle surrounded by the particle boundary is defined as a particle in the present disclosure. When observed with a transmission electron microscope at a high magnification, finer crystal grains may be present in the particles.
- the particle size definition of the present disclosure uses the particle size.
- the number of slices to be measured (number of crystal grains to be measured) be large. It is desirable to increase the number of intercept measurements until it converges to a certain value.
- the specified observation surface may be mirror-polished. The polished observation surface is evaluated at a magnification of 5,000 to 50,000 times with a scanning electron microscope or a transmission electron microscope having a resolution of 0.1 ⁇ m or less. The observation magnification depends on the size of the structure of the toughening phase.
- the particle diameter in the direction perpendicular to the joint surface with the base material corresponding to the thickness of the composite ceramic is larger than the particle diameter in the in-plane direction parallel to the substrate corresponding to the width of the composite ceramic. Often small. For this reason, it is preferable that the composite ceramic of the present disclosure has a larger effect of inhibiting cracks that propagate in the thickness direction. Accordingly, the shape of the composite ceramic particles of the present disclosure (particularly, particles of the toughening phase) is preferably flattened so as to be crushed in the thickness direction.
- the average particle diameter of the toughening phase in the direction perpendicular to the joint surface between the base material and the composite ceramic is It is desirable that the ratio of the average particle size of the toughening phase in the parallel direction is 1.2 or more (average particle size composite in the direction parallel to the joint surface / average particle in the direction perpendicular to the joint surface) Diameter).
- the average particle size ratio is desirably 1.2 or more for both the oxide phase and the nitride phase regardless of whether the toughening phase is an oxide phase or a nitride phase.
- the nitride applied to the composite ceramic is not limited.
- the nitride is preferably silicon nitride (Si 3 N 4 ) or aluminum nitride (AlN).
- silicon nitride is most preferable.
- Silicon nitride has excellent strength and fracture toughness values among engineering ceramics that require mechanical properties. By using silicon nitride, basic characteristics necessary for the nitride phase constituting the composite ceramic of the present disclosure can be obtained. Silicon nitride belongs to a class having high thermal conductivity among engineering ceramics.
- the thermal expansion coefficient of silicon nitride is about 2.9 ⁇ 10 ⁇ 6 / K, which is a small category among engineering ceramics that require strength. These characteristic thermal properties are useful as a nitride phase constituting the ceramic composite ceramic laminate of the present disclosure. Therefore, by using silicon nitride as the nitride, the composite ceramic laminate is useful for applications such as an insulating heat dissipation substrate, a transport roll, and a rolling roll. In order to improve the thermal conductivity of the composite ceramic, the ⁇ -silicon nitride phase is preferable among the silicon nitrides.
- Silicon nitride includes trigonal ⁇ -Si 3 N 4 and hexagonal ⁇ -Si 3 N 4 . Silicon nitride may include one of the crystal structures or both of the crystal structures.
- the first phase of the composite ceramic may be a nitride phase.
- the nitride phase as the first phase is preferably a silicon nitride phase or an aluminum nitride phase, more preferably a silicon nitride phase, and a ⁇ -silicon nitride phase Is more preferable.
- the oxide applied to the composite ceramic is not limited.
- the oxide is preferably any one of zirconia, alumina, or rare earth oxide.
- zirconia zirconia (ZrO 2 ) is more preferable.
- Zirconia like silicon nitride, is excellent in strength, and is a substance with excellent fracture toughness value in a single ceramic. By using zirconia as the oxide, desirable characteristics can be obtained as an oxide phase constituting the composite ceramic of the present disclosure.
- Zirconia has a thermal expansion coefficient of about 11 ⁇ 10 ⁇ 6 / K, and belongs to the largest class of oxides used as engineering ceramics that require strength. Therefore, by using zirconia, a thermal expansion coefficient close to that of a metal can be obtained. Furthermore, the thermal conductivity of zirconia belongs to the smallest class of oxides used as engineering ceramics. Such characteristic thermal properties of zirconia are useful as an oxide phase constituting the composite ceramic laminate of the present disclosure.
- Zirconia is stable monoclinic at room temperature. By incorporating yttrium, calcium, magnesium, and cerium ions into the zirconia crystal structure, tetragonal crystals and cubic crystals can exist stably at room temperature. Zirconia applied to the composite ceramic laminate of the present disclosure may have any crystal structure.
- the first phase of the composite ceramic may be an oxide phase.
- the oxide phase as the first phase is preferably any of a zirconia phase, an alumina phase, or a rare earth oxide phase, and more preferably a zirconia phase.
- the nitride phase and oxide phase constituting the composite ceramic are silicon nitride phase and zirconia phase, silicon nitride phase and alumina phase, silicon nitride phase and rare earth oxide phase, aluminum nitride phase And a zirconia phase, an aluminum nitride phase and an alumina phase, or an aluminum nitride phase and a rare earth oxide phase.
- a combination of a nitride phase and an oxide phase a combination of a silicon nitride phase and a zirconia phase, an aluminum nitride phase and an alumina phase, or a silicon nitride phase and a rare earth oxide phase is preferable.
- a combination of a silicon nitride phase and a zirconia phase is extremely useful.
- the silicon nitride phase combined with the oxide phase is preferably a ⁇ -silicon nitride phase.
- the combination of the first phase and the toughening phase constituting the composite ceramic includes silicon nitride phase and zirconia phase, silicon nitride phase and rare earth oxide phase, aluminum nitride phase and zirconia phase, or aluminum nitride phase.
- a rare earth oxide phase is preferred.
- a combination of a silicon nitride phase and a zirconia phase, an aluminum nitride phase and a zirconia phase, a silicon nitride phase and a rare earth oxide phase is preferable, and a combination of a silicon nitride phase and a zirconia phase is more preferable.
- the Young's modulus (elastic modulus) of zirconia is about 220 GPa, while that of ⁇ -silicon nitride is about 290 GPa.
- the ratio of these Young's moduli differs by 32% as the value obtained by the above-mentioned formula 1. Therefore, if these substances are combined microscopically and rigidly as a phase constituting the composite ceramic of the composite ceramic laminate of the present disclosure, the composite is formed when a macroscopic stress field or strain occurs. A microscopic and complex stress field is formed inside ceramics. Thereby, the propagation path of cracks in the composite ceramic becomes complicated, and it can be expected that the toughness is improved as compared with the ceramic single phase.
- the thermal characteristics of silicon nitride and zirconia are opposite to each other among engineering ceramics having high mechanical properties. By combining these, characteristics that cannot be obtained with a single phase of silicon nitride and a single phase of zirconia can be expressed.
- micro cracks may be generated inside the material due to a large difference in thermal expansion coefficient between silicon nitride and zirconia.
- the particle size of silicon nitride and zirconia is microscopically combined with the average particle size of the composite ceramic having a size of 1 ⁇ m or less, as described in the structural form [2] of the present disclosure, thermal expansion occurs.
- Microcracks are formed due to the difference in coefficient. This microcrack inhibits the progress of fracture cracks, and can be expected to improve fracture toughness.
- the base material is a metal
- the ratio of the zirconia phase to the silicon nitride phase is increased, the difference in thermal expansion coefficient between the base material in the composite ceramic laminate and the composite ceramic coated on the base material is increased. Get smaller. In this case, the reliability with respect to the thermal cycle of the composite ceramic laminate can be enhanced.
- the ratio of silicon nitride phase to zirconia phase can be widely determined by designing according to the thermal characteristics required by the application.
- the zirconia phase in the composite ceramic is not specified, and may have a plurality of crystal structures.
- the zirconia phase preferably has a tetragonal structure in part of the zirconia phase. If the zirconia phase contains zirconia having a tetragonal crystal, cracks develop and tensile stress is generated at the tip of the crack, and the tetragonal zirconia phase undergoes stress-induced transformation due to the tensile stress. Transform to monoclinic. This transformation can be expected to relieve stress.
- the microcrack produced in the composite ceramics can be expected to inhibit crack propagation and increase the fracture toughness.
- composite ceramics made of a combination of silicon nitride and zirconia is an excellent material.
- this combination is difficult to be densified even when heated at a high temperature in the sintering method.
- a large amount of Si 2 N 2 O, which is a reaction phase of silicon nitride and oxide, is formed, and mechanical and thermal characteristics are impaired.
- Useful combinations other than the combination of silicon nitride and zirconia include a combination of silicon nitride and alumina, and aluminum nitride and alumina.
- the Young's modulus of alumina is about 370 GPa, which is about 28% different from the Young's modulus of ⁇ -silicon nitride ( ⁇ -Si 3 N 4 ).
- the Young's modulus of aluminum nitride is about 310 GPa, which is about 19% different from the Young's modulus of alumina. Therefore, composite ceramics obtained by these combinations can increase fracture toughness compared to single-phase ceramics due to the crack deflection effect.
- the combination of ⁇ -Si 3 N 4 and Al 2 O 3 has a difference in Young's modulus of 5.4%.
- Alumina and magnesia have high thermal conductivity among oxides, and by combining with aluminum nitride or silicon nitride, which has high thermal conductivity, composite ceramics with excellent mechanical properties and heat dissipation can do. Therefore, the composite ceramic coating of such a combination is useful as a ceramic laminate used for an insulating heat dissipation substrate.
- Rare earth oxides have a small Young's modulus and are particularly suitable for compounding with nitrides having a large Young's modulus.
- the film formation rate can be improved and the film thickness can be increased.
- a composite ceramic mainly composed of silicon nitride, zirconia and rare earth oxide have an effect of lowering the porosity.
- a combination of silicon nitride and at least one of zirconia and rare earth oxide is effective for densification.
- the base material in the ceramic laminate of the present disclosure is not limited.
- the substrate may be an inorganic material substrate such as ceramics.
- the substrate may be an organic substrate such as a resin.
- the base material may be a composite base material of an organic substance and an inorganic substance such as CFRP (Carbon Fiber Reinforced Plastics).
- CFRP Carbon Fiber Reinforced Plastics
- the substrate may be a metal substrate.
- the ceramic laminate of the present disclosure is an insulating heat dissipation substrate, an insulating heat dissipation circuit substrate, a transport roll, a rolling roll, and the like. It is desirable that the base material used for these applications is made of metal. In the insulating heat dissipation substrate, it is desirable that copper or aluminum is applied as the metal base material. Further, in the roll, it is particularly desirable that an iron-based metal structural material or a refractory metal material based on nickel is applied as the metal substrate.
- the manufacturing method of the composite ceramic laminate of the present disclosure is not limited.
- a preferred example of the method for producing a composite ceramic laminate of the present disclosure includes a method of controlling the raw material powder and controlling the process conditions to a suitable one using an aerosol deposition method (AD method).
- AD method aerosol deposition method
- the composite ceramic laminate of the present disclosure can be realized.
- nitride particles and oxide raw material particles are mixed with gas, and the nitride raw material particles and oxide raw material particles are injected and collided with the gas toward the surface of the base material layer.
- This is a method of laminating a composite ceramic film on the surface.
- a dense film can be formed at room temperature, and the generation of a reaction phase such as an oxynitride phase at the crystal grain boundary of the composite ceramic can be extremely reduced.
- a preferred example of the method for producing a composite ceramic laminate of the present disclosure includes the following steps.
- nitride raw material particles also called nitride raw material powders
- oxide raw material particles also called oxide raw material powders
- the film formation composition and the mixed composition are greatly different, the composition of the composite ceramic is changed, or only one component in the raw material powder is missing, so that stable film formation for a long time cannot be performed. Therefore, when the film forming composition and the mixed composition are greatly different, a composite ceramic having a large area and a large film thickness cannot be obtained. In this respect, it is much more difficult to form a composite ceramic film by the AD method than when a single-phase film is formed. Therefore, in order to obtain a good composite ceramic film, the form of the raw material powder must be individually examined depending on the configuration of the composite ceramic laminate and the combination of the composite ceramics.
- an aerosol in which nitride raw material particles are mixed in a gas and an aerosol in which oxide raw material particles are mixed in a gas are individually formed, and two aerosols are separately formed. It may be a manufacturing method in which each aerosol is collided with the surface of the base material and the composite ceramics are laminated on the surface of the base material by spraying simultaneously from the nozzles.
- a gas is mixed with a mixed raw material in which nitride raw material particles and oxide raw material particles are mixed with a predetermined composition to generate an aerosol of the mixed raw material, and one nozzle
- the manufacturing method may be such that the aerosol of the mixed raw material is sprayed toward the surface of the base material, the aerosol is collided with the surface of the base material, and the composite ceramic is laminated on the surface of the base material.
- the mixed raw material used as a raw material is kneaded sufficiently sufficiently in advance with nitride raw material particles and oxide raw material particles using a rolling ball mill, planetary ball mill, bead mill, jet mill, or the like. It is important to keep it.
- the nitride raw material particles and oxide raw material particles used as the raw material powder have a median diameter (median diameter) of 10 ⁇ m or less (preferably 1 ⁇ m or less) and 0.1 ⁇ m or more. Particles exceeding 10 ⁇ m are not deposited on the substrate and damage the substrate by the blast effect. If the particles are too fine, the composite ceramic film will not be dense. Also, particles less than 0.1 ⁇ m are likely to aggregate and it is difficult to control the state in the aerosol. In order to uniformly mix the nitride raw material particles and the oxide raw material particles, they are mixed by the above-described ball mill or the like.
- the median diameter is measured using a laser diffraction type particle size distribution measuring device in a wet and sufficiently dispersed state in a medium.
- the gas forming the aerosol is not particularly limited, and examples thereof include an inert gas such as nitrogen gas, helium, and argon. Since helium gas is light, the aerosol injection speed can be increased. In this regard, the use of helium gas widens the process window such as the range of median diameters in which the nitride raw material particles and oxide raw material particles can be formed. Considering the cost, it is desirable to use nitrogen gas as the gas forming the aerosol.
- an inert gas such as nitrogen gas, helium, and argon. Since helium gas is light, the aerosol injection speed can be increased. In this regard, the use of helium gas widens the process window such as the range of median diameters in which the nitride raw material particles and oxide raw material particles can be formed. Considering the cost, it is desirable to use nitrogen gas as the gas forming the aerosol.
- the optimal film formation conditions depend on the size of the raw material.
- the film forming conditions are not particularly limited.
- the film forming gas flow rate so that the flow rate of the passing gas is in the range of 50 m / s to 800 m / s and the pressure in the film forming chamber is in the range of 50 Pa to 1000 Pa.
- the size of the raw material particles of the mixed powder of the nitride raw material particles and the oxide raw material particles is within the above-mentioned median diameter range, and when nitrogen gas is used as the gas for forming the aerosol, the lower limit (50 m / It is desirable to set the flow rate on the s) side. On the other hand, when helium gas is used, it is desirable to set the flow rate on the upper limit (800 m / s) side. When the flow rate of the gas passing through the nozzle is too small, the kinetic energy of the particles is small, so that no film is formed or the green compact has many voids. On the other hand, if the flow rate of the gas passing through the nozzle is too high, the raw material particles contained in the aerosol sprayed toward the base material will destroy the base material and will not form a film.
- the following method is exemplified.
- a composite ceramic film is formed on the peripheral surface of a base material as a columnar or cylindrical workpiece
- the composite ceramic film is formed while rotating about the central axis of the workpiece.
- the following method can be used as in the case of forming a film on the surface of a flat substrate.
- the composite ceramic When a dense composite ceramic is formed by the AD method under suitable conditions, the composite ceramic has a fine structure smaller than the size of the raw material particles. Therefore, the strength of the composite ceramic is increased, and the composite ceramic laminate of the present disclosure has improved mechanical and thermal reliability.
- each nitride phase and oxide phase is the bonding surface with the substrate (surface on which the ceramic laminate is formed).
- a structure flattened in a direction parallel to the film that is, a structure crushed in the film thickness direction of the composite ceramic. Therefore, it is difficult for cracks to advance in the direction perpendicular to the plane of the base material, and it is difficult for breakage to penetrate in the film thickness direction. For this reason, the mechanical reliability of the composite ceramic laminate is enhanced.
- a film formed by the AD method forms a compressive stress field inside.
- the elastic modulus of the nitride phase and the elastic modulus of the oxide phase differ by 10% or more.
- the elastic modulus of the nitride phase and the elastic modulus of the oxide phase are different, it is possible to form a state in which the stress field changes microscopically. As a result, the effect of inhibiting the progress of cracks is further increased.
- the ceramic insulated circuit board In the conventional ceramic insulated circuit board, ceramics and a metal base material such as copper are joined at a high temperature. For this reason, the ceramic insulated circuit board generates a residual thermal stress due to a difference in thermal expansion coefficient between the ceramic coating and the base material, and the ceramic may be destroyed. Further, conventionally, thermal stress is applied to a ceramic insulated circuit board by a process of incorporating semiconductors, peripheral devices, and the like, and repeated thermal cycles during use, and the ceramic may be destroyed.
- the size of the oxide phase and the nitride phase, the form of the oxide phase and the nitride phase, and the compressive stress in the in-plane direction remaining inside the composite ceramic are:
- the stress which destroys the film of such a composite ceramic is relieved. Therefore, when the composite ceramic laminate of the present disclosure is used as a ceramic insulated circuit board, a hot roll, or the like, it can be expected to suppress breakage due to thermal stress caused by repeated thermal cycles during use.
- zirconia In zirconia, monoclinic crystals are stable at room temperature, tetragonal crystals are stable at 1170 ° C. to 2200 ° C. including the sintering temperature range, and cubic crystals are stable at temperatures higher than this temperature range. Therefore, zirconia undergoes non-diffusion transformation from tetragonal to monoclinic when cooled to room temperature after sintering. Since zirconia undergoes a large volume change due to phase transformation, cracks are generated in the oxide phase, which may significantly reduce the mechanical strength. Therefore, in a general sintered body of zirconia, a certain amount of a stabilizer such as yttria, ceria, calcia, magnesia, etc. is added to suppress a decrease in mechanical strength, and a high temperature phase (that is, cubic and tetragonal) To stabilize.
- a stabilizer such as yttria, ceria, calcia, magnesia, etc.
- the crystal form of the oxide phase is not limited when the operating temperature is 1170 ° C. or lower.
- the toughening mechanism that absorbs the energy at the crack tip by the stress-induced transformation of the oxide phase from tetragonal to monoclinic phase, at least some of the oxide phase is It is important to be tetragonal.
- the dense composite ceramic film produced by the manufacturing method of the present disclosure can create a situation in which a phase containing tetragonal oxide is formed under certain process conditions even when monoclinic oxide is used as a raw material. .
- a composite ceramic containing a tetragonal oxide is coated on a base material, a composite ceramic laminate having excellent mechanical properties can be obtained without containing a stabilizer for stabilizing the high-temperature phase. It is advantageous in terms of cost that it is not necessary to intentionally contain expensive yttria.
- the above stabilizers are mixed into the composite ceramic film for reasons such as use at high temperatures, and a cubic oxide phase having excellent tetragonal and mechanical strength, and a nitride phase.
- the amount of yttria as a stabilizer is smaller than that in the sintering method.
- the stabilizer may be 4.5% by mass or less.
- the quantity of the cubic oxide which has ionic conductivity will increase. Therefore, when a cubic oxide is used as the first phase of the composite ceramic as the ceramic insulating substrate, attention should be paid to the insulating property.
- the composite ceramic laminate of the present disclosure and the method of manufacturing the composite ceramic laminate can achieve excellent fracture toughness by the above configuration.
- a composite ceramic in which a nitride phase and an oxide phase having different elastic moduli are finely and densely formed is formed on a substrate. For this reason, strength and toughness are higher than single-phase ceramics, and control of the thermal expansion coefficient and thermal conductivity is expected. In addition, high mechanical reliability and high thermal reliability are expected.
- mechanical reliability and thermal reliability refer to strength as a laminate, fracture resistance to thermal cycling, wear resistance, thermal conductivity, thermal insulation, and the like.
- the composite ceramic is formed on a base material at room temperature (20 ° C. ⁇ 15 ° C.). For this reason, the nitride phase and the oxide phase can be finely and densely combined. Furthermore, even when the composite ceramic is coated on a base material having a difference from the thermal expansion coefficient of the composite ceramic, the residual thermal stress generated at the interface between the composite ceramic and the base is small. For this reason, manufacture of the composite ceramic laminated body with high mechanical reliability and thermal reliability is anticipated.
- the compressive stress field generated in the composite ceramic is formed by superimposing the residual tensile stress generated when the base material and the composite ceramic are joined together with the thermal stress and mechanical stress received during use. It is expected to suppress the breakage that occurs on the side of the composite ceramic in the vicinity of the joint surface between the ceramic and the composite ceramic.
- the thermal stress when forming the composite ceramic laminate is small, there is no limitation on the thickness of the substrate due to the thermal stress. Therefore, by increasing the thickness of the base material, the base material itself can be provided with functions such as a heat sink and a heat spreader.
- ceramic insulated circuit boards are required to have higher heat resistance and higher durability against thermal cycles due to the electrification of automobiles and the use of SiC semiconductors.
- the rolling roll and the transport roll are required to be materials having a tougher roll surface and excellent wear resistance.
- the composite ceramic laminate of the present disclosure has excellent fracture toughness and is expected to have the above characteristics. For this reason, the composite ceramic laminate of the present disclosure is useful for application to, for example, a ceramic insulating substrate applied to a power semiconductor device.
- the composite ceramic laminate of the present disclosure is useful for application to, for example, a rolling roll and a transport roll.
- Example 1 a composite ceramic that is a combination of a silicon nitride phase and a zirconia phase is coated as a combination of an oxide phase and a nitride phase on a copper plate as a base material using an aerosol deposition method. A composite ceramic laminate was prepared. Moreover, a ceramic laminate in which a silicon nitride single phase or zirconia single phase ceramic was coated on a substrate was prepared.
- the silicon nitride raw material powder used as the raw material is ⁇ -silicon nitride containing less than 5% ⁇ -silicon nitride.
- the zirconia raw material powder used as a raw material is zirconia mainly composed of monoclinic crystals to which no stabilizer is added. These powders were weighed to a predetermined amount and kneaded, and kneaded in a planetary ball mill for 24 hours using acetone as a medium.
- the pot and ball of the planetary ball mill were made of ⁇ -silicon nitride, and the size of the ball was ⁇ 5 mm.
- the powder obtained by kneading was heated to 150 ° C. and sufficiently dried. This dried powder was used as a raw material powder.
- the produced raw material powder is as follows. The mixing ratio is based on mass.
- the raw material 1 is a raw material powder of zirconia alone to which no silicon nitride is added.
- the raw material 2 is a raw material powder in which zirconia and silicon nitride are mixed at 17: 3 (zirconia: silicon nitride).
- the raw material 3 is a raw material powder in which zirconia and silicon nitride are mixed in 1: 1 (zirconia: silicon nitride).
- the raw material 4 is a raw material powder in which zirconia and silicon nitride are mixed in 1: 5 (zirconia: silicon nitride).
- the raw material 5 is a raw material powder of silicon nitride alone. The median diameter (median diameter) of the raw material powders of the raw materials 1 to 5 was 0.5 ⁇ m to 0.9 ⁇ m.
- a ceramic was formed on a pure copper plate of 13 mm ⁇ 13 mm ⁇ 1 mmt (width ⁇ length ⁇ thickness). Specifically, 10 L / min. Of nitrogen gas was sprayed onto the raw material powder in the aerosolization chamber while vibrating in the aerosolization chamber containing the raw material to form an aerosol.
- the formed aerosol is transferred from the upper part of the aerosol chamber to the film forming chamber connected by a pipe and depressurized to 90 Pa using a pressure difference, and the opening size provided at the tip of the pipe is 0.3 mm in the X direction and 15 mm in the Y direction.
- the film was formed by accelerating and spraying toward a 13 mm ⁇ 13 mm surface of a pure copper plate (copper substrate) as a substrate by a slit nozzle, and spraying on the surface of the pure copper plate.
- the driving speed of the base material was 1 mm / s in the X direction, and the base material was reciprocated with a driving length of 15 mm.
- a copper base material was placed in the center of a 15 mm ⁇ 15 mm region through which the nozzle passes on a 13 mm ⁇ 13 mm base material film formation surface.
- the number of laminations was 60 times.
- a ceramic laminate in which a composite ceramic coating was laminated on the entire surface of one side of a 13 mm ⁇ 13 mm square copper base material was produced.
- the composite ceramic laminate or ceramic laminate produced using the raw materials 1 to 5 was designated as Sample 1 to Sample 5, respectively. Further, using the raw material 2, the gas flow rate was 30 L / min.
- a composite ceramic laminate produced by forming the film forming chamber pressure at 310 Pa and forming the rest under the same conditions was used as Sample 6.
- the film forming surface was subjected to X-ray analysis to identify the constituent materials.
- the X-ray diffraction peak of each sample coincided with silicon nitride, zirconia used as a raw material, and copper used as a substrate.
- the peak of Si 2 N 2 O produced when silicon nitride and an oxide shown in Patent Document 3 and the like reacted was not recognized. It was found that the peak of the zirconia phase is not only the same monoclinic crystal as that of the zirconia raw material powder, but also contains a tetragonal crystal that is a high-temperature phase, although it does not contain a stabilizer. This is presumably because compressive stress was applied to the film during the film formation process, which caused stress-induced transformation.
- the cross section perpendicular to the bonding surface between the copper base material and the composite ceramic was mirror-polished, subjected to conductive treatment with ultrathin carbon, and the structure of the cross section was observed.
- FE-SEM ULTRA55, manufactured by Zeiss
- Table 1 shows the observation results of the tissues.
- the silicon nitride phase, zirconia phase, and void ratio (area ratio) were obtained by image processing from a secondary electron image of 20000 times obtained at an acceleration voltage of 5 kV of a scanning electron microscope (SEM).
- SEM scanning electron microscope
- EDS distinguishes the zirconia phase as the brightest white contrast, the silicon nitride phase as the middle gray contrast, and the voids (recesses) as dark black contrast. Confirmed with.
- the distinction between the zirconia phase and the silicon nitride phase was confirmed by EDS laid on a scanning electron microscope.
- the size of the field of view of the 20000 times image was 56.6 ⁇ m ⁇ 42.5 ⁇ m, and particles having a size of 0.01 ⁇ m could be identified.
- the acquired image is separated and extracted into a silicon nitride phase, a zirconia phase, and a void having a major axis of 0.1 ⁇ m or more using image processing software (Image Pro, manufactured by Nippon Roper), and the area ratio of these Asked.
- image processing software Image Pro, manufactured by Nippon Roper
- the ratio shown in Table 1 is an average value from five images at different locations.
- the area ratio between the silicon nitride phase and the zirconia phase of the composite ceramic was close to the volume ratio calculated from the raw material charge weight ratio and the theoretical density.
- the reason why the total area ratio of the silicon nitride phase, the zirconia phase, and the voids does not become 100% is that there are a few voids whose major axis is 0.1 ⁇ m or less.
- the area ratio of voids having a major axis of 0.1 ⁇ m or less was small except for Sample 2.
- the reason why the porosity of Sample 2 was large is considered to be that the median diameter (median diameter) of the raw material was as large as 0.9 ⁇ m and the film forming conditions were not suitable.
- the median diameter (median diameter) of the raw material was as large as 0.9 ⁇ m and the film forming conditions were not suitable.
- the density of the sample 6 produced by changing the film forming conditions as described above could be increased even when the same raw material was used.
- the phases constituting the composite ceramic of the composite ceramic laminate are a silicon nitride phase and a zirconia phase. Therefore, in the composite ceramics of Sample 2 and Sample 6, since the area ratio occupied by the zirconia phase is large, the first phase is the zirconia phase and the second phase is the silicon nitride phase. And since a 1st phase is an oxide phase, a silicon nitride phase turns into a toughening phase. In the composite ceramics of Sample 3 and Sample 4, since the area ratio occupied by the silicon nitride phase is large, the first phase is a silicon nitride phase and the second phase is a zirconia phase. And since a 1st phase is a nitride phase, a zirconia phase turns into a toughening phase.
- the measurement of the particle diameter of the toughening phase is as follows. First, the secondary electron image of 30000 times observed by SEM was obtained about the cross section orthogonal to the joint surface between the composite ceramic and the substrate. Next, a parallel straight line and a vertical straight line were drawn with respect to the joint surface between the substrate and the composite ceramic. Next, for each of the parallel straight line and the vertical straight line, the different phase boundary portion where the first phase and the toughening phase intersect was marked. Next, for each of the direction parallel to and perpendicular to the bonding surface of the substrate and the composite ceramic, the distance between the toughening phase marks (intercept distance) is converted to the actual length, and the average The interval was determined and used as the average particle size.
- the particle size shown in Table 1 is an average value of approximately 50 toughening phase intercepts.
- the average particle diameter in the direction perpendicular to the bonding surface is expressed as the thickness direction particle diameter
- the average particle diameter in the direction parallel to the bonding surface is expressed as the width direction particle diameter. ing.
- sample 1 and sample 5 are a zirconia single phase and a silicon nitride single phase, respectively, there is no toughening phase.
- the average particle diameter of the interface of the first phase particles observed by SEM was measured by the intercept method.
- the average particle size of the ceramic film was smaller than that of a dense ceramic of silicon nitride or zirconia obtained by a normal sintering method. Moreover, the average particle diameter in the film thickness direction perpendicular to the bonding surface between the ceramic and the substrate was smaller than that in the direction parallel to the bonding surface between the ceramic and the substrate. That is, the zirconia phase and the silicon nitride phase have a form that is crushed in the film thickness direction.
- the grain boundaries of the zirconia phase and the silicon nitride phase in the composite ceramic are firmly bonded except where voids exist.
- the grain boundary was observed by magnifying it up to 50000 times, no reaction phase was observed not only at the grain boundaries between the silicon nitride phases and between the zirconia phases, but also at the grain boundaries between the silicon nitride phase and the zirconia phase. No phases other than the zirconia phase were observed.
- a diamond Vickers indenter (hereinafter simply referred to as an indenter) is pushed into the mirror-polished observation surface with a load of 50 gf, and after holding for 15 seconds, the tip of the crack generated from the indenter does not overlap. Repeated enough distance. Since the indenter is a quadrangular pyramid, the indentation has a shape close to a square. Of the diagonal lines connecting the vertices of the squares of the indentation, the other diagonal line is parallel to the bonding surface between the ceramic and the substrate so that one diagonal line is perpendicular to the bonding surface between the ceramic and the substrate. The indenter was pushed so that the direction would be correct. After making the indentation, the indentation and cracks were observed with FE-SEM. The number of indentations was 7 points.
- any of Sample 1 to Sample 6 from the top of the square in the indentation, from the top of the two indentations on the diagonal in the direction parallel to the bonding surface between the ceramic and the substrate, the direction from the indentation to the outside. Cracks were observed.
- the top of the indentation on the diagonal line in the thickness direction of the substrate that is, the direction perpendicular to the bonding surface between the ceramic and the substrate
- the occurrence of cracks facing in the thickness direction was not observed. This indicates that the occurrence of cracks and the progress of cracks are unlikely to occur in the thickness direction of the ceramics provided on the substrate. Therefore, the fracture toughness is high in the direction perpendicular to the bonding surface between the ceramic and the substrate.
- One is the crack that propagates between the particles of the oxide phase and the nitride phase because the form of each phase of the oxide phase and the nitride phase is deformed in a direction parallel to the joint surface between the composite ceramic and the substrate. This is an organizational effect that is difficult to progress.
- the other is due to the process effect due to the compressive stress of the coating in the in-plane direction parallel to the joint surface between the composite ceramic and the substrate.
- cracks running in a plane perpendicular to the thickness direction are mainly between crystal grains observed by SEM or the crystal grains. It turns out that it passes through the neighborhood. Some of the particles having a particle diameter of more than 1 ⁇ m were found to penetrate through the grains. Depending on the sample, a difference was observed in the length of the crack and the path through which the crack progresses.
- the crack evaluation shown in Table 1 shows the result of evaluating the length of the crack generated in the direction parallel to the joint surface between the composite ceramic and the substrate.
- the crack evaluation in Table 1 was evaluated according to the following evaluation criteria A to C.
- a crack with a distance between the tips of the cracks extending on both sides of the diagonal in the Vickers indentation is less than twice as long.
- B On the both sides of the diagonal in the Vickers indentation.
- C The distance between the leading ends of the crack that spreads on both sides of the diagonal line in the Vickers impression is more than three times.
- Sample 1 and Sample 5 are judged as B, and the crack evaluation is superior to the alumina film produced by the same process. From this result, it was found that the fracture toughness was relatively high even with ceramics of silicon nitride alone and ceramics of zirconia alone. Furthermore, it was found that Sample 3, Sample 4, and Sample 6 had better crack evaluation than Sample 1 and Sample 5, and improved fracture toughness. Looking at the path of the crack in detail, the crack propagates mainly at the grain boundary (that is, the grain interface) observed by SEM, and there are many detours near the heterogeneous interface between silicon nitride and zirconia. It was. This indicates that the fracture toughness is improved because the crack deflection effect is exhibited.
- the manifestation of the crack deflection effect is caused by the fact that silicon nitride and zirconia having different elastic moduli are finely and firmly bonded microscopically and without reacting. Further, it is considered that tetragonal zirconia is transformed into monoclinic crystals by the tensile stress at the crack tip, which has propagated, and the toughening action is also effective.
- Silicon nitride and zirconia each have a high strength and fracture toughness value even in a single phase, and their properties are mechanically reduced by being densely and finely compounded without being damaged by changing to other phases by reaction. Improved characteristics. However, the improvement in fracture toughness is not sufficient.
- Example 2 a composite ceramic that is a combination of silicon nitride and zirconia as a combination of oxide and nitride on a copper plate (copper substrate) as a substrate using an aerosol deposition method.
- a composite ceramics laminate coated with was prepared.
- the oxide and nitride raw materials a raw material in which both raw materials were uniformly mixed and a raw material in which both raw materials were not uniformly mixed were used.
- a raw material in which both raw materials are not uniformly mixed is a raw material that is mixed so as to be apparently uniform but is not substantially uniformly mixed.
- the silicon nitride raw material powder used as a raw material is ⁇ -silicon nitride containing less than 5% ⁇ -silicon nitride, and the zirconia powder used as a raw material is mainly composed of monoclinic crystals to which no stabilizer is added. It is zirconia. Using this raw material, a raw material powder was prepared as follows.
- Raw material 21 Silicon nitride and zirconia were weighed 1: 2 in a mass ratio, and kneaded in a planetary ball mill for 20 hours using acetone as a medium.
- the pot and ball of the planetary ball mill were made of ⁇ -silicon nitride, and the size of the ball was ⁇ 5 mm.
- the mixed powder obtained by kneading was heated to 150 ° C. and sufficiently dried to obtain a raw material powder. The median diameter (median diameter) of the mixed powder was 0.71 ⁇ m.
- Raw material 22 Silicon nitride or zirconia was individually pulverized with a planetary ball mill using acetone as a medium, and each medium diameter was adjusted to 0.7 ⁇ m.
- silicon nitride and zirconia are in a mass ratio of 1: 2, and are placed in a Teflon (registered trademark) ball mill container. It was prepared by kneading for a minute so that it looks uniform.
- a ceramic was formed on a pure copper plate of 40 mm ⁇ 40 mm ⁇ 1 mmt (width ⁇ length ⁇ thickness). Specifically, 12 L / min. Of nitrogen gas was sprayed onto the raw material powder in the aerosolization chamber while vibrating in the aerosolization chamber containing the raw material 21 or 22 to form an aerosol. The formed aerosol is transferred from the upper part of the aerosol chamber to the film forming chamber connected by a pipe and depressurized to 99 Pa using a pressure difference, and the opening size provided at the tip of the pipe is 0.3 mm in the X direction and 5 mm in the Y direction. Films were formed by accelerating and spraying toward a 40 mm ⁇ 40 mm surface of a pure copper plate (copper substrate) as a substrate by a slit nozzle, and spraying on the surface of the pure copper plate.
- the driving speed of the substrate was 2 mm / s in the X direction, and the substrate was reciprocated with a driving length of 15 mm.
- a substrate film formation surface shape of 40 mm ⁇ 40 mm was arranged at the center of a 5 mm ⁇ 15 mm region through which the nozzle passes.
- the number of laminations was 20 times.
- stacked in the center of one side of a 40 mm x 40 mm square copper base material was produced.
- a sample prepared using the raw material 21 as a raw material was used as a sample 21, and a sample prepared using the raw material 22 as a raw material was used as a sample 22.
- the film forming surface was subjected to X-ray analysis to identify the constituent materials.
- the X-ray diffraction peak of each sample coincided with silicon nitride, zirconia used as a raw material, and copper used as a substrate.
- other peaks such as Si 2 N 2 O produced when the silicon nitride and the oxide shown in Patent Document 3 react with each other were not recognized.
- the peak of the zirconia phase was found to contain a large amount of tetragonal crystals, which are high-temperature phases, although no stabilizer was contained.
- the film thicknesses of the composite ceramics of Sample 21 and Sample 22 were both about 4 ⁇ m.
- the composite ceramic structures were different between the two samples.
- Sample 21 was dense and voids were observed only by 0.2% in area ratio.
- sample 22 a void of 4% was recognized in area ratio.
- a composite film in which a silicon nitride phase and a zirconia phase were mixed was formed in the observation field of view.
- Sample 22 a portion where silicon nitride particles and zirconia particles aggregated was observed, and in particular, many voids were observed between the silicon nitride particles.
- the area ratio of the silicon nitride phase and the zirconia phase in sample 21 evaluated by the same method as in Example 1 is 43.5% (silicon nitride phase) and 56.0% (zirconia phase), respectively.
- the average particle diameter of the silicon nitride phase, which is the second phase and toughening phase evaluated by the intercept method, is 0.066 ⁇ m in the film thickness direction, and the direction parallel to the joint surface between the composite ceramic and the substrate It was 0.114 ⁇ m.
- FIG. 4 is a cross-sectional photograph of the cross section of the composite ceramic laminate in the sample 21 observed with a transmission electron microscope.
- the composite ceramic 11 is coated on a copper plate as the base 12.
- Reference numeral 14 shown in FIG. 4 is a joint surface between the base 12 and the composite ceramic 11.
- the sample 21 has a fine and dense composite ceramic film formed thereon.
- the bright contrast portion is mainly a ⁇ -Si 3 N 4 phase, and a very small amount of ⁇ -Si 3 N 4 was observed.
- the phase indicated by dark contrast was a phase of ZrO 2 . Both particles are flat in the film thickness direction. There were no voids in the field of view.
- Code 151 shown in FIG. 4 is silicon nitride (Si 3 N 4) is a phase, reference numeral 161 denotes a zirconia (ZrO 2) phases.
- both the silicon nitride phase and the zirconia phase were composed of finer crystal grains in the grains observed with the SEM. It has been found that silicon nitride has a portion composed of crystal grains of about 0.1 ⁇ m to 0.2 ⁇ m and a portion composed of aggregates of particles of several tens of nm. On the other hand, the zirconia phase is composed of an aggregate of particles of several nm to 20 nm, and particles of about several tens nm to 100 nm are partially recognized.
- the particle size measured by SEM is not the crystal particle size, but the crack after hitting the Vickers indenter in each example often propagates along the boundary of the particle observed by SEM. It is the particle size of the toughening phase observed by SEM that greatly affects the mechanical properties, particularly fracture toughness.
- the formation of an amorphous phase of several nanometers of silicon oxide was partially observed at the silicon nitride phase interface.
- the silicon oxide amorphous phase was observed in a small part even at the interface between the zirconia phases, but no crystal phase other than the silicon nitride phase and the zirconia phase was observed.
- Silicon nitride and zirconia are materials having high strength and high fracture toughness among engineering ceramics. In the thermal process, it is difficult to form a dense structure with the nitride phase and the oxide phase, but by combining two phases with excellent mechanical properties without undergoing a thermal process such as sintering, As compared with a single-phase material of nitride phase or oxide phase, an insulating film having further excellent mechanical characteristics can be formed.
- Example 3 using an aerosol deposition method, on a steel substrate as a base material, as a combination of oxide and nitride, silicon nitride, aluminum nitride, alumina, zirconia, yttria, ceria, and Composite ceramic laminates coated with composite ceramics were prepared in various combinations using titania.
- “substantially not contained” refers to the extent that the ⁇ -Si 3 N 4 peak cannot be detected as a result of measurement by powder X-ray diffraction.
- As the alumina corundum type ⁇ -Al 2 O 3 was used.
- Zirconia used as a raw material was partially stabilized zirconia containing tetragonal and monoclinic zirconia containing yttrium as a stabilizer.
- yttria (Y 2 O 3 ) ceria (CeO 2 ), aluminum nitride (AlN), and rutile type (TiO 2 )
- reagents having a purity of 99.9% were used.
- ⁇ -Si 3 N 4 has a particle diameter larger than that of other raw material powders in a commercially available state. For this reason, a planetary ball mill was used in advance and kneaded for 20 hours using acetone as a medium to adjust the median diameter of ⁇ -Si 3 N 4 to 0.8 ⁇ m, and then a dried powder was used.
- a ceramic was formed on a steel substrate (STKM13A) of 13 mm ⁇ 13 mm ⁇ 1 mmt (width ⁇ length ⁇ thickness).
- an aerosol was formed by spraying 30 L / min. Of nitrogen gas onto the raw material powder in the aerosolization chamber while vibrating the aerosolization chamber containing the raw material.
- the formed aerosol is transferred from the upper part of the aerosol chamber to the film forming chamber connected by a pipe and depressurized to 250 Pa using a pressure difference, and the opening size provided at the tip of the pipe is 0.3 mm in the X direction and 15 mm in the Y direction.
- the slit nozzle was accelerated and sprayed toward the 13 mm ⁇ 13 mm surface of the steel substrate as a base material, and film formation was performed by spraying on the surface of the steel substrate.
- the driving speed of the substrate was 2 mm / s in the X direction, and the substrate was reciprocated with a driving length of 15 mm.
- a substrate film forming surface of 13 mm ⁇ 13 mm was placed at the center of a 15 mm ⁇ 15 mm region through which the nozzle passes.
- the number of laminations was 120 times. In this manner, a ceramic laminate in which a composite ceramic film was laminated on the entire surface of one side of a 13 mm ⁇ 13 mm square steel material was produced.
- the film forming surface was subjected to X-ray analysis to identify the constituent materials.
- the X-ray diffraction peak of each sample no peaks other than the raw material and the steel substrate used as the base material were observed. Further, no ⁇ -Si 3 N 4 peak was observed in the film formed using the raw powder of ⁇ -Si 3 N 4 . No ⁇ -Si 3 N 4 peak was observed in the film formed using the raw powder of ⁇ -Si 3 N 4 .
- the zirconia peak was almost tetragonal. The raw material zirconia contains yttrium, but no yttrium peak was observed in the zirconia on the film formation surface. On the other hand, yttria, ceria, or titania peaks were observed from the composite ceramic film produced using yttria, ceria, or titania as raw materials.
- the cross section orthogonal to the joining surface of the steel substrate and the composite ceramic was mechanically polished, subjected to a conductive treatment with ultrathin carbon, and the structure of the cross section was observed. It was found that a ceramic film having a thickness of 15 ⁇ m to 55 ⁇ m was formed on the surface of the substrate.
- the composite ceramic film formed using a mixed raw material containing zirconia, yttria, or ceria as oxide raw material particles is formed with silicon nitride powder alone even if the content of these oxides is small.
- the film thickness was larger than that obtained.
- Sample 5 of Example 1 Sample 31 and Sample 32 of Example 3
- nitride has a low film formation rate.
- zirconia and rare earth oxide have an effect of increasing the film formation efficiency.
- the rare earth oxide has a great effect of increasing the film formation efficiency.
- the use of rare earth oxides reduces the porosity and contributes to densification.
- the thickness of the ceramic film formed only with ⁇ -Si 3 N 4 is small is that the film thickness was evaluated at the portion where peeling occurred.
- Each phase derived from each raw material and the ratio of voids were obtained by image processing from a secondary electron image of 20000 times obtained at an acceleration voltage of 5 kV observed by SEM. After confirming each phase using EDS, the contrast and brightness of the SEM image were adjusted to distinguish each phase as contrast. Then, the area ratio of each phase was calculated by image processing. In the image processing, an image taken at 20000 times and having a visual field size of 56.6 ⁇ 42.5 ⁇ m was used. A crystal grain having a size of 0.01 ⁇ m could also be discriminated.
- image processing software (Image Pro, manufactured by Nippon Roper) was used to separate and extract into voids having a major axis of 0.1 ⁇ m or more, and the area ratio of the voids was obtained.
- image processing software Image Pro, manufactured by Nippon Roper
- a clear contrast cannot be obtained as in the combination of silicon nitride and zirconia as described in the first embodiment.
- the composite ceramics is a sample in which it is difficult to obtain a separated image of each phase from the SEM image, the observer artificially painted the phase with a marker to give contrast while looking at the composition analysis result of EDS. Images were used.
- the ratio of the cross-sectional area ratio shown in Table 3 is an average value from five images.
- the five images are images at five different places.
- the reason why the total area ratio of the respective phases and voids does not become 100% is that there are a few voids having a major axis of 0.1 ⁇ m or less and an error in image processing occurs.
- the composite ceramics of Sample 34 to Sample 41 are as follows. It is as follows.
- the first phase of the sample 34 is an ⁇ -Si 3 N 4 phase
- the second phase is an Al 2 O 3 phase.
- the difference in Young's modulus between the ⁇ -Si 3 N 4 phase and the second phase Al 2 O 3 phase is 9.5% according to the definition of the present disclosure.
- the first phase of the sample 35 is a ⁇ -Si 3 N 4 phase
- the second phase is an Al 2 O 3 phase.
- the toughening phase of sample 35 is Al 2 O 3 .
- the first phase of the sample 36 is an ⁇ -Si 3 N 4 phase
- the second phase is an Al 2 O 3 phase
- the third phase is a Y 2 O 3 phase.
- the toughening phase of the sample 36 is Young's modulus more than the Al 2 O 3 phase. Is a small Y 2 O 3 phase.
- the first phase of the sample 37 is an ⁇ -Si 3 N 4 phase
- the second phase is a ZrO 2 phase.
- the area ratio is less than 1%, the sample 37 has no toughening phase.
- the first phase of the sample 38 is an ⁇ -Si 3 N 4 phase
- the second phase is a ZrO 2 phase. Since the area ratio of the second phase is 1% or more, the toughening phase of the sample 36 is a ZrO 2 phase.
- the first phase of the sample 39 is an ⁇ -Si 3 N 4 phase
- the second phase is a ZrO 2 phase
- the third phase is a CeO 2 phase. Since the phase having an area ratio of 1% or more and the elastic modulus having the largest difference from the elastic modulus of the first phase is the toughening phase, the toughening phase of the sample 36 is CeO 2 having a Young's modulus smaller than that of the ZrO 2 phase. Is a phase.
- the first phase is an Al 2 O 3 phase
- the second phase is an AlN phase.
- the toughening phase of sample 40 is an AlN phase.
- the first phase is an ⁇ -Si 3 N 4 phase and the second phase is a TiO 2 phase.
- the toughening phase of sample 41 is a TiO 2 phase.
- the measurement of the particle diameter of the toughening phase is as follows. First, the secondary electron image of 30000 times observed by SEM was obtained about the cross section orthogonal to the joint surface between the composite ceramic and the substrate. Next, a straight line parallel to and perpendicular to the joint surface between the substrate and the composite ceramics was drawn. Next, for each of the parallel straight line and the vertical straight line, a different phase boundary portion where the toughening phase intersects with another phase was marked. Next, for each direction parallel to and perpendicular to the joint surface between the substrate and the composite ceramic, the distance between the second phase marks (intercept distance) is converted into the actual length, and the average is obtained. The interval was determined and used as the average particle size.
- the particle size shown in Table 4 is an average value of approximately 50 second phase intercepts.
- the relationship between the Young's modulus of the second phase and the Young's modulus of the first phase is less than 10%, so the second phase is not a toughening phase.
- sample 37 since the area ratio of the second phase is less than 1%, the second phase is not a toughening phase.
- the sample 34 and the sample 37 measured the particle diameter of the alumina phase and zirconia phase which are 2nd phases.
- the average particle diameter in the direction perpendicular to the bonding surface is expressed as the thickness direction particle diameter
- the average particle diameter in the direction parallel to the bonding surface is expressed as the width direction particle diameter. ing.
- the average particle size of the toughening phase of the composite ceramic was a submicron size.
- the average particle diameter in the film thickness direction perpendicular to the joint surface between the composite ceramic and the substrate was smaller than that parallel to the joint surface. That is, the particles had a form that was crushed in the film thickness direction.
- the second phase was dispersed in the first phase having the largest area ratio, and the third phase was evenly and finely dispersed depending on the sample, and the grain boundaries were firmly bonded except where voids existed. .
- the grain boundary of each phase was observed by magnifying it up to 50000 times, no reaction phase was observed at the grain boundary of each phase, and no phase other than the substance used as the raw material was observed.
- the indenter was pushed into the mirror-polished observation surface with a load of 50 gf, held for 15 seconds, and then the operation of raising the indenter was repeated with a sufficient distance so that the tip of the crack generated from the indenter would not overlap.
- the indenter is a quadrangular pyramid, the indentation has a shape close to a square. Of the diagonal lines connecting the vertices of the squares of the indentation, the other diagonal line is parallel to the joint surface between the ceramic and the substrate so that one diagonal line is perpendicular to the joint surface between the ceramic and the substrate.
- the indenter was pushed so that After making the indentation, the indentation and cracks were observed with FE-SEM. The number of indentations was 7 points.
- any of the samples 31 to 41 from the top of the square in the indentation, the top of the two indentations on the diagonal in the direction parallel to the bonding surface between the ceramic and the substrate is directed to the outside of the indentation. Cracks were observed.
- any of the samples 31 to 41 has a base from the top of the indentation on the diagonal line in the thickness direction of the base material (that is, the direction perpendicular to the bonding surface between the composite ceramic and the substrate). The generation of cracks facing the thickness direction of the material was not observed. This indicates that cracks are less likely to occur and the cracks are less likely to develop in the thickness direction of the ceramics provided on the substrate.
- the fracture toughness is high in the direction perpendicular to the bonding surface between the ceramic and the substrate. This is due to the following two effects. One is the effect on the structure in which the form of each phase is deformed in a direction parallel to the joint surface between the composite ceramics and the substrate, so that cracks that progress between the phases are difficult to progress. . The other is due to the process effect due to the compressive stress of the coating in the in-plane direction parallel to the joint surface between the composite ceramic and the substrate.
- cracks running in a plane perpendicular to the thickness direction are mainly between crystal grains observed by SEM or between the crystal grains. It turns out that it is passing the vicinity of. Some of the large particles having a particle diameter exceeding 1 ⁇ m also had a portion where cracks penetrated the inside of the particles. Depending on the sample, a difference was observed in the length of the crack and the path of the crack.
- the crack evaluation in Table 4 shows the result of evaluating the length of the crack generated in the direction parallel to the joint surface between the composite ceramic and the substrate. The crack evaluation in Table 4 was evaluated based on the same standard as the evaluation standard shown in Example 1.
- Sample 31 in which ⁇ -Si 3 N 4 single-phase ceramics were laminated had large cracks, and the ceramic film was destroyed.
- Sample 37 and Sample 38 in which zirconia was dispersed in ⁇ -Si 3 N 4 cracks remained in the film.
- the crack introduction length was extremely small. This is because the fracture toughness value increased due to the dispersion of zirconia having different elastic moduli with respect to ⁇ -Si 3 N 4 .
- Sample 39 combined with an area ratio of zirconia phase of 25.9% and an area ratio of ceria phase of 1.2% is the smallest crack introduction amount among the samples evaluated in Example 3. The characteristic was excellent.
- the fracture toughness of the sample 36 is superior to that of the sample 34 having an alumina phase of 2.3% because yttria having a large difference in elastic modulus with respect to ⁇ -Si 3 N 4 is added, and the addition of yttria makes it denser. This is because it has become.
- Example 4 With respect to Sample 4, Sample 31, Sample 32, and Sample 39 having the silicon nitride phase as the first phase, the wear resistance was evaluated. The wear resistance was evaluated as follows.
- the tungsten carbide ball having a diameter of 5 mm was pressed against the ceramic coating on the ceramic laminate with a load of 9.8 N, and was reciprocated at a sliding distance of 6 mm. When the total sliding distance reached 100 m, the sliding was finished. The depth of the wear scar after the end of sliding was measured.
Abstract
Description
基材と、
前記基材を被覆する複合セラミックスと、
を備え、
前記複合セラミックスは、窒化物相、及び前記窒化物相が有する弾性率と10%以上異なる弾性率を有する酸化物相を含み、残部が不純物である複合材料であり、
前記複合セラミックスと前記基材との接合面に対して直交する断面において、
前記窒化物相及び前記酸化物相のうち、最も大きな面積率を占める相を第1相とし、1%以上の面積率を占め、前記第1相の弾性率と最も差が大きい弾性率である相を強靭化相とし、
前記第1相が前記窒化物相であるとき、前記強靭化相は前記酸化物相であり、前記第1相が前記酸化物相であるとき、前記強靭化相は前記窒化物相である、複合セラミックス積層体。
[2]
前記複合セラミックスと前記基材との接合面に対して直交する断面において、複合セラミックスは、長径0.1μm以上の空隙が、面積率で、0%以上3%以下である、[1]に記載の複合セラミックス積層体。
[3]
前記複合セラミックスと前記基材との接合面に対して直交する断面において、前記接合面に対して垂直な方向における前記強靭化相の粒子径の平均が1μm以下である、[1]又は[2]に記載の複合セラミックス積層体。
[4]
前記第1相が、窒化珪素相、又は窒化アルミニウム相である、[1]~[3]のいずれか1つに記載の複合セラミックス積層体。
[5]
前記第1相がジルコニア相、アルミナ相、又は希土類酸化物相のいずれかである、[1]~[3]のいずれか1つに記載の複合セラミックス積層体。
[6]
前記ジルコニア相の一部が正方晶構造である、[5]に記載の複合セラミックス積層体。
[7]
前記窒化物相と前記酸化物相との組み合わせとして、窒化珪素相とジルコニア相、窒化珪素相とアルミナ相、窒化珪素相と希土類酸化物相、窒化アルミニウム相とジルコニア相、窒化アルミニウム相とアルミナ相、又は窒化アルミニウム相と希土類酸化物相のいずれかである、[1]~[5]のいずれか1つに記載の複合セラミックス積層体。
[8]
前記ジルコニア相の一部が正方晶構造である、[7]に記載の複合セラミックス積層体。
[9]
前記基材が金属製基材である、[1]~[8]のいずれか1つに記載の複合セラミックス積層体。
[10]
窒化物原料粒子、及び前記窒化物原料粒子の弾性率と10%以上異なる弾性率を有する酸化物原料粒子を混合した混合原料を準備する工程と、
前記混合原料に対し、気体を混合させてエアロゾルを生成し、前記エアロゾルを基材に向けて噴射する工程と、
を有する、セラミックス積層体の製造方法。
また、前記複合セラミックスと前記基材との接合面に対して直交する断面において、窒化物相又は酸化物相のうち、最も大きな面積率を占める相を第1相とし、1%以上の面積率を占め、第1相の弾性率と最も差が大きい弾性率である相を強靭化相とする。
そして、前記第1相及び前記強靭化相は、前記第1相が前記窒化物相であるとき、前記強靭化相は前記酸化物相であり、前記第1相が前記酸化物相であるとき、前記強靭化相は前記窒化物相である。
本開示において、「複合セラミックス積層体」とは、基材上に複合セラミックスが被覆された形態を含む構造体をいう。
本開示において、「複合セラミックス」とは、窒化物と酸化物とが概ね100μm以下の粒子径で混じり合って結合された微視的に複相化されている状態をいう。
本開示において、「接合面」とは、基材と、基材に被覆している複合セラミックスとの被覆界面を表す。
本開示において、「窒化物相、及び前記窒化物相が有する弾性率と10%以上異なる弾性率を有する酸化物相」とは、第1相の弾性率と強靭化相の弾性率との差の絶対値を、第1相及び強靭化相のうち、弾性率の低い相の弾性率で除した100分率が10%以上である。つまり、この用語は、窒化物相(又は酸化物相)、及び前記窒化物相(又は酸化物相)が有する弾性率と10%以上異なる弾性率を有する酸化物相(又は窒化物相)であることを表し、下記式1を満たすことを表す。強靭化相の面積率は1%以上であるから、第1相の最大面積率は99%になる。
(式1) {|「第1相の弾性率」-「強靭化相の弾性率」|/「第1相及び強靭化相のうち、弾性率の低い相の弾性率」}×100≧10%
本開示において、「弾性率」とは、多結晶体の縦弾性率(すなわち、ヤング率)を表す。
本開示において、「不純物」とは、不可避的に存在していた不純物由来の小さな相、薄く結晶粒界に生じた非晶質相、及び酸窒化物相を表す。
本開示において、「第2相」とは、複合セラミックスにおいて、第1相の次に大きな面積率を占める相を表す。つまり、面積率の大きな順に「第1相」、「第2相」、及び「第3相」と称する。
本開示において、「粒子径」とは、後述の切片法により求められる各相の径を表し、結晶学的な結晶粒径とは区別されるものである。
本開示において、「工程」との用語は、独立した工程だけではなく、他の工程と明確に区別できない場合であってもその工程の所期の目的が達成されれば、本用語に含まれる。
本開示において、「常温」又は「室温」との用語は、20℃±15℃(つまり、5℃~35℃)の範囲の温度を意味する。この温度は、成膜中の基材の平均温度である。原料紛体が衝突した瞬間において、衝突の衝撃で、極微視的には、基材の温度はこれ以上に上がっていることは否定できない。しかし、基材のごく微細な領域に発生した熱はその瞬間に放散し、基板全体の温度は常温(つまり、上記範囲の温度)に保たれる。
本開示の複合セラミックス積層体は、積層体全体として、優れた強靭性(つまり、機械的、及び熱的に信頼性の高い)性を有する。そのために、本開示の複合セラミックス積層体を構成する複合セラミックスは、窒化物と酸化物とが微視的に複合化されている。ここで、微視的とは、粒子径の大きさとして、概ね100μm以下の大きさに複相化されている状態をいう。微視的に複合化されているセラミックスと基材との積層体は、接合面での長さとして、概ね1ミリメートル以上の大きさで被覆された形態を示す。複合セラミックスの中で、窒化物と酸化物との微視的な組織を表現する場合、窒化物と酸化物とをそれぞれ窒化物相及び酸化物相と表現する。窒化物相及び酸化物相の2つ以上の相が複相化された相を複合セラミックス相と表現する。なお、上記の微視的に複合化された複合セラミックスが基材に被覆されていることにより、外部応力、及び温度の上下に伴う基材と複合セラミックスの熱膨張係数の違いによって生じる内部応力である熱応力に対して(すなわち熱的な負荷に対して)、破壊しにくい信頼性を高い複合セラミックス積層体の実現が期待される。
本開示で用いられる複合セラミックスは、これまでに実現できていない窒化物相及び酸化物相で構成される系で緻密に複合化されていればよい。これらが複合化された効果である優れた破壊靭性を得るためには、微視的に複合化されていることが望ましい。複合セラミックス相の平均粒子径が、複合セラミックスと基材との接合面に対して、垂直な方向及び平行な方向のそれぞれについて、1μm以下であることが望ましく、0.5μm以下であることがより望ましい。複合セラミックス相の平均粒子径は、0.1μm以下であってもよく、透過型電子顕微鏡で観察可能な0.005μm以下の結晶粒が含まれていてもよい。複合セラミックス相の平均粒子径は、酸化物相及び窒化物相全体の平均粒子径である。平均粒子径の下限値は、窒化物、又は酸化物の単位格子が1000個程度で構成された程度の大きさである0.005μm以上としてもよい。また、酸化物相の平均粒子径及び窒化物相の平均粒子径は、それぞれ、1μm以下であってもよく、0.5μm以下であってもよく、0.1μm以下であってよい。また、0.005μm以上であってもよい。
以上のように、本開示では複合セラミックスを構成している全ての相で微細化されることがより望ましい。本開示の目的である複合セラミックスの強靭化は、主には強靭化相の存在で達成しうるものであるから、少なくとも強靭化相が微細化されていることが好ましい。なお、酸化物相の平均粒子径及び窒化物相の平均粒子径の好適な範囲は、酸化物相と窒化物相との組み合わせ、強靭化相の体積率(面積率)等によって、変化し得るものである。
本開示の複合セラミックス積層体において、複合セラミックスに適用される窒化物は限定されるものではない。窒化物としては、窒化珪素(Si3N4)、又は窒化アルミニウム(AlN)であることが好ましい。複合セラミックス積層体の複合セラミックスに適用される窒化物としては、窒化珪素が最も好ましい。窒化珪素は機械的特性が必要とされるエンジニアリングセラミックスの中でも強度及び破壊靭性値が優れる。窒化珪素を用いることで、本開示の複合セラミックスを構成する窒化物相として必要な基本特性が得られる。また、窒化珪素は、エンジニアリングセラミックスの中では熱伝導率が高い部類に属する。更に、窒化珪素の熱膨張係数は約2.9×10-6/Kであり、強度を必要とするエンジニアリングセラミックスの中では小さい部類に入る。これらの特徴的な熱的物性は、本開示のセラミックス複合セラミックス積層体を構成する窒化物相として有用である。したがって、窒化物として、窒化珪素を用いることで、複合セラミックス積層体は、絶縁放熱基板、搬送ロール、圧延ロール等の用途への適用が有用である。複合セラミックスの熱伝導率を向上させようとした場合、窒化珪素の中でも、β-窒化珪素相が好ましい。
本開示の複合セラミックス積層体において、複合セラミックスに適用される酸化物は限定されるものではない。酸化物としては、ジルコニア、アルミナ、又は希土類酸化物のいずれかであることが好ましい。本開示の複合セラミックス積層体の複合セラミックスに適用される酸化物としては、ジルコニア(ZrO2)がより好ましい。ジルコニアも窒化珪素と同様、強度が優れ、単体のセラミックスの中では破壊靭性値が優れた物質である。酸化物として、ジルコニアを用いることで、本開示の複合セラミックスを構成する酸化物相として望ましい特性が得られる。また、ジルコニアの熱膨張係数は約11×10-6/Kであり、強度を必要とするエンジニアリングセラミックスとして使用される酸化物としては最も大きい部類に属する。したがって、ジルコニアを用いることで、金属に近い熱膨張率が得られる。更に、ジルコニアの熱伝導率は、エンジニアリングセラミックスとして使用される酸化物としては最も小さい部類に属する。ジルコニアのこのような特徴的な熱的物性は、本開示の複合セラミックス積層体を構成する酸化物相として有用である。
本開示の複合セラミックス積層体において、複合セラミックスを構成する窒化物相と酸化物相とは、窒化珪素相とジルコニア相、窒化珪素相とアルミナ相、窒化珪素相と希土類酸化物相、窒化アルミニウム相とジルコニア相、窒化アルミニウム相とアルミナ相、又は窒化アルミニウム相と希土類酸化物相のいずれかであることが好ましい。これらの中でも、窒化物相及び酸化物相の組み合わせとして、窒化珪素相とジルコニア相、窒化アルミニウム相とアルミナ相、窒化珪素相と希土類酸化物相の組み合わせが好ましい。特に、窒化珪素相とジルコニア相との組み合わせは極めて有用である。また、酸化物相と組み合わせる窒化珪素相はβ-窒化珪素相であることが好ましい。
本開示のセラミックス積層体における基材は、限定されるものではない。基材は、セラミックスのような無機材料製基材であってもよい。基材は、樹脂のような有機物製基材であってもよい。基材は、CFRP(Carbon Fiber Reinforced Plastics)のような有機物と無機物の複合体製基材であってもよい。基材は、金属製基材であってもよい。
本開示の複合セラミックス積層体の製造方法は限定するものではない。本開示の複合セラミックス積層体の製造方法の好ましい一例としては、エアロゾルデポジション法(AD法)を用いて、原料粉の調整とプロセス条件を好適なものに制御する方法が挙げられる。このような方法によれば、本開示の複合セラミックス積層体が実現できる。AD法は、窒化物粒子と酸化物原料粒子とを、気体と混合し、窒化物原料粒子と酸化物原料粒子とを、気体と共に基材層の表面に向けて噴射して衝突させ、基材の表面に、複合セラミックスの被膜を積層する方法である。原料とプロセスの条件を好適なものに制御することによって、常温で緻密膜を形成でき、複合セラミックスの結晶粒界に酸窒化物相のような反応相の生成を極めて小さくすることができる。
前記混合原料に対し、気体を混合させてエアロゾルを生成し、前記エアロゾルを前記基材に向けて噴射する工程。
(1)成膜幅と同じノズル幅のノズルを用いて、基材の成膜面に沿ってノズル幅方向と垂直方向に、ノズル、又はワークとしての基材を成膜長さ分単純往復させる方法。
(2)成膜幅よりも小さいノズル幅のノズルを用いて、ノズル又は基材が当該基材の成膜面に沿って往復移動する過程で、ノズル又はワークを往復移動方向(成膜面長さ方向とも呼ぶ)と直交する水平方向に送りながら成膜する方法。
(1)成膜幅と同じノズル幅のノズルを用いて、ノズルを固定して成膜する方法。
(2)成膜幅よりも小さいノズル幅のノズルを用いて、ノズルをワークの中心軸に対して平行としたまま、幅方向(軸方向)に送りながら、成膜面幅方向端部(軸方向端部)で送りを反転させて引き返らせ、周面に成膜する方法。
ここでは、実施例1として、エアロゾルデポジション法を使用して、基材としての銅板上に、酸化物相及び窒化物相の組み合わせとして、窒化珪素相及びジルコニア相の組み合わせである複合セラミックスを被覆した複合セラミックス積層体を用意した。また、窒化珪素単相、又はジルコニア単相のセラミックスを、基材上に被覆したセラミックス積層体を用意した。
原料1は、窒化珪素を添加していないジルコニア単体の原料粉である。
原料2は、ジルコニアと窒化珪素とを17:3(ジルコニア:窒化珪素)で混合した原料粉である。
原料3は、ジルコニアと窒化珪素とを1:1(ジルコニア:窒化珪素)に混合した原料粉である。
原料4は、ジルコニアと窒化珪素とを1:5(ジルコニア:窒化珪素)に混合した原料粉である。
原料5は、窒化珪素単体の原料粉である。
原料1~原料5の原料粉における中位径(メディアン径)は、0.5μm~0.9μmであった。
A:ビッカースの圧痕における対角線の長さに対して、その両側に広がるクラックの先端間の距離が2倍未満の長さのクラック
B:ビッカースの圧痕における対角線の長さに対して、その両側に広がるクラックの先端間の距離が2倍~3倍である長さのクラック
C:ビッカースの圧痕における対角線の長さに対して、その両側に広がるクラックの先端間の距離が3倍を超える長さのクラック
表1に示したクラック評価結果は、7点の評価基準のうち、最も頻度の多かった評価基準を表したものである。
一方、プロセス条件を適化して空隙が生じないようにして作製した試料6では、破壊靭性は大きく改善した。
ここでは、実施例2として、エアロゾルデポジション法を使用して、基材としての銅板(銅基材)上に、酸化物及び窒化物の組み合わせとして、窒化珪素とジルコニアとの組み合わせである複合セラミックスを被覆した複合セラミックス積層体を用意した。実施例2では、酸化物及び窒化物の原料について、両者の原料が均一に混合された原料と、両者の原料が均一に混合されていない原料を使用した。両者の原料が均一に混合されていない原料は、見かけ上均一になるように混合しているが、実質的に均一に混合されていない原料である。
原料22:窒化珪素又はジルコニアを個別に遊星型ボールミルにてアセトンを媒体として粉砕して、それぞれの中位径が0.7μmになるように調整した。個別に150℃に加熱して十分乾燥した後、窒化珪素及びジルコニアが質量比で1:2になるようにして、テフロン(登録商標)製のボールミル容器に入れ、ボールを入れずに乾式で30分間混練して、見かけ上均一になるようにして準備したものである。
ここでは、実施例3として、エアロゾルデポジション法を使用して、基材としての鋼材基板上に、酸化物及び窒化物の組み合わせとして、窒化珪素、窒化アルミニウム、アルミナ、ジルコニア、イットリア、セリア、及びチタニアを用い、種々の組み合わせで、複合セラミックスを被覆した複合セラミックス積層体を用意した。
基材の表面には、15μm~55μmの厚さを示すセラミックス膜が形成されていることが分かった。酸化物原料粒子として、ジルコニア、イットリア、又はセリアを含有する混合原料を用いて成膜した複合セラミックスの膜厚は、これら酸化物の含有量が少量であっても、窒化珪素粉単独で成膜したものに比較して膜厚が大きくなった。実施例1の試料5、実施例3の試料31及び試料32に見られるように、窒化物は、成膜レートが小さい。一方で、ジルコニア、及び希土類酸化物は、成膜効率を高める作用がある。特に、希土類酸化物で、成膜効率を高める作用は大きい。さらに、希土類酸化物の使用は、空隙率を低減し、緻密化にも寄与する。一方、α-Si3N4のみで成膜した場合、膜厚を厚くしていくと、基材からの剥離が起きる。α-Si3N4のみで成膜したセラミックスの膜厚が小さいのは、膜厚は剥離が生じた部分で評価したためである。
試料34の第1相はα-Si3N4相であり、第2相はAl2O3相である。ただし、α-Si3N4相と第2相のAl2O3相のヤング率の違いは本開示の定義で9.5%である。
試料35の第1相はβ-Si3N4相であり、第2相はAl2O3相である。試料35の強靭化相はAl2O3である。
試料36の第1相はα-Si3N4相であり、第2相はAl2O3相であり、第3相はY2O3相である。しかし、面積率が1%以上で、第1相の弾性率と最も差が大きい弾性率である相が強靭化相であるから、試料36の強靭化相は、Al2O3相よりヤング率の小さいY2O3相である。
試料37の第1相はα-Si3N4相であり、第2相はZrO2相である。しかし、面積率が1%未満であるから、試料37に強靭化相は存在しない。
試料38の第1相はα-Si3N4相であり、第2相はZrO2相である。第2相の面積率が1%以上であるから、試料36の強靭化相は、ZrO2相である。
試料39の第1相はα-Si3N4相であり、第2相はZrO2相であり、第3相はCeO2相である。面積率が1%以上で、第1相の弾性率と最も差が大きい弾性率である相が強靭化相であるから、試料36の強靭化相は、ZrO2相よりヤング率の小さいCeO2相である。
試料40は第1相がAl2O3相であり、第2相はAlN相である。試料40の強靭化相はAlN相である。
試料41は第1相がα-Si3N4相であり、第2相のTiO2相である。試料41の強靭化相はTiO2相である。
窒化珪素相を第1相とする試料4、試料31、試料32、及び試料39について、耐摩耗性の評価を行った。耐摩耗性の評価は次のようにして行った。
10 複合セラミックス積層体
11 複合セラミックス
12 基材
13 金属などの被覆物
14 接合面
15 窒化物相
16 酸化物相
17 空隙
28 接合面に垂直な方向な線
29 接合面に垂直な方向な線と結晶粒界の交点
38 接合面に平行な方向な線
39 接合面に平行な方向な線と結晶粒界の交点
本明細書に記載された全ての文献、特許出願、および技術規格は、個々の文献、特許出願、および技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。
Claims (10)
- 基材と、
前記基材を被覆する複合セラミックスと、
を備え、
前記複合セラミックスは、窒化物相、及び前記窒化物相が有する弾性率と10%以上異なる弾性率を有する酸化物相を含み、残部が不純物である複合材料であり、
前記複合セラミックスと前記基材との接合面に対して直交する断面において、
前記窒化物相及び前記酸化物相のうち、最も大きな面積率を占める相を第1相とし、1%以上の面積率を占め、前記第1相の弾性率と最も差が大きい弾性率である相を強靭化相とし、
前記第1相が前記窒化物相であるとき、前記強靭化相は前記酸化物相であり、前記第1相が前記酸化物相であるとき、前記強靭化相は前記窒化物相である、複合セラミックス積層体。 - 前記複合セラミックスと前記基材との接合面に対して直交する断面において、複合セラミックスは、長径0.1μm以上の空隙が、面積率で、0%以上3%以下である、請求項1に記載の複合セラミックス積層体。
- 前記複合セラミックスと前記基材との接合面に対して直交する断面において、前記接合面に対して垂直な方向における前記強靭化相の粒子径の平均が1μm以下である、請求項1又は請求項2に記載の複合セラミックス積層体。
- 前記第1相が、窒化珪素相、又は窒化アルミニウム相である、請求項1~請求項3のいずれか1項に記載の複合セラミックス積層体。
- 前記第1相がジルコニア相、アルミナ相、又は希土類酸化物相のいずれかである、請求項1~請求項3のいずれか1項に記載の複合セラミックス積層体。
- 前記ジルコニア相の一部が正方晶構造である、請求項5に記載の複合セラミックス積層体。
- 前記窒化物相と前記酸化物相との組み合わせとして、窒化珪素相とジルコニア相、窒化珪素相とアルミナ相、窒化珪素相と希土類酸化物相、窒化アルミニウム相とジルコニア相、窒化アルミニウム相とアルミナ相、又は窒化アルミニウム相と希土類酸化物相のいずれかである、請求項1~請求項5のいずれか1項に記載の複合セラミックス積層体。
- 前記ジルコニア相の一部が正方晶構造である、請求項7に記載の複合セラミックス積層体。
- 前記基材が金属製基材である、請求項1~請求項8のいずれか1項に記載の複合セラミックス積層体。
- 窒化物原料粒子、及び前記窒化物原料粒子の弾性率と10%以上異なる弾性率を有する酸化物原料粒子を混合した混合原料を準備する工程と、
前記混合原料に対し、気体を混合させてエアロゾルを生成し、前記エアロゾルを基材に向けて噴射する工程と、
を有する、セラミックス積層体の製造方法。
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JP2006131992A (ja) * | 2004-10-04 | 2006-05-25 | Sumitomo Electric Ind Ltd | セラミックス膜およびその製造方法、セラミックス複合膜およびその製造方法ならびに切削工具 |
JP2011131348A (ja) * | 2009-12-25 | 2011-07-07 | Mitsubishi Materials Corp | 表面被覆切削工具 |
JP2013248691A (ja) * | 2012-05-31 | 2013-12-12 | Mitsubishi Materials Corp | 表面被覆切削工具 |
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KR100724070B1 (ko) * | 1999-10-12 | 2007-06-04 | 도토기키 가부시키가이샤 | 복합 구조물 및 그의 제조방법과 제조장치 |
JP2002309384A (ja) * | 2001-04-12 | 2002-10-23 | National Institute Of Advanced Industrial & Technology | 複合構造物およびその製造方法 |
JP4521062B2 (ja) * | 2007-10-16 | 2010-08-11 | パナソニック株式会社 | 成膜方法および成膜装置 |
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- 2019-04-03 CN CN201980023387.3A patent/CN112004960A/zh active Pending
- 2019-04-03 WO PCT/JP2019/014860 patent/WO2019194240A1/ja unknown
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US20210101840A1 (en) | 2021-04-08 |
KR20200128119A (ko) | 2020-11-11 |
EP3778989A4 (en) | 2021-12-01 |
CN112004960A (zh) | 2020-11-27 |
JPWO2019194240A1 (ja) | 2021-04-01 |
JP6992879B2 (ja) | 2022-01-13 |
EP3778989A1 (en) | 2021-02-17 |
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