Silicon alloy, alloy powder thereof, manufacturing apparatus, manufacturing process and sintered alloy thereof

Abstract

A controlled combustion synthesis apparatus comprises an ignition system, a pressure sensor for detecting internal pressure, a nitrogen supply, a gas pressure control valve for feeding nitrogen and exhausting reaction gas, means for detecting the internal temperature of the reaction container, a water cooled jacket, and a cooling plate. A temperature control system controls the temperature of the reaction container by controlling the flow of cooling water supplied to the jacket and the cooling plate in response to the detected temperature. By combustion synthesizing, while controlling the internal pressure and temperature, the apparatus can synthesize a silicon alloy including 30-70 wt. % silicon, 10-45 wt. % nitrogen, 1-40 wt. % aluminum, and 1-40 wt % oxygen.

Description

CROSS REFERENCE TO RELATED. APPLICATION[0001]This application claims priority from Japanese patent application No. 354835 / 2006, filed Dec. 28, 2006.FIELD OF THE INVENTION[0002]This invention relates generally to alloys based on silicon, and specifically to a silicon alloy, an alloy powder, a manufacturing apparatus, a manufacturing process, and a sintered alloy.BACKGROUND OF THE INVENTION[0003]Silicon is now in very limited use as an industrial material, and is used mainly as a silicon nitride (Si3N4) compound. For information on silicon nitride industrial materials, reference may be made to “2006 Fine Ceramics Industry Trend Search,” Japan Fine Ceramics, published in December, 2006. However, silicon in the form of a silicon alloy has not yet been used as an industrial material in applications where its structural strength is relatively important.[0004]Since silicon nitride is formed by a covalent bond of silicon and nitrogen in the uniform ratio of 3:4, impurities, especially metal...

AI Technical Summary

Benefits of technology

[0011]While vast quantities of silicon exist on the earth, almost all of the naturally occurring silicon is in the form of silicon dioxide, as desert sand for example. This invention makes it practical to utilize, silicon as a general purpose industrial structural material.

Problems solved by technology

However, silicon in the form of a silicon alloy has not yet been used as an industrial material in applications where its structural strength is relatively important.

Material costs, and the cost of synthesis and processing of silicon nitride are extremely high, and consequently, the silicon nitride is yet to become an efficient form in which to utilize silicon as an industrial material.

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