WO2002086180A2 - A process for converting a metal carbide to diamond by etching in halogens - Google Patents
A process for converting a metal carbide to diamond by etching in halogens Download PDFInfo
- Publication number
- WO2002086180A2 WO2002086180A2 PCT/US2002/010678 US0210678W WO02086180A2 WO 2002086180 A2 WO2002086180 A2 WO 2002086180A2 US 0210678 W US0210678 W US 0210678W WO 02086180 A2 WO02086180 A2 WO 02086180A2
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- WO
- WIPO (PCT)
- Prior art keywords
- diamond
- metal carbide
- halogen
- hydrogen
- bearing
- Prior art date
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
- A61L27/28—Materials for coating prostheses
- A61L27/30—Inorganic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/18—Carbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- B01J27/20—Carbon compounds
- B01J27/22—Carbides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J3/00—Processes of utilising sub-atmospheric or super-atmospheric pressure to effect chemical or physical change of matter; Apparatus therefor
- B01J3/06—Processes using ultra-high pressure, e.g. for the formation of diamonds; Apparatus therefor, e.g. moulds or dies
- B01J3/065—Presses for the formation of diamonds or boronitrides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/22—Halogenating
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- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F2310/00—Prostheses classified in A61F2/28 or A61F2/30 - A61F2/44 being constructed from or coated with a particular material
- A61F2310/00389—The prosthesis being coated or covered with a particular material
- A61F2310/00574—Coating or prosthesis-covering structure made of carbon, e.g. of pyrocarbon
- A61F2310/00586—Coating made of graphite
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2203/00—Processes utilising sub- or super atmospheric pressure
- B01J2203/06—High pressure synthesis
- B01J2203/065—Composition of the material produced
- B01J2203/0655—Diamond
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
- C04B2111/00344—Materials with friction-reduced moving parts, e.g. ceramics lubricated by impregnation with carbon
- C04B2111/00353—Sliding parts
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00836—Uses not provided for elsewhere in C04B2111/00 for medical or dental applications
-
- 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
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/90—Electrical properties
- C04B2111/94—Electrically conducting materials
-
- 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
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
-
- 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
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
- C04B2235/383—Alpha silicon carbide
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- C—CHEMISTRY; METALLURGY
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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
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
- C04B2235/3834—Beta silicon carbide
Definitions
- halogens F 2 , Cl 2 , Br 2 , 1 2 or mixtures
- compounds containing one or more halogens e.g., HF, CC1 4 , and the like
- MC is a metal carbide
- D is a gaseous halogen or halogen-containing etchant (e.g., Cl 2 , HCl, and the like)
- M y D x is a gaseous fragment reaction product species
- D 2 is another possible fragment reaction product species.
- This type of reaction can lead to the formation of free carbon, that may maintain the sp 3 structure which it has in carbide and form diamond.
- it can be transformed to graphite, or form various amorphous or disordered carbon structures intermediate to diamond and graphite.
- a metal-halogen e.g., SiCl 4
- a carbon-halogen e.g., CC1 4
- the structure of the carbon layer is affected by temperature and by the composition of the chlorinating gas mixture.
- carbon films or surface layers were formed as an integral part of monolithic metal carbide parts on the surface of commercially available monolithic ⁇ -SiC and ⁇ -SiC specimens by high temperature (100° C or greater) chlorination at atmospheric pressure in H 2 -C1 2 and Cl 2 gas mixtures, using an inert gas, such as Argon, to dilute the halogen gas content to a desired concentration.
- an inert gas such as Argon
- CVD Physical Vapor Deposition
- diamond films deposited with the CVD and PVD * methods do not generally adhere to the substrate, often peeling off during loading which can take place in tribological applications of carbon coatings, such as in cutting tools, bearings, seals, and the like.
- Special techniques used to improve adhesion between diamond films and other ceramic substrates have not been completely successful, particularly on WC tools because of the large differences in physical properties between diamond and WC.
- Other methods that have been used to produce diamond films with special properties include laser vaporization - see Mistry, U.S. Patent No. 5,731 ,046 - Mar. 1998; high temperature synthesis, sputtering - Pulker, U.S. Patent No. 4, 173,522 - Nov.
- a metal carbide preferably a monolithic part that is predominantly a metal carbide or has predominantly a metal carbide surface, e.g., coating
- a gaseous mixture of a halogen and hydrogen containing 0 to two moles, preferably at least 0.3 mole of hydrogen for every two moles of halogen, more preferably at least 0.5 mole of hydrogen per two moles of halogen, most preferably at least 0.75 mole of hydrogen per two moles of halogen relatively thick diamond coatings or surface layers are obtained.
- the process of the present invention can be carried out at atmospheric pressure and does not require plasma or other high-energy sources.
- Impure raw SiC can be used in accordance with the present invention containing predominantly (more than 50 % by weight) SiC, preferably at least 80% SiC, because halogenation will remove most metallic impurities from the predominantly SiC material.
- SiC predominantly (more than 50 % by weight)
- SiC preferably at least 80% SiC
- halogenation will remove most metallic impurities from the predominantly SiC material.
- carbide components or fibers can be coated, but also powders, whiskers and platelets.
- Monolithic parts with complex shapes and surface morphologies can be diamond "coated” in accordance with the present invention. It is the halogen reaction gas in contact with the carbide surface that transforms the material to diamond and minimum hydrogen content at atmospheric pressure that maintains the diamond surface with time without the diamond surface deteriorating to amorphous carbon. This is important for two reasons. First, the reaction can proceed anywhere the gas can reach, e.g., crevices, channels, intricate layered surfaces, holes, and the like. This would be impossible with most of the other current available processes. Second, it allows control of growth on the atomic level.
- Templating of the surface structure/coating will allow various pore sizes (angstroms to nanometers).
- the process of the present invention is environmentally friendly " technology since it can be operational as a closed loop process with the recovery of Si by decomposition of the metal halide, e.g., SiCl 4 , and returning the halogen gas to the manufacturing process.
- the metal halide e.g., SiCl 4
- relatively large volumes of nano- and microcrystalline diamond can be synthesized, at low cost, by the extraction of silicon from silicon carbide in chlorine-containing gases, and preferably at ambient pressure, and preferably at temperatures not exceeding 1,000° C. No plasma or other high-energy activation is required, thus providing an opportunity for large-scale production.
- the presence of at least 0.3 mole of hydrogen for each two moles of halogen in the gas mixture leads to a complete conversation of SiC to diamond, with the average crystallite size of 5-10 nm, and without deterioration of the diamond to graphitic carbon as the reaction proceeds with time.
- Thick and thin coatings, poly crystalline powders with any grain size or micro-components can be made in accordance with the method of the present invention.
- the linear diamond growth kinetics allows transformation of metal carbide to diamond to any depth, ultimately until the whole SiC particle or component is transformed to diamond.
- Nanocrystalline diamond coatings demonstrate hardness values in excess of 50 GPa and Young's modulus up to 800 GPa.
- the molar ratio of hydrogen to halogen should be less than 1 : 1 to avoid complete conversion to HCl, which would reduce the activity of the halogen to a level at which it would be ineffective.
- the most preferred molar ratio of hydrogen to halogen is in the range of 0.5 to 1 mole of hydrogen for every two moles of halogen.
- One object of the present invention is to provide a new method of producing diamond layers at low cost on metal carbides on the surface of commercially available SiC (and other metal carbides).
- Another object of the present invention is to provide improved interfacial strength between the diamond layer and the substrate metal carbide compared to other methods.
- a further object of the present invention is to provide a new method of diamond or diamond layer (coating) formulation.
- a further object of the present invention is to provide a new method of non-cubic diamond synthesis (hexagonal diamond and nanocrystalline diamond structures).
- Yet another object of the present invention is to provide a new method of diamond coating on metal carbides at atmospheric pressure vs. higher pressures or lower (vacuum) pressures (which are more dangerous, expensive, and slow).
- Still yet another object of the present invention is to provide a new method of diamond coating on metal carbides that does not require plasma or other expensive high-energy sources.
- Another object of the present invention is to allow the use of impure, raw SiC (or other metal carbide) to be used (hence save money) in the production of diamond coated metal carbides.
- Another object of the present invention is to allow not only carbide components or fibers to be coated with diamond, but also powders, whiskers and platelets (not possible with current processes, CVD, PVD, and the like).
- a further object of the present invention is to allow parts with complex shapes and surface morphologies to be diamond coated, e.g. , crevices, channels, intricate layered surfaces, holes, etc.
- Yet another object of the present invention is to allow control of diamond coating growth on the atomic level. Still yet another object of the present invention is to allow variation in pore sizes (angstroms to nanometers) of diamond coatings to tailor surface properties.
- Another object of the present invention is to provide a new environmentally friendly technology for diamond coating of metal carbides.
- FIG. 1 is a graph showing the results of nanoindentation tests, (a), typical indentation load -displacement curves obtained on polished surfaces of sintered SiC (blue curve), as well as carbon coatings produced in Ar containing 3.5% Cl 2 (black curve) and in Ar containing 2.77% Cl 2 ; 1.04% H 2 (red curve).
- Inset shows a SEM micrograph of the hard coating produced by treatment in Ar containing 2.77% Cl 2 ; 1.04% H 2 for 30 hours at 1,000° C.
- H is hardness
- E Young's modulus measured on the polished surface using depth-sensing indentation
- (b) hardness vs. Young's modulus for various carbon materials, silicon and SiC. Bars show standard deviations.
- FIG. 2 is high-resolution TEM micrographs showing the structure of the carbon coating within a micrometer from the SiC/carbon interface, (a), diamond nanocrystals surrounded by graphitic carbon, including onion-like structures, (b), region of nanocrystalline diamond.
- the sample was treated for 24 hours at 1,000° C in Ar containing 3.5 % Cl 2 .
- FIG. 3 shows diamond microcrystals embedded in amorphous carbon, (a), TEM image, (b), SEM image, (c), EELS spectra.
- the [Oil] SAD pattern (inset in (a)) and the EELS spectra in (c) show that the rounded particles are diamonds.
- the light material in (a) was identified as carbon with a high content of sp 3 bonding and some sp 2 bonding using EELS (c).
- Etching in hydrogen plasma removes selectively amorphous and disordered carbon revealing diamond crystals in the carbon layer (b).
- the rounded shape of the microcrystals can be explained by their solid-state growth via coalescence of nanocrystals when constrained by the carbon matrix.
- FIG. 4 shows the microstructure of a diamond film produced in
- FIG. 5 shows convergent-beam electron diffraction patterns from nanocrystals (5-10 nm size) in a sample treated in Ar containing 3.5% chlorine at 1,000° C.
- the diamond-containing area was within a micrometer from the SiC/carbon interface, (a) and (b), may be attributed to cubic diamond with reflections 0.206 nm (111), and 0.126 nm (022), as well as forbidden diamond reflections, (c) and (d) may be attributed to hexagonal diamond lonsdaleite with reflections at 0.219 (100) and 0.126 nm (110).
- (e) EDS spectrum showing that the analyzed material is nearly pure carbon. Traces of amorphous silica were presented due to oxygen impurity in the gas. The copper peak comes from the supporting grid. Other EDS spectra from the analyzed areas showed even lower content of impurities in carbon.
- FIG. 6 is a SAD pattern from the nanocrystalline film. Sharp Bragg reflections are visible up to the order of (800), indicating good crystallinity. No scattering intensity from either graphite or amorphous carbon can be seen, suggesting that the film is pure diamond, but high intensity of forbidden reflections suggests a lower symmetry or impurity superstructure. Sample was sintered ⁇ -SiC treated in 2.77% Cl 2 ; 1.04% H 2 (balance Ar) for five hours at 1,000° C.
- FIG. 7 schematically illustrates a ball and socket prosthesis adapted for shoulder arthroplasty in accordance with the present invention
- FIG. 8 schematically illustrates a hinge joint prosthesis adapted for finger, elbow and knee arthroplasty in accordance with the present invention
- FIG. 9 schematically illustrates an ovoidal joint prosthesis adapted for wrist arthroplasty in accordance with the present invention.
- FIG. 10 schematically illustrates a saddle joint prosthesis adapted for thumb joint arthroplasty in accordance with the present invention
- FIG. 11 schematically illustrates a pivot joint prosthesis adapted for forearm arthroplasty in accordance with the present invention
- FIG. 12 schematically illustrates a gliding joint prosthesis adapted for carpus arthroplasty in accordance with the present invention
- FIG. 13 schematically illustrates a complete knee joint prosthesis adapted in accordance with the present invention.
- FIG. 14 is an exploded view of an automotive water pump showing a seal treated in accordance with the present invention.
- the present invention is directed to a process for the synthesis of diamond, and diamond coatings on the surface of metal carbides by etching a metal carbide with an etchant gas containing both a halogen and hydrogen comprising the steps of etching a metal carbide with a halogen-containing gaseous etchant containing hydrogen gas in an amount in the range of 0 moles to less than two moles of hydrogen, preferably 0.5 mole to one mole of hydrogen, for every two moles of halogen gas, leading to the formation of a gaseous fragment reaction product species and possibly other fragment species, leading to the formation of diamond or a diamond surface layer on the metal carbide.
- the reaction is performed in such hydrogen and halogen gas mixtures at temper atures from about 100° C to about 4,000° C over any time range, preferably maintaining a pressure of at least about 0.001 atmosphere, more preferably about one atmosphere, to about 100 atmospheres, and leading to the formation of said diamond layer on the surface of the metal carbide or to the complete transformation of the carbide material into diamond.
- the preferred metal carbide is silicon carbide, SiC, preferably ⁇ -SiC, however the diamond conversion process of the present invention can be performed on any metal carbide.
- the process of the present invention is inherently different from other coating processes in that the metal carbide substrate (carbide surface) is actually transformed into diamond from the surface down into the metal carbide substrate. This differs from "film” or coating applications which are applied or grown on top of the substrate.
- diamond layers are formed on the surface of metal carbides by etching in halogens and hydrogen with a particular ratio of halogen to hydrogen gas.
- reaction gas which contains from 0 to less than two moles of hydrogen gas for every two moles of halogen gas; preferably 0.5 to one mole of hydrogen for every two moles of halogen; most preferably 0.75 to one mole of hydrogen for every two moles of halogen, in a reaction vessel at a temperature between 100° C to 4,000° C at a pressure between 0 atmospheres and 100 atmospheres, preferably about one atmosphere.
- the temperamre is between 800° C and 1,000° C and at atmospheric pressure (about one atmosphere) with the metal carbide being silicon carbide and the halogen etchant being chlorine gas, at a hydrogen gas to chlorine gas molar ratio of 0.75:2.
- the advantages of this method are the adherence of the film or coating.
- the interface is where the coating "grows into” the metal carbide substrate, providing excellent resistance to fracture and wear.
- the method of the present invention does not add a coating material on top of the metal carbide, but rather transforms the metal carbide into diamond, one can achieve a complete transformation of the metal carbide substrate into diamond.
- the reaction is controlled and initiated by the contact of a gaseous phase with the surface of the metal carbide structure, it allows monolithic parts with complex shapes, crevices, channels, intricate layered surfaces, holes, and other intricate surface morphologies to be treated.
- the process of the present invention is extremely advantageous compared to existing coating processes which generally require a "line-of-sight" to lay down the coating.
- not only carbide components or fibers can be diamond coated, but also powders, whiskers, nanotubes, and platelets (not possible with current processes, CVD, PVD and the like), can be produced as diamond, or diamond coated.
- the tailoring of the process by change of reaction gas composition, temperature, and time allows the production of diamond layers with varying structure, porosity, density, and other properties.
- the process allows the control of diamond layer growth on the atomic level. It is to be noted that since the metal carbide itself is transformed into diamond, the original size and dimensions of a monolithic SiC part are retained, allowing the part to be treated without loss of dimensional integrity , hence saving machining costs.
- this process allows the use of the same reactor vessel, of almost any volume, for all types of diamond coatings desired. Since the process in its preferred embodiment takes place at atmospheric pressure, it is safer and cheaper than those processes (like hydrothermal etching) which take place at elevated pressures as well as those processes that take place under- vacuum. Attention is also drawn to the fact that this process does not require plasma or other expensive high-energy sources. Means is provided for an environmentally friendly technology since the process can be performed close- circuit with all products reclaimed.
- the advantages of this invention include the production of diamond layers on a metal carbide for the purpose of achieving an adherent diamond layer with tailored structure and mechanical properties in an inexpensive, simple, environmentally friendly manner. Not only can the dimensional accuracy of a monolithic part be retained, but complex shapes of any size (nano to macro) can be treated in a way not possible by any existing method.
- the synthesis of diamond was conducted at ambient pressure in a quartz tube furnace at or below 1,000° C.
- the SiC samples were exposed to flowing gas mixtures of 1-3.5% Cl 2 , 0-2% H 2 , with the balance Ar as a carrier gas. Since SiCl 4 is much more thermodynamically stable than CC1 4 , chlorine reacts selectively with the silicon at SiC surfaces by the reaction
- SiC + 2C1 2 SiCl 4 + C, (1)
- FIG. 2a shows that it consists of a mixture of graphitic carbon (onions, ribbons and disordered carbon) and nanocrystalline diamond (FIG. 2a).
- FIG. 2b large areas of nanocrystalline diamond (FIG. 2b) or diamond microcrystals (FIG. 3) were embedded in amorphous carbon.
- SAD selected area electron diffraction
- CBED convergent-beam electron diffraction
- EELS electron energy loss spectroscopy
- SiC + 4HC1 SiCl 4 + C + 2H 2 (2)
- reaction (1) compared to reaction (1).
- K r 1.6 ⁇ m h, which is only about 20 % lower than for Ar-3.5 % Cl 2 . Because the kinetics is linear, the controlling factor of the reaction is not the diffusion of reactant species through the growing carbon layer. If this were the case, one would expect a parabolic rate equation.
- the tetrahedrally coordinated SiC lattice acts as a template of growth of diamond and that diamond grows by direct transformation of the SiC lattice because of sp3 bonding of carbon in SiC and a similar structure of ⁇ -SiC, which has a diamond lattice where 50% of carbon atoms are replaced with Si.
- the work done using cc-SiC showed that any SiC poly type can be converted to diamond.
- nanocrystalline diamond occurred from highly disordered sp 3 carbon produced by selective etching of SiC.
- Growth of larger diamond crystals (FIG. 3a) was the result of coalescence of continuous nanocrystalline regions (FIG. 2a).
- nanocrystalline diamond was slowly transformed to the thermodynamically stable graphitic carbon during the long-term treatment at 1,000° C, and only amorphous and graphitic carbon resulted at a distance of more than 3 ⁇ m from the SiC/carbon interface.
- the role of hydrogen is primarily in stabilization of dangling bonds of carbon. This helps to maintain sp 3 hybridization of carbon and prevent formation of sp 2 bonded carbon.
- the manufacturing of CDC has been well developed and scaled up during the past few years, and a variety of useful products, ranging from nanoporous carbon for supercapacitors and batteries to nanotubes, onion-like carbon and tribological coatings have been reported.
- the process of the present invention is versatile because it allows synthesis of diamond powders or coatings of virtually any thickness. Since the transformation is conformal and does not change the shape of the particle, powders with any grain size can be produced by using raw SiC powders of different particle sizes. However, the product will be diamond grains built of nanocrystals. Presence of micrometer- size crystals in the samples (FIG. 3a) shows that coalescence of diamond nanocrystals may occur under appropriate conditions and lead to microcrystalline diamond growth.
- Nanocrystalline diamond films have particular applications in tribology, e.g. , to coat SiC dynamic seals for water pumps. Graphitic carbon in composite diamond/graphite films can act as a solid lubricant. Remarkable electron emission with turn-on fields of ⁇ 1 V/ ⁇ m and a high current density has been achieved using thin films of nanocrystalline diamond. Nanocrystalline diamond has a higher conductivity than boron-doped microcrystalline diamond and can be used for electrodes in chemically aggressive environments.
- Conformal coatings produced by the selective etching are useful in micro-electro-mechanical systems (MEMS) applications where very thin and uniform coatings are required.
- MEMS micro-electro-mechanical systems
- permeability of the films produced by chlorination of SiC and an extremely narrow pore size distribution in CDC provide effective molecular sieves, high-surface area electrodes and other applications, where vapor-deposited diamond films cannot be applied.
- the large-scale solid-state synthesis of technical diamond at ambient pressure and moderate temperatures with no plasma activation provides diamond materials at low cost for a variety of high-volume applications such as brake pads, where diamond could not be used before because of its cost.
- the reaction specimens were analyzed using optical microscopy and SEM, energy-dispersive spectroscopy (EDS), EELS, XRD, and Raman spectroscopy (Ar ion laser, 514.5 nm excitation wavelength).
- JEOLJEM-3010 (300kV) and JEOL JEM-2010F (200kV) TEMs, and JEOL 6320 field emission SEM were used for this work.
- EDS was used to identify the carbon areas, which were free from impurities and showed only traces of silicon and chlorine.
- SAD was performed on about 50-nm in size nanocrystalline areas and microcrystals
- CBED was performed on 5-nm and 10-nm nanocrystals.
- a Nano Indenter XP (MTS) equipped with a Berkovich indenter (diamond pyramid) was used to measure the hardness and Young's modulus of the coating.
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EP1426013A1 (en) * | 2002-12-03 | 2004-06-09 | ArthroSurface, Inc. | Tibial resurfacing system |
EP1612851A1 (en) * | 2004-06-30 | 2006-01-04 | Xycarb Ceramics B.V. | A method for the treatment of a surface of a metal-carbide substrate for use in semiconductor manufacturing processes as well as such a metal-carbide substrate |
US7678151B2 (en) | 2000-05-01 | 2010-03-16 | Ek Steven W | System and method for joint resurface repair |
US7723155B2 (en) | 2004-06-30 | 2010-05-25 | Xycarb Ceramics B.V. | Method for the treatment of a surface of a metal-carbide substrate for use in semiconductor manufacturing processes as well as such a metal-carbide substrate |
EP1905387B1 (en) * | 2006-09-29 | 2010-12-01 | DePuy Products, Inc. | Manufacturing orthopaedic joint prosthesis components |
US7896885B2 (en) | 2002-12-03 | 2011-03-01 | Arthrosurface Inc. | Retrograde delivery of resurfacing devices |
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Also Published As
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US20010047980A1 (en) | 2001-12-06 |
EP1414770A2 (en) | 2004-05-06 |
AU2002309542A1 (en) | 2002-11-05 |
WO2002086180A3 (en) | 2003-02-06 |
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