Patent Application
20140069327
The present invention relates to a process for in situ growth of carbonaceous composite coating on silicon carbide (SiC) grains by thermal dissociation of SiC by indirect arc plasma heating. More particularly, the present invention relates to a process for in situ growth of carbonaceous composite coating having diamond like carbon (DLC) and graphite on silicon carbide grain by thermal dissociation of SiC by indirect arc plasma heating. Further, the present invention relates to modified arc plasma which provides an indirect heating of SiC (charge or material). Further, the present invention also relates to high temperature dissociation of silicon carbide (SiC) and selected removal of silicon from silicon carbide grain surface.
The mono carbide of silicon (SiC) exhibits non-melting property. It directly dissociates into Si and C above 2200° C. and the process completes at 2825° C. Dissociation of high temperature withstanding carbides by thermal method is generally done by heating carbide compounds to required temperatures in electrically heated furnace but going for heating above 1800° C. usually poses difficulty. Graphite furnaces and arc furnaces are used to attain temperature above 2000° C. While graphite furnace requires graphite tube or granule heating for several hours before reaching the desired temperature, arc furnace on the other hand is difficult to control selected temperature and that too the furnaces are mostly available for large scale processing. More over, arc furnace uses air medium which is not independent of oxidation potential.
Arc plasma heating, as an alternative method, does not suffer from the demerits as occur in case of arc furnace where inert gas like argon (Ar) is used to form plasma between anode and cathode. This kind of plasma heating is also an instantaneous method which can produce temperature up to 10,000° C. under laboratory conditions. In spite of such advantages, the notable shortcoming of arc plasma heating includes difficulty in placement of charge (material under processing) in the limited space available between anode and cathode and their vicinity. Thus, plasma flame directly hits upon the charge/material (its grains) and interferes in the physical and chemical processing. Secondly, uniform heating of charge is not possible due to existence of several varying temperature zones in arc region of plasma.
Journal Nature, vol 193, 1962, page 569-570, wherein the conversion of α SiC (6H) to graphite by heating in vacuo is reported.
Journal Ognepory, No. 8, August 1967, page 44-50, Translated and reported in Refr. Industr. Ceram., vol. 8, No. 7-8, page 499-504, DOI: 10.1007/BF01284829, wherein the thermodynamic analysis of dissociative volatilization of silicon carbide in the temperature range 2500-3150K is reported and the composition of equilibrium gaseous phase over silicon carbide and the degree of progress of reactions of dissociation and volatilization of SiC have been established.
Journal Jpn. J. Appl. Phys. Vol 30, 1991, page 545-553, wherein the stability of 3C—SiC in the temperature range 1800-2400° C. (in Argon atmosphere) has been investigated and a solid state phase transformation from 3C—SiC to 6H—SiC above 2150° C. is reported.
Journal Appl. Phys. Lett, vol. 71, 1997, page 2620-2622, wherein the sublimation decomposition of silicon carbide at 1700° C. using YAG laser heating in a transmission electron microscope (TEM) was studied by Kusunoki, Rokkaku and Suzuki. They observed growth of carbon nanotube (CNT) oriented along [111] direction on the (111) surface plane of β-SiC single crystal.
Journal Nature, vol. 411, 2001, page 283-286, relates to Si extraction from SiC by reacting a toxic gas like chlorine with SiC at high temperature (1000° C.) for a time between 30 min to 30 hours. The drawback of the prior art is the use of toxic halogen gas, relatively long reaction time and slow reaction kinetics.
Journal Surf. Engg., vol. 20, 2004, page 139-142, wherein direct exposure of SiC powder to Ar arc plasma for 15-30 min followed by cooling exhibits small XRD peaks corresponding to several phases of carbon that include diamond, lonsdaleite, DLC and graphite.
Stiver of University of Massachussets, USA (The 2009 NNIN Research Accomplishments, page 164-165) discloses a epitaxial layer of graphene (two dimensional thin graphite lattice) has been grown by thermal decomposition of silicon (Si) terminated 4H—Si(0001) in ultra high vacuum (UHV) at a temperature 1150-1600° C. The shortcoming of the prior art process is that it uses expensive and sophisticated process like UHV and produces graphene layer only. No DLC is produced by the process as disclosed in the present application. Hence the dual advantages of high hardness and lubricating property of a layer cannot be derived from the disclosed process of the prior art.
U.S. Pat. No. 5,756,061, patent describes a process involving heating a mixture of SiC with oxides like MgO, FeO, CaO, BaO, etc. at high temperature (up to 1200° C.) and high pressure (5-6 GPa) for two days and then cooling the mixture to ambient temperature while under pressure. The carbon in the solid matrix converts to diamond phase and is isolated from other associated materials by adoption of standard physical methods.
US 2001047980 patent application describes a process for the synthesis of carbon coating on the surface of metal carbides, preferably SiC, by etching in halogen containing gaseous etchant, and optionally hydrogen gas, leading to the formation of a carbon layer on the metal carbide. The temperature of etching by halogen (CI) is between 600-1100° C. and the time taken is between 30 minutes to 30 hours in case of SiC. Flowing gas mixture of 1-3.5% CI2, 0-2% H2 and balance Ar was used.
U.S. Pat. No. 7,241,475, patent describes a method for producing carbon surface films on titanium carbide by exposure to radio frequency plasma using halogen gases and it claims the process to be generic and applicable to silicon carbide, tungsten carbide, etc.
U.S. Pat. No. 7,678,452 and U.S. Pat. No. 7,744,843, describes the decomposition/dissociation of various carbides including silicon carbide by treatment with halogen to produce carbon nanotubes (CNT).
IN 238049, patent discloses a only a diamond like carbon (DLC) coating prepared by directly exposing silicon carbide (SiC) powder to arc plasma flame produced within the graphite crucible. The DLC coating is characterized by higher hardness and therefore more brittle. However, in the present invention composite coating of DLC+ graphite is deposited by indirect arc plasma. Major drawback of the prior art is that it did not address the issue of uniform heating of charge, interference of plasma flame in the in situ film/coating growth process and mixing of impurities emanated from electrode with charge in the arc plasma heating.
In order to overcome these difficulties faced in direct arc plasma heating, an indirect arc plasma heating process has been developed which produces uniform heating in a crucible to dissociate high temperature carbide compound like SiC and removes Si atoms from SiC grain surface. The limitation of inter-electrode spacing causing restriction in charge throughput (in direct arc plasma heating) does not arise in the indirect heating process. If SiC is treated in an indirect arc plasma heated reactor/furnace at a temperature above the boiling point of Si (2680° C.), Si will dissociate and vaporize from SiC grain. The left out C will produce/develop a composite layer of DLC and graphite on the grain in situ when plasma heating will be switched off and the grain shall be allowed to cool to lower temperatures below 2200° C. The graphite and DLC (diamond like carbon) composite has a good scope for application as grinding and polishing medium/compound (for of metals, ceramics, leathers, marbles, etc.), for use in dynamic seals of water pumps and brake pads, etc., where both good lubricating property as well as higher hardness value are desirable at the same time. As a process, the indirect arc plasma heating dissociation is also applicable to other types of compounds (e.g. B4C) which do not undergo melting but directly dissociate under thermal heating.
The above mentioned prior art reports basic investigations involving graphite formation from SiC and in some of the prior art polluting gases like halogens are used in high temperature etching to dissociate SiC. Halogen gases are toxic and chlorine is known to be responsible for ozone hole creation.
No work has so far been reported on the deposition of a composite coating of DLC and graphite on SiC grain using indirect arc plasma heating. The composite layer characterized by both improved hardness (wear resistance property) due to DLC and lubricating property due to graphite finds industrial applications in grinding, polishing and lapping of metals, ceramics, leather, and in the making of water pump seal, braking pad, etc.
An advantage of the present invention of composite coating over the prior art is the combination of hard DLC and soft graphite composite coating that overcomes peeling off behavior of the coating on SiC surface.
The novelty of the invented process lies in the idea that a single step process is employed where a conducting ceramic crucible (e.g graphite crucible) is configured in a special manner so as to serve as the cathode while being heated up from its bottom by plasma flame during arc discharge (
The non-obviousness of the process involves the high temperature (2900-3100° C.) produced in arc plasma which is able to cause complete dissociation and selective removal and vaporization of Si atoms as 2680° C. (Boiling Point of silicon). Also, use of inert gas/Ar as plasma forming gas and circulation of inert gas/Ar in the crucible and reactor/furnace prevents oxidation of SiC, DLC, graphite, Si and C.
The main object of the present invention is to provide a process for in situ growth of carbonaceous composite coating on silicon carbide (SiC) grains by thermal dissociation of SiC by indirect arc plasma heating.
Another objective of the present invention is to provide a process for in situ growth of carbonaceous composite coating having diamond like carbon (DLC) and graphite on silicon carbide grains by thermal dissociation of SiC by indirect arc plasma heating.
Yet another object of the present invention is to provide a process for high temperature dissociation of silicon carbide (SiC) and selected removal of silicon from silicon carbide grain surface.
Yet another object of the present invention is providing a process for dissociation of non-melting type high temperature carbides and other compounds including silicon carbide.
Accordingly, the present invention provides a process for in situ growth of carbonaceous composite coating of diamond like carbon (DLC) and graphite on silicon carbide (SiC) grains by carrying out thermal dissociation of SiC by an indirect arc plasma heating and the said process comprising the steps of: (i) providing SiC grains in a graphite crucible; (ii) passing inert gas in the arc zone situated below the graphite crucible at the rate of 3 to 15 litre per minute to produce high temperature in the range of 2900 to 3100° C.; (iii) passing inert gas inside the graphite crucible at the rate of 1 to 3 litre per minute; (iv) heating the graphite crucible by arc plasma for a period in the range of 15 to 30 minutes maintaining arc length in the range of 1 to 3 cm, voltage in the range of 50 to 70 V and current in the range of 400 to 550 A; (v) continuing the inert gas flow in arc zone and in graphite crucible for 50 to 70 minutes; (vi) cooling the reactor for a period in the range of 3 to 5 hours until temperature reaches in the range of 25 to 30° C. to obtain a carbonaceous composite coating having diamond like carbon and graphite on silicon carbide (SiC) grains. Further, the present invention relates to a process for high temperature dissociation of silicon carbide (SiC) and selected removal of silicon from silicon carbide grain surface.
While the invention is susceptible to various modifications and alternative forms, specific aspect thereof has been shown by way of example and graphs and will be described in detail below. It should be understood, however that it is not intended to limit the invention to the particular forms disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the invention as defined by the appended claims.
The Applicants would like to mention that the examples are mentioned to show only those specific details that are pertinent to understanding the aspects of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such process.
In the following detailed description of the aspects of the invention, reference is made to the accompanying drawings and graphs that form part hereof and in which are shown by way of illustration specific aspects in which the invention may be practiced. The aspects are described in sufficient details to enable those skilled in the art to practice the invention, and it is to be understood that other aspects may be utilized and that charges may be made without departing from the scope of the present invention. The following description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
Accordingly, the present invention relates to a process for in situ growth of carbonaceous composite coating of diamond like carbon (DLC) and graphite on silicon carbide (SiC) grains by carrying out thermal dissociation of SiC by an indirect arc plasma heating and the said process comprising the steps of: (i) providing SiC grains in a graphite crucible; (ii) passing inert gas in the arc zone situated below the graphite crucible at the rate of 3 to 15 litre per minute to produce high temperature in the range of 2900 to 3100° C.; (iii) passing inert gas inside the graphite crucible at the rate of 1 to 3 litre per minute; (iv) heating the graphite crucible by arc plasma for a period in the range of 15 to 30 minutes maintaining arc length in the range of 1 to 3 cm, voltage in the range of 50 to 70 V and current in the range of 400 to 550 A; (v) continuing the inert gas flow in arc zone and in graphite crucible for 50 to 70 minutes; (vi) cooling the reactor for a period in the range of 3 to 5 hours until temperature reaches in the range of 25 to 30° C. to obtain a carbonaceous composite coating comprising diamond like carbon and graphite on silicon carbide (SiC) grains.
In another aspect of the invention in step (ii) inert gas in the arc zone is passed through a central axial hole in the graphite anode.
In another aspect of the invention, SiC grains used are selected from the group consisting of coarse, fine, ultrafine, nano crystalline or lumps or combination thereof.
In another aspect of the invention, inert gas used in step (ii) is argon.
In another aspect of the invention, inert gas used in step (iii) is selected from the group consisting of Ar, N2 or their mixture with H2 in the ratio ranging 1:1 to 1:3.
In another aspect of the present invention high temperature dissociation of silicon carbide (SiC) and selected removal of silicon from silicon carbide grain surface is carried out.
In another aspect of the invention, silicon is selectively removed from the surface of SiC grains to the extent of 98-99%.
In another aspect of the invention, recovery percentage of heat treated SiC grains is in the range of 98 to 99%.
In another aspect of the invention, the process achieves a carbonaceous composite layer of DLC and graphite on SiC grain surface with 98 to 99 at % carbon.
In another aspect of the invention, diamond like carbon and graphite composite coated silicon carbide (SiC) grains are useful in grinding, polishing, lapping of surfaces of metals, marbles, granite, leather, in the making of water pump seals and brake pads.
In another aspect of the invention, diamond like carbon (DLC)+ graphite composite coated silicon carbide (SiC) grains exhibit hardness in the range of 1900-2600 VHN0.1 due to presence of DLC.
In another aspect of the invention diamond like carbon + graphite composite coated silicon carbide (SiC) grains exhibit lubricating property due to the presence of graphite.
In another aspect of the invention, the micro Raman spectra peaks of the composite on SiC grains are observed in the range 1335-1368 cm−1 due to DLC and at 1569-1596 cm−1 & 2677-2730 cm−1 due to graphite.
In another aspect of the invention, said process is useful for all non-melting compounds including the carbides which dissociate on heating for producing coatings of different kinds including DLC and graphite.
In another aspect of the invention, said process leads to an in situ composite coating endowed with higher hardness as well as good lubricating property.
In another aspect of the invention, said process leads to the development of a layer of two allotropes of carbon in the form of a composite on SiC grain surface which is coherent with the surface and less prone to peel off because it grows from within the surface matrix by selective removal of Si atoms and rearrangement/epitaxy of C atoms.
In another aspect of the invention, said process results to get rid of the addition of impurities in the charge, kept within the crucible, from the anode during arc discharge process by introduction of crucible wall (base) as a barrier between the anode and the charge (SiC).
In another aspect of the invention, the indirect heating process by arc plasma where the plasma flame cannot interfere with the charge while undergoing physical or chemical processing within the crucible, thus facilitating epitaxial growth process on SiC grain surface for production of DLC phase.
The present invention provides a process for high temperature dissociation of SiC producing an in situ growth DLC+ graphite composite on SIC grains by selected removal of Si from grain surface by indirect arc plasma heating of SIC grains placed inside a conducting ceramic crucible. The special arc configuration is shown in
Graphite crucible is connected to negative polarity (cathode) and the graphite rod below the crucible is connected to positive polarity of electricity (anode). The cathode is in the form of a graphite crucible and the anode is a graphite rod placed below the crucible at a small distance which is maintained variable. Higher heat generation at cathode (due to ions hitting) compared to anode (where electrons used hit) results in generation of temperature as high as 2900-3100° C. within few minutes that causes dissociation of SiC to produce the DLC+ graphite composite coating.
SiC grains in the form of powder are kept inside the graphite crucible by opening its lid provided at the top. The lid was kept open and also partially closed during heat treatment. SiC powder of three different makes and of different grain sizes were used in the heat treatment. The plasma flame is formed in the arc zone by passing Ar or inert gas between the anode and cathode and the flame hits upon the crucible base and thus heats up the crucible from the bottom to produce a uniform heat treatment of the SiC grains placed inside the crucible.
The entire arc configuration including the crucible containing charge are placed inside a water cooled enclosure such as reactor or furnace which is provided with an exhaust system to continuously let out gases and vapours emanating from the reactor/furnace. The crucible is provided with a non-melting ceramic lid to open and close as per requirement. Voltage and current conditions in the dc arc plasma were maintained as follows: 50-70V, 400-550 A. The length of arc in the plasma was maintained in the range 2-3 cm. Argon gas was used as the plasma forming gas and it was introduced into the arc zone at a rate of 3-15 lit per min through a central axial hole in the anode. Inert gas like N2 or Ar at a rate of 2 lit per min was passed into the crucible space by a separate arrangement to prevent any oxidation in the charge as well as product. H2 was also introduced with Ar/N2 in the crucible at 1:1 to 1:3 ratio to observe their influence in the dissociation and coating growth and to reduce the occurrence of graphite phase in the carbonaceous composite coated on SiC grains.
The temperature of the graphite crucible was maintained at 2900-3100° C. while heat treatment of the SiC powder/grains kept in the crucible was carried out for 15-30 min by the indirect arc plasma heating and then it was followed by switching off of the electrical power in the arc to cool off the reactor/furnace. Cooling of the reactor including SiC powder in graphite crucible was carried out until room temperature and it took around 4 hours to reach the room temperature. Inert gas or its mixture (Ar, Ar+N2, Ar+H2 and N2+H2) was circulated in the graphite crucible during arc plasma heating as well as during cooling cycle for 1 hour after power switch off. After cooling off, the SiC powder was removed from graphite crucible and was characterized by micro Raman spectra to identify the constituents present in the composite surface coating on SiC grains.
Micro Raman spectra showed peaks in the range 1335-1368 cm−1 due to DLC and in the range 1569-1596 cm−1 and 2677-2730 cm−1 due to graphite. Recovery of the heat treated SiC powder was obtained up to 98 wt %. Si removal from surface of SiC grain by the thermal dissociation (heat treatment) was observed in the range 98-99 at %. Surface microhardness of the resulting carbonaceous composite layer (DLC+ graphite) on SiC grain was determined and it exhibited upper range value between 1900 to 2600 VHN0.1.
Heat treatment at 2900-3100° C. causes dissociation of the carbide; selected removal of Si atoms in vapour form from the surface of SiC grains are sent out from furnace/reactor by an exhaust leaving behind the dissociated SIC grains and thus resulting in the growth of DLC+ graphite composite in the form of coating/layer on SiC surface by rearrangement of some dissociated C atoms on underlying grain surface during cooling process below 2200° C. leading to an epitaxial growth of these carbon on SiC (SiC has similar crystallographic structure as that of diamond) in situ in a diamond lattice (in the form of DLC).
The following examples are given by way of illustration of the present invention and therefore should not be construed to limit the scope of the present invention.
SiC powder in mixed phase (α+β) prepared from rice husk by carbothermic reduction in arc plasma (B. B. Nayak et al., J. Am. Ceram. Soc. Vol. 93, page 3080-3083, 2010) was used for high temperature dissociation by indirect arc plasma heating to produce composite coating of DLC and graphite. 10% of SiC grains in the powder were <10 μm and the rest were 10-163 μm size. In the beginning, 50 g of SiC powder was kept in the graphite crucible with 6 cm inner diameter and 10 cm height (
Aldrich make SiC powder (No. 409-21-2) in mixed phase (α+β) with 20-50 μm grain size was used for high temperature dissociation by indirect arc plasma heating to produce the DLC+ graphite composite. Heat treatment procedure adopted was similar to example 1 described above. Experimental conditions adopted here are as follows:
Wt. of SiC powder taken: 20 g
Rate of Ar (plasma forming gas) flow in arc: 7 lit per min
Gas passed in graphite crucible: Ar+H2
Rate of flow of gas in graphite crucible: Ar at the rate of 3 lit per min,
Micro Raman spectra characterization (
CUMI (Carborandum Universal) make SiC powder of 800 grit size (grain size 6.50 μm) underwent high temperature dissociation to grow DLC+ graphite composite on SiC grains in the same way as described in example 1. The experimental conditions adopted are as follows:
Wt. of SiC powder taken: 20 g
Rate of Ar (plasma forming gas) flow in arc: 6 lit per min
Gas passed in graphite crucible: Ar
Rate of Ar flow in graphite crucible: 2 lit per min,
Arc length: 2 cm, Arc conditions: voltage 60-65 V dc, current 500-550 A
Time duration of SiC heat treatment in crucible: 15 min
Temperature of heat treatment: 3030° C.
Micro Raman spectra characterization (
CUMI (Carborandum Universal) make SiC powder of 800 grit size (grain size 6.50 μm) underwent high temperature dissociation to grow DLC+ graphite composite on SiC grains in the same way as described in example 3 but with change in gas conditions. The experimental conditions adopted are as follows:
Wt. of SiC powder taken: 20 g
Rate of Ar (plasma forming gas) flow in arc: 15 lit per min
Gas passed in graphite crucible: N2+H2
Rate of gas flow in graphite crucible: 2 lit per min each for N2 and H2
Arc length: 2 cm, Arc conditions: voltage 60-65 V dc, current 520-550 A
Time duration of SiC heat treatment in crucible: 15 min
Temperature of heat treatment: 3050° C.
Micro Raman spectra characterization (
| Number | Date | Country | Kind |
|---|---|---|---|
| 0360/DEL/2011 | Feb 2011 | IN | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB2012/050655 | 2/14/2012 | WO | 00 | 11/21/2013 |
