TW202024000A - Ｃｒ－Ｓｉ系燒結體、濺鍍靶材及薄膜的製造方法 - Google Patents
Ｃｒ－Ｓｉ系燒結體、濺鍍靶材及薄膜的製造方法 Download PDFInfo
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- TW202024000A TW202024000A TW108142049A TW108142049A TW202024000A TW 202024000 A TW202024000 A TW 202024000A TW 108142049 A TW108142049 A TW 108142049A TW 108142049 A TW108142049 A TW 108142049A TW 202024000 A TW202024000 A TW 202024000A
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- sintered body
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- silicon
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- 229910019819 Cr—Si Inorganic materials 0.000 title claims abstract description 36
- 239000011651 chromium Substances 0.000 claims abstract description 36
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 31
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 19
- 239000010703 silicon Substances 0.000 claims abstract description 19
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 18
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 13
- 238000002441 X-ray diffraction Methods 0.000 claims abstract description 8
- CHXGWONBPAADHP-UHFFFAOYSA-N [Si].[Si].[Cr] Chemical compound [Si].[Si].[Cr] CHXGWONBPAADHP-UHFFFAOYSA-N 0.000 claims abstract description 6
- 238000000034 method Methods 0.000 claims description 26
- 239000002245 particle Substances 0.000 claims description 20
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 15
- 239000001301 oxygen Substances 0.000 claims description 15
- 229910052760 oxygen Inorganic materials 0.000 claims description 15
- 238000005477 sputtering target Methods 0.000 claims description 15
- 238000004544 sputter deposition Methods 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 239000010409 thin film Substances 0.000 claims description 6
- 239000013077 target material Substances 0.000 claims description 3
- 229910019974 CrSi Inorganic materials 0.000 claims 2
- 229910021357 chromium silicide Inorganic materials 0.000 abstract description 18
- 239000013078 crystal Substances 0.000 abstract description 7
- 239000000843 powder Substances 0.000 description 34
- 238000002844 melting Methods 0.000 description 29
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- 238000007731 hot pressing Methods 0.000 description 28
- 238000009689 gas atomisation Methods 0.000 description 22
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- 229910021359 Chromium(II) silicide Inorganic materials 0.000 description 15
- 239000012535 impurity Substances 0.000 description 14
- 230000000052 comparative effect Effects 0.000 description 12
- 239000002994 raw material Substances 0.000 description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 8
- 229910052799 carbon Inorganic materials 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 8
- 239000010949 copper Substances 0.000 description 6
- 239000010408 film Substances 0.000 description 6
- 229910021332 silicide Inorganic materials 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 5
- 229910052802 copper Inorganic materials 0.000 description 5
- 238000001036 glow-discharge mass spectrometry Methods 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
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- 230000006837 decompression Effects 0.000 description 4
- 229910052748 manganese Inorganic materials 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000000227 grinding Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 238000007088 Archimedes method Methods 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- OLBVUFHMDRJKTK-UHFFFAOYSA-N [N].[O] Chemical compound [N].[O] OLBVUFHMDRJKTK-UHFFFAOYSA-N 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000013001 point bending Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 239000011863 silicon-based powder Substances 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000000859 sublimation Methods 0.000 description 1
- 230000008022 sublimation Effects 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/74—Physical characteristics
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
Abstract
包含矽化鉻（CrSi2
）、矽（Si）的Cr-Si系燒結體難以實現高強度。本發明提供一種Cr-Si系燒結體，是包含Cr（鉻）、矽（Si）的Cr-Si系燒結體，所述Cr-Si系燒結體的特徵在於：於X射線繞射中所歸屬的結晶結構是由矽化鉻（CrSi2
）、矽（Si）構成，CrSi2
相於塊體中存在60 wt%以上，燒結體密度為95%以上，CrSi2
相的平均粒徑為60 μm以下。
Description
本發明是有關於一種薄膜形成用Cr-Si系燒結體。
近年來，如CrSi2
般的矽化物由於其特性而在半導體、太陽能電池等眾多的地方被用作薄膜。薄膜的製作於工業上大多採用濺鍍法。但是，已知含有如CrSi2
般的矽化物的組成物通常強度低，在濺鍍靶材的加工時及成膜的放電時存在破裂的現象而難以用作濺鍍靶材。因此，在專利文獻1中利用噴鍍法來製作Cr、Si的結晶相的濺鍍靶材。但是，在噴鍍法中，在Cr的分配少的地方，強度未充分提高，另外，使用矽化物相的粉末並藉由噴鍍法製作的濺鍍靶材未高強度化。
另外，在專利文獻2中，利用熔融法製作具有微細的共晶組織的組成物。但是，在熔融法中共晶組織的比例少，在存在大量初晶的組成中無法實現高強度化。進而，在大型化時，由於冷卻速度的不同，結晶組織的控制變得困難，強度的不均變大。
進而，在專利文獻3、專利文獻4中，由於矽化物相脆，因此並未提及含有大量的矽化物的系統。
[現有技術文獻]
[專利文獻]
[專利文獻1]日本專利特開2017-82314號公報
[專利文獻2]日本專利特表2013-502368號公報
[專利文獻3]日本專利特開2002-173765號公報
[專利文獻4]日本專利特開2003-167324號公報
[發明所欲解決之課題]
本發明的目的在於提供一種包含Cr（鉻）、矽（Si）的高強度的Cr-Si系燒結體。
[解決課題之手段]
本發明者等人對化學計量組成中由矽化鉻（CrSi2
）、矽（Si）構成且CrSi2
相具有特定量以上的Cr-Si系燒結體的製造製程進行了努力研究，結果發現，藉由使用氣體霧化粉末等急冷合金粉末，可獲得高強度的Cr-Si系燒結體，從而完成了本發明。
即，本發明的態樣為如下所述。
（1）一種Cr-Si系燒結體，是包含Cr（鉻）、矽（Si）的Cr-Si系燒結體，所述Cr-Si系燒結體的特徵在於：於X射線繞射中所歸屬的結晶結構是由矽化鉻（CrSi2
）、矽（Si）構成，CrSi2
相於塊體中存在60 wt%以上，燒結體密度為95%以上，CrSi2
相的平均粒徑為60 μm以下。
（2）如（1）所述的Cr-Si系燒結體，其特徵在於抗折強度為100 MPa以上。
（3）如（1）或（2）所述的Cr-Si系燒結體，其特徵在於塊體中的氧量為1 wt%以下。
（4）一種濺鍍靶材，其特徵在於包含如（1）～（3）中任一項所述的Cr-Si系燒結體。
（5）一種薄膜的製造方法，其特徵在於使用如（4）所述的濺鍍靶材進行濺鍍。
以下，對本發明進行詳細說明。
本發明為包含Cr（鉻）、矽（Si）的Cr-Si系燒結體，所述Cr-Si系燒結體的特徵在於：於X射線繞射中所歸屬的結晶結構是由矽化鉻（CrSi2
）、矽（Si）構成，CrSi2
相於塊體中存在60 wt%以上，燒結體密度為95%以上，CrSi2
相的平均粒徑為60 μm以下。
本發明的Cr-Si系燒結體的結晶相的特徵在於是於X射線繞射（X-Ray Diffraction，XRD）中包含矽化鉻（CrSi2
）相、矽（Si）相的系統。若矽化反應未充分進行，本來於組成上應不存在的其他矽化物相（Cr3
Si、Cr5
Si3
、CrSi）或鉻（Cr）相局部地存在，則由於密度差而內含微裂紋，尤其是在大型的燒結體中容易破裂，無法良率良好地製造燒結體。另外，於使用所述燒結體且利用濺鍍投入高功率的情況下，於放電過程中容易產生破裂而成為使成膜步驟的生產性降低的原因，因此欠佳。
本發明的Cr-Si系燒結體的特徵在於：CrSi2
相於塊體中存在60 wt%以上。較佳為70 wt%以上，尤佳為80 wt%以上。
本發明的Cr-Si系燒結體的燒結體密度的特徵在於：以相對密度計為95%以上。若燒結體密度低於95%，則強度減少。進而，於用作濺鍍靶材的情況下，電弧放電產生的頻率變高，因此較佳為97%以上，更佳為98%以上。
另外，本發明的Cr-Si系燒結體的矽化鉻的粒徑的特徵在於為60 μm以下。若大於60 μm，則強度急劇地減少。為了穩定地獲得高強度，粒徑較佳為1 μm～60 μm，更佳為1 μm～20 μm，尤佳為1 μm～10 μm。
就製成膜時的顆粒的產生及膜製品的良率的觀點而言，本發明的Cr-Si系燒結體的塊體中的氧量較佳為1 wt%以下，更佳為0.5 wt%以下，進而佳為0.1 wt%以下，進一步佳為0.05 wt%以下。
本發明的Cr-Si系燒結體的抗折強度較佳為100 MPa以上，更佳為100 MPa～500 MPa，進而佳為150 MPa～500 MPa，尤佳為200 MPa～500 MPa。若燒結體的強度高，則於研磨加工、接合步驟中亦不易產生破裂，良率高，因此生產性良好。進而，於在濺鍍過程中投入高功率的情況下，亦不易產生破裂的問題。
本發明的Cr-Si系燒結體可含有作為總量為1 wt%以下的Cr（鉻）、矽（Si）以外的不可避免的金屬雜質，亦可含有較佳為0.5 wt%以下、進而佳為0.05 wt%以下、進一步佳為0.01 wt%以下。
作為Cr（鉻）、矽（Si）以外的不可避免的金屬雜質，尤其是可含有作為總量為1 wt%以下的Fe、Ni、Al、Mn、Cu等金屬雜質，亦可含有較佳為0.5 wt%以下、進而佳為0.05 wt%、進一步佳為0.01 wt%以下。
作為各元素，Fe可含有0.1 wt%以下、較佳為0.05 wt%以下、進而佳為0.01 wt%以下。Ni可含有0.01 wt%以下、較佳為0.005 wt%以下、進而佳為0.001 wt%以下。Al可含有0.1 wt%以下、較佳為0.05 wt%以下、進而佳為0.01 wt%以下。Mn可含有0.005 wt%以下、較佳為0.001 wt%以下、進而佳為0.005 wt%以下。Cu可含有0.01 wt%以下、較佳為0.005 wt%以下、進而佳為0.001 wt%以下。
其次，對本發明的Cr-Si系燒結體的製造方法進行說明。
本發明的Cr-Si系燒結體的製造方法可藉由包括（1）合金原料調整步驟、（2）煆燒步驟的步驟而加以製造，所述（1）合金原料調整步驟使用鉻、矽，利用氣體霧化法、電弧熔解法等，所述（2）煆燒步驟使用熱壓製爐等加壓煆燒爐，於壓力50 MPa以下、煆燒溫度1100℃～1300℃下對所得的原料粉末進行煆燒。
以下，關於本發明的Cr-Si系燒結體的製造方法，對每個步驟進行說明。
（1）合金原料調整步驟
原料使用鉻、矽。原料的純度較佳為99.9%以上，更佳為99.99%以上。若含有大量的雜質，則成為煆燒步驟中的異常晶粒生長的原因或成膜時的顆粒的產生源。另外，以原料的氧量較少者為佳。若原料中的氧量較多，則最終濺鍍靶材中的氧量變多而成為顆粒產生的原因。
合成原料粉末可藉由氣體霧化法、電弧熔解法而加以製造。
合金原料粉末較佳為藉由氣體霧化法等進行快速冷卻而製作具有微細組織的粉末。尤其是藉由氣體霧化法製作的粒子成為數十μm左右的球狀，成為於球狀內具有微細的CrSi2
相與Si相的粉末。由於表面積小且為微細粒，因此可使煆燒後的燒結體為低氧且高強度。於微粉末混合中亦可製作高強度的塊體，但氧量變多。相反地若為粗粒的混合，則可實現低氧化，但強度變低。作為其他的原料製作方法，有急冷薄帶、電弧熔解等快速冷卻的方法。
氣體霧化法的條件較佳為設為熔融溫度+50℃～300℃。進而佳為設為+100℃～250℃。此處，所謂熔融溫度，表示原料粉末熔融的溫度，通常為1300℃～1500℃。於與熔融溫度的差小的情況下，2相的結晶相的熔點較高者先析出，粒子的微細化困難。另一方面，於與熔融溫度的差較高時，於霧化後粒子彼此燒結，固著於壁面，因此粉末的回收率變差。
另外，氣體霧化後的粉末較佳為於真空中或氮氣、氬氣等惰性環境中進行管理。若於大氣下放置粉末，則表面會發生氧化，粉末中的氧量變多。
電弧熔解法的條件重要的是電弧的輸出功率。藉此，決定是否可將熔點差大的材料合金化。例如於鉻與矽的情況下，由於鉻的熔點為1863℃，矽的熔點為1414℃，因此必須以輸出功率為50 A～200 A進行熔解。若電弧電流過高，則鉻的昇華量會增加，因此電弧熔解的輸出功率較佳為50 A～150 A的範圍內。
（2）煆燒步驟
其次，較佳為對所得的粉末使用熱壓製爐等加壓煆燒爐。若利用未加壓爐，則矽的擴散係數低，因此難以進行高密度化。
煆燒時的熱壓製壓力較佳為設為50 MPa以下。若超過50 MPa，則可加壓的熱壓製模具的準備困難。於製作大型的燒結體時，熱壓製壓力較佳為5 MPa～50 MPa，進而佳為5 MPa～20 MPa，尤佳為5 MPa～10 MPa。
煆燒溫度設為1100℃～1300℃。若未滿1100℃，則密度未充分提高，若超過1300℃，則藉由熱壓製的壓力有可能熔解。另外，降溫速度並無特別限定，可考慮煆燒爐的容量、燒結體的尺寸及形狀、破裂容易度等適宜決定。
煆燒時的保持時間設為1小時～5小時以內。於短於1小時時，於爐內及熱壓製的模具中會產生溫度不均，難以獲得均勻的組織。反之，於保持時間較長時，生產性變差。
作為煆燒時的環境，並無特別限制，較佳為真空或氬氣等惰性環境。
本發明的Cr-Si系燒結體可使用平面磨床、圓筒磨床、旋床、切割機、加工中心等機械加工機，研磨加工成板狀形狀。
本發明的Cr-Si系燒結體可製成包含本發明的Cr-Si系燒結體的濺鍍靶材。作為濺鍍靶材的製造方法，可視需要藉由使用銦焊料等結合（接合）於包含無氧銅或鈦等的背板、背管而獲得濺鍍靶材。
另外，亦可藉由使用所得的濺鍍靶材進行濺鍍而製造薄膜。
[發明的效果]
本發明的Cr-Si系燒結體具有高強度，於用作濺鍍靶材的情況下，即便於高輸出功率下亦無破裂，可獲得高生產性，進而佳為氧量少，因此於成膜時可進行低顆粒化。
以下，藉由實施例更具體地說明本發明，但本發明並不限定於此。再者，本實施例中的各測定以如下方式進行。
（1）燒結體的密度
燒結體的相對密度是依據日本工業標準（Japanese Industrial Standards，JIS）R 1634，藉由阿基米德法測定體積密度，並除以真密度而求出相對密度。燒結體的真密度是使用CrSi2
相的重量a[g]及Si相的重量為b[g]、各自的真密度為4.98[g/cm3
]、2.3[g/cm3
]，根據下述式所表示的相加平均來算出。
d=（a+b）/（（a/4.98）+（b/2.3））
（2）X射線繞射試驗
測定鏡面研磨後的燒結體試樣的2θ=20°～70°的範圍的X射線繞射圖案。
掃描方法：步進掃描法（FT法）
X射線源：CuKα
功率：40 kV、40 mA
步長：0.01°
（3）燒結體粒徑
進行鏡面研磨，並利用掃描式電子顯微鏡觀察，根據所得的燒結體組織圖像利用直徑法測定燒結體粒徑。至少觀察任意3點以上，進行300個以上的粒子的測定。
（掃描式電子顯微鏡的觀察條件）
加速電壓：10 kV
（4）抗折強度
依據JIS R 1601進行了測定。
（抗折強度的測定條件）
試驗方法：三點彎曲試驗
支點間距離：30 mm
試樣尺寸：3 mm×4 mm×40 mm
噴頭速度：0.5 mm/分鐘。
（5）氧量的分析
將從自煆燒後的燒結體表面研磨1 mm以上後的任意部分切出的樣品的分析值作為測定資料。
測定方法：脈衝爐熔融-紅外線吸收法
裝置：LECO TC436 氧-氮分析裝置
（6）金屬雜質量的分析
將從自煆燒後的燒結體表面研磨1 mm以上後的任意部分切出的樣品的分析值作為測定資料。
測定方法：輝光放電質譜（Glow Discharge Mass Spectrometry，GDMS）
（實施例1）
在碳坩堝內熔解Cr薄片（4N）：42 wt%、Si薄片（5N）：58 wt%，將熔融溫度設為1650℃，藉由氣體霧化法製作粉末。將粉末在大氣下藉由篩子（篩目尺寸：300 μm）實施粉末的粒度調整。
其次，將該粉末放入碳模具（53 mmϕ）中，藉由熱壓製法煆燒，獲得燒結體。
（煆燒條件）
煆燒爐：熱壓製爐
升溫速度：200℃/小時
升溫環境：真空減壓環境
煆燒溫度：1250℃
壓力：10 MPa
煆燒時間：3小時
獲得燒結體尺寸為53 mmϕ×7 mmt的無微裂紋的燒結體。燒結體特性如表1所示。
（實施例2～實施例5）
除了變更煆燒條件以外，利用與實施例1同樣的方法製作燒結體。燒結體的燒結體特性如表1所示。
（實施例6）
在輸出功率100 A的條件下藉由電弧熔解法熔解Cr薄片（4N）：29 wt%、Si薄片（5N）：71 wt%。將所得的塊體利用乳缽粉碎，在實施例3的條件下煆燒。燒結體的特性如表1所示。
（實施例7）
在碳坩堝內熔解Cr薄片（4N）：42 wt%、Si薄片（5N）：58 wt%，將熔融溫度設為1650℃，藉由氣體霧化法製作粉末。將粉末在手套箱內（氧濃度：0.1 wt%以下）藉由篩（篩目尺寸：300 μm）實施粉末的粒度調整。
其次，將該粉末放入碳模具（53 mmϕ）中，藉由熱壓製法煆燒，獲得燒結體。
（煆燒條件）
煆燒爐：熱壓製爐
升溫速度：200℃/小時
升溫環境：真空減壓環境
煆燒溫度：1200℃
壓力：20 MPa
煆燒時間：3小時
獲得燒結體尺寸為53 mmϕ×7 mmt的無微裂紋的燒結體。燒結體特性如表1所示。
另外，對金屬雜質量進行GDMS分析，Cr、Si以外的金屬雜質總量為0.034 wt%以下，各自的雜質量是Fe為0.0066 wt%，Ni為0.00082 wt%，Al為0.000048 wt%，Mn為0.00011 wt%，Cu為0.000051 wt%。
（實施例8）
在碳坩堝內熔解Cr薄片（4N）：29 wt%、Si薄片（5N）：71 wt%，將熔融溫度設為1540℃，藉由氣體霧化法製作粉末。將粉末在手套箱內（氧濃度：0.1 wt%以下）藉由篩（篩目尺寸：300 μm）實施粉末的粒度調整。
其次，將該粉末放入碳模具（53 mmϕ）中，藉由熱壓製法煆燒，獲得燒結體。
（煆燒條件）
煆燒爐：熱壓製爐
升溫速度：200℃/小時
升溫環境：真空減壓環境
煆燒溫度：1200℃
壓力：20 MPa
煆燒時間：3小時
獲得燒結體尺寸為53 mmϕ×7 mmt的無微裂紋的燒結體。燒結體特性如表1所示。
另外，對金屬雜質量進行GDMS分析，Cr、Si以外的金屬雜質總量為0.026 wt%以下，各自的雜質量是Fe為0.0027 wt%，Ni為0.00039 wt%，Al為0.000022 wt%，Mn為0.000041 wt%，Cu為0.000012 wt%。
（實施例9）
除了變更煆燒條件以外，利用與實施例8同樣的方法製作燒結體。燒結體的燒結體特性如表1所示。
（實施例10）
在碳坩堝內熔解Cr薄片（4N）：47 wt%、Si薄片（5N）：53 wt%，將熔融溫度設為1540℃，藉由氣體霧化法製作粉末。將粉末在手套箱內（氧濃度：0.1 wt%以下）藉由篩（篩目尺寸：300 μm）實施粉末的粒度調整。
其次，將該粉末放入碳模具（53 mmϕ）中，藉由熱壓製法煆燒，獲得燒結體。
（煆燒條件）
煆燒爐：熱壓製爐
升溫速度：200℃/小時
升溫環境：真空減壓環境
煆燒溫度：1200℃
壓力：20 MPa
煆燒時間：3小時
獲得燒結體尺寸為53 mmϕ×7 mmt的無微裂紋的燒結體。燒結體特性如表1所示。
另外，對金屬雜質量進行GDMS分析，Cr、Si以外的金屬雜質總量為0.03 wt%以下，各自的雜質量是Fe為0.0062 wt%，Ni為0.00078 wt%，Al為0.000035 wt%，Mn為0.000068 wt%，Cu為0.000041 wt%。
（實施例11）
除了變更煆燒條件以外，利用與實施例10同樣的方法製作燒結體。燒結體的燒結體特性如表1所示。
（比較例1）
利用電弧熔解法熔解Cr薄片（4N）：42 wt%、Si薄片（5N）：58 wt%。熔解後所得的塊體的特性如表1所示。
（比較例2）
將比較例1中製作的塊體利用乳缽粉碎，利用熱壓製法製作。燒結體特性如表1所示。
（比較例3）
藉由V型混合法混合Cr粉末（45 μm）、Si粉末（9 μm），對混合粉末進行熱壓製，製作燒結體。燒結體特性如表1所示。
（比較例4）
變更煆燒條件，對藉由氣體霧化法製作的粉末進行煆燒。燒結體特性如表1所示。
（比較例5）
利用電弧熔解法熔解Cr薄片（4N）：29 wt%、Si薄片（5N）：71 wt%。熔解後所得的塊體的特性如表1所示。
[表1]
| Cr | Si | 塊體製作方法 | 溫度 | 壓力 | 保持時間 | 結晶相 | CrSi2 相比例 | CrSi2 相粒徑 | 密度 | 抗折強度 | 氧量 | |
| （wt%） | （wt%） | （℃） | （MPa） | （h） | （wt%） | （μm） | （%） | （MPa） | （wt%） | |||
| 實施例1 | 42 | 58 | 氣體霧化+熱壓製 | 1250 | 10 | 3 | CrSi2、Si | 87.1 | 7 | 99.0 | 255 | 0.5 |
| 實施例2 | 42 | 58 | 氣體霧化+熱壓製 | 1200 | 10 | 3 | CrSi2、Si | 87.1 | 7 | 98.8 | 249 | 0.5 |
| 實施例3 | 42 | 58 | 氣體霧化+熱壓製 | 1150 | 10 | 3 | CrSi2、Si | 87.1 | 6 | 95.9 | 204 | 0.6 |
| 實施例4 | 42 | 58 | 氣體霧化+熱壓製 | 1150 | 40 | 3 | CrSi2、Si | 87.1 | 7 | 99.4 | 247 | 0.6 |
| 實施例5 | 42 | 58 | 氣體霧化+熱壓製 | 1050 | 40 | 3 | CrSi2、Si | 87.1 | 6 | 95.9 | 166 | 0.6 |
| 實施例6 | 29 | 71 | 電弧熔解+熱壓製 | 1150 | 40 | 3 | CrSi2、Si | 60.1 | 58 | 97.1 | 129 | 0.1 |
| 實施例7 | 42 | 58 | 氣體霧化+熱壓製 | 1200 | 20 | 3 | CrSi2、Si | 87.1 | 6 | 99.9 | 321 | 0.02 |
| 實施例8 | 29 | 71 | 氣體霧化+熱壓製 | 1200 | 20 | 3 | CrSi2、Si | 60.1 | 3 | 97.6 | 245 | 0.02 |
| 實施例9 | 29 | 71 | 氣體霧化+熱壓製 | 1250 | 20 | 3 | CrSi2、Si | 60.1 | 3 | 99.9 | 277 | 0.01 |
| 實施例10 | 47 | 53 | 氣體霧化+熱壓製 | 1200 | 20 | 3 | CrSi2、Si | 97.6 | 9 | 96.6 | 185 | 0.02 |
| 實施例11 | 47 | 53 | 氣體霧化+熱壓製 | 1250 | 20 | 3 | CrSi2、Si | 97.6 | 10 | 99.0 | 192 | 0.02 |
| 比較例1 | 42 | 58 | 電弧熔解 | - | - | - | CrSi2、Si | 87.1 | 223 | 99.8 | 9 | 0.01 |
| 比較例2 | 42 | 58 | 電弧熔解+熱壓製 | 1150 | 40 | 3 | CrSi2、Si | 87.1 | 106 | 97.3 | 50 | 0.1 |
| 比較例3 | 42 | 58 | 粉末混合+熱壓製 | 1150 | 40 | 3 | Cr5Si3、Si | - | - | 75.6 | 31 | 1.1 |
| 比較例4 | 42 | 58 | 氣體霧化+熱壓製 | 1000 | 10 | 3 | CrSi2、Si | 87.1 | 4 | 92.3 | 84 | 0.6 |
| 比較例5 | 29 | 71 | 電弧熔解 | - | - | - | CrSi2、Si | 60.1 | 144 | 99.7 | 68 | 0.02 |
無
圖1是實施例1與比較例3的X射線分析圖。
Claims (5)
- 一種Cr-Si系燒結體，是包含Cr（鉻）、矽（Si）的Cr-Si系燒結體，所述Cr-Si系燒結體的特徵在於：於X射線繞射中所歸屬的結晶結構是由矽化鉻（CrSi2 ）、矽（Si）構成，CrSi2 相於塊體中存在60 wt%以上，燒結體密度為95%以上，CrSi2 相的平均粒徑為60 μm以下。
- 如申請專利範圍第1項所述的Cr-Si系燒結體，其中抗折強度為100 MPa以上。
- 如申請專利範圍第1項或第2項所述的Cr-Si系燒結體，其中塊體中的氧量為1 wt%以下。
- 一種濺鍍靶材，其特徵在於包含如申請專利範圍第1項至第3項中任一項所述的Cr-Si系燒結體。
- 一種薄膜的製造方法，其特徵在於使用如申請專利範圍第4項所述的濺鍍靶材進行濺鍍。
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| US20230220538A1 (en) * | 2020-05-26 | 2023-07-13 | Tosoh Corporation | METAL-Si BASED POWDER, METHOD FOR PRODUCING SAME, METAL-Si BASED SINTERED BODY, SPUTTERING TARGET, AND METAL-Si BASED THIN FILM MANUFACTURING METHOD |
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| CN112376023A (zh) * | 2020-11-04 | 2021-02-19 | 宁波江丰电子材料股份有限公司 | 一种铬硅合金溅射靶材的制备方法 |
| KR20230132862A (ko) * | 2021-03-29 | 2023-09-18 | 도소 가부시키가이샤 | Cr-Si 계 막 |
| JP7394085B2 (ja) * | 2021-04-05 | 2023-12-07 | Ｊｘ金属株式会社 | スパッタリングターゲット及びその製造方法 |
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