G-D. Zhan et al.: Effects of heat treatment and sintering additives on therm. cond. and elec. resist. in fine-grained SiC ceramics
Al2O3 and a material with Al2O3 and Y2O3 additives,
respectively.14,15 The electrical resistivity of these mate-
rials was not reported.
oxide glass modifies the physical properties by increas-
ing softening temperatures, elastic modulus, and the
hardness of the glasses.21,22 Accordingly, Y–Mg–Si–Al–
O–N (G1) and Y–Al–Si–O–N (G2) oxynitride glasses,
which have appreciable SiC solubility, were selected as
the grain-boundary phases. To directly compare the ef-
fects of the oxide or oxynitride additives on the thermal
and electrical properties, the total additive amounts were
kept the same (10 wt%).
More recently, we have reported that liquid-phase-
sintered SiC with rare-earth additives exhibits desirable
thermal and electrical properties for an electronic sub-
strate application.17 In the present study, oxide and oxy-
nitride additives were used to enhance densification of
fine-grained SiC. A seeding technique and annealing
treatment were used to control grain growth.18–20 The
thermal and electrical properties of these materials meas-
ured at room temperature are reported here. High-
resolution electron microscopy (HREM) and energy
dispersive x-ray spectroscopy (EDS) were used to exam-
ine the state and compositions at the grain boundaries
and within the grains. The electrical and thermal proper-
ties were analyzed in terms of the geometry and chem-
istry of the microstructure and grain boundaries.
For the oxide additives, either 2.7 wt% coarse ␣–SiC
powder (A-1 grade, 0.45 m, Showa Denko, Tokyo, Ja-
pan) or –SiC powder (B-1, grade, 0.43 m, Showa
Denko, Tokyo, Japan) was added as a nuclei for grain
growth, which corresponds to 3.0 wt% SiC powder. The
ultrafine SiC powder was eventually blended with
10 wt% of these sintering additives. The powder mixture
was dried and hot pressed at 1750 °C for 40 min under a
pressure of 25 MPa in Ar atmosphere for the mixture
with oxide additives and in N2 atmosphere for the mix-
ture with oxynitride additives. The hot-pressed materials
were further annealed at different temperatures and for
different times. The processing conditions and the result-
ing densities of the hot-pressed and annealed materials
are given in Table I. The chemical vapor deposition sili-
con carbide (CVD-SiC) with -phase polycrystalline and
thermal expansion coefficient of 4.5 × 10−6/°C was pre-
pared in reactant gases of SiC14 and CH4. The total im-
purities were less than 1 ppm, including Cu < 100 ppb,
K < 60 ppb, Cr ס
26 ppb, Mo < 40 ppb, and
Fe ס
35 ppb. The bending strength, Vickers hardness,
and Young’s modulus were 784 MPa, 34.3 GPa, and
490 GPa, respectively.
The density of the hot-pressed and annealed materials
was determined by the Archimedes method using dis-
tilled water as an immersion medium. The materials were
cut, polished, and then etched by a plasma of CF4 con-
taining 7.8% O2. The microstructures were observed by
scanning electron microscopy (SEM). Note that the ob-
served surfaces for all materials were perpendicular to
the hot-pressing direction. SEM micrographs were ana-
lyzed using image analysis (Model Luzex III, Nireco
Co., Tokyo, Japan) to determine grain size and aspect
ratio (R95).23 X-ray diffraction (XRD) patterns were
II. EXPERIMENTAL
The starting material was an ultrafine –SiC powder
with an average particle size of 90 nm (Sumitomo-Osaka
Cement Co., Tokyo, Japan). Oxide and oxynitride addi-
tives were used. The oxide additive was a mixture of
7 wt% Al2O3 (99.9% pure, Sumitomo Chemical Co.,
Tokyo, Japan), 2 wt% Y2O3 (99.9% pure, Shin-Etsu
Chemical Co., Tokyo, Japan), and 1.785 wt% CaCO3
(high-purity grade, Wako Chemical Co., Osaka, Japan)
that decomposes to 1 wt% CaO at high temperature. The
oxynitride additive was a mixture of 42 wt% SiO2 (re-
agent grade, Kanto Chemical Co., Tokyo, Japan),
10.9 wt% MgO (high-purity grade, Wako pure Chemical
Industries, Ltd., Osaka, Japan), 23.7 wt% Y2O3 (99.9%
pure, Shin-Etsu Chemical Co., Tokyo, Japan), 13.0 wt%
Al2O3, and 10.4 wt% AlN (Grade F, Tokuyama Soda
Co., Tokyo, Japan) powders. The oxynitride composition
of Y0.124 Mg0.160 Si0.414 Al0.302 O1.4 N0.151, designated
as G1, was prepared by ball milling in hexane for 3 h
using SiC media and a SiC container. A second mixture
of 36.9 wt% Y2O3, 55.8 wt% Al2O3 and 7.3 wt% AlN
powders was designated as G2. For the case of oxynitride
additives, the incorporation of nitrogen atoms into the
TABLE I. Sintering additives, processing conditions, and densities of fine-grained SiC ceramics.
Materials
Additives
Processing conditions
HP: 1750 °C/40min
HP: 1750 °C/40min + HT: 1850 °C/4h
HP: 1750 °C/40min + HT: 1850 °C/4h
HP: 1750 °C/40min + HT: 2000 °C/3h
HP: 1750 °C/40min + HT: 2000 °C/3h
Chemical vapor deposition
Density (g/cm3)
SC0
SC1
SC2
SC3
SC4
CVD-SiC
Oxide additives + ␣–SiC seeds
Oxide additives + ␣–SiC seeds
Oxide additives + –SiC seeds
Oxynitride additives, G1
Oxynitride additives, G2
Reactant gases: SiC14 and CH4
3.21
3.19
3.18
3.17
3.21
3.21
HP: hot-pressing; HT: heat treatment.
2328
J. Mater. Res., Vol. 17, No. 9, Sep 2002
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