High temperature ceramic powder systems
View Patent ↗Disclosed are ceramic powder compositions that include Si, N, O, C, Mg, and/or Mn in tailored combinations of different crystalline phases for producing high temperature resistant and high strength ceramic products. In some aspects, a ceramic powder for producing high temperature-resistant and/or high mechanical strength materials comprises a silicon nitride (Si 3 N 4 ) powder, comprising Si 3 N 4 particles having a size within a range of 30 nm to 700 nm, wherein the Si 3 N 4 powder include alpha and beta phase silicon nitride in an amount up to about 1-100% vol; and an impurity constituent intermixed with the Si 3 N 4 powder within the ceramic powder, the impurity constituent comprising at least one of silicon (Si), nitrogen (N), oxygen (O), carbon (C), magnesium (Mg), or manganese (Mn), wherein the impurity constituent constitutes less than about 0.1% wt to 15% wt of the ceramic powder.
1 . A ceramic powder for producing high temperature-resistant and/or high mechanical strength materials, comprising:
a silicon nitride (Si 3 N 4 ) powder, comprising Si 3 N 4 particles that include alpha phase silicon nitride (α-Si 3 N 4 ) and beta phase silicon nitride (β-Si 3 N 4 ), wherein the Si 3 N 4 powder includes the β-Si 3 N 4 in an amount up to about 1% vol; and
an impurity constituent intermixed with the Si 3 N 4 powder within the ceramic powder, the impurity constituent comprising manganese oxide (MnO), wherein the impurity constituent constitutes about 0.1% wt to about 5% wt of the ceramic powder,
wherein the Si 3 N 4 particles have a size within a range of 30 nm to 70 nm.
2 . The ceramic powder of claim 1 , wherein the impurity constituent further includes at least one of elemental Si, C, Mg or Mn.
3 . The ceramic powder of claim 1 , wherein the impurity constituent includes at least one of SiO 2 , SiC, or MgO compound.
4 . The ceramic powder of claim 1 , wherein the Si 3 N 4 powder consists essentially of alpha phase silicon nitride (α-Si 3 N 4 ) in an amount up to about 99.99% vol and the beta phase silicon nitride (β-Si 3 N 4 ) in an amount up to about 1% vol.