SiCN compositions and methods
First Claim
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1. A method of making a superabrasive composite material having the general formula SixCyNz, comprising the steps of:
- a) depositing a metal-containing catalyst on a substrate;
b) heating the metal-containing catalyst to a temperature sufficient to melt the metal-containing catalyst; and
c) depositing Si, C, and N atoms from a vapor source onto the molten metal-containing catalyst to produce a composite SixCyNz material having an interatomic structure substantially like that of silicon nitride.
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Abstract
The present invention provides a method for making a superabrasive composite material having the general formula SixCyNz, and tools containing such a material. In one aspect, vapor forms of Si, C, and N atoms are deposited onto a molten metal catalyst and solid SixCyNz is precipitated therefrom. The composite SixCyNz materials have an interatomic structure substantially like that of silicon nitride. Such SixCyNz materials can be used to form superabrasive particles, fibers, or coatings for various tools.
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Citations
45 Claims
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1. A method of making a superabrasive composite material having the general formula SixCyNz, comprising the steps of:
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a) depositing a metal-containing catalyst on a substrate;
b) heating the metal-containing catalyst to a temperature sufficient to melt the metal-containing catalyst; and
c) depositing Si, C, and N atoms from a vapor source onto the molten metal-containing catalyst to produce a composite SixCyNz material having an interatomic structure substantially like that of silicon nitride. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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35. A method of making a superabrasive composite material having the general formula SixCyNz, comprising the steps of:
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a) depositing a metal-containing a catalyst selected from the group consisting of gold, silver, platinum, copper, nickel, iron, cobalt, alloys thereof, and mixtures thereof, on a substrate;
b) heating the metal-containing catalyst to a temperature of from about 800°
C. to about 1000°
C., thereby melting the metal-containing catalyst;
c) decomposing single bond compounds containing Si, C, and N atoms from a vapor source; and
d) depositing the Si, C, and N atoms from the single bond compounds onto the molten metal-containing catalyst, to produce a composite SixCyNz material having an interatomic structure substantially like that of silicon nitride, such that X is less than half of Y and Z is greater than X or Y.
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36. A method for making a SixCyNz compound comprising:
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a) depositing Si, C and N elements from a vapor source into a molten metal catalyst; and
b) precipitating the SixCyNz compound out of the molten metal catalyst. - View Dependent Claims (37, 38, 39)
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- 40. A superabrasive composite material having the general formula SixCyNz such that X is less than half of Y and is substantially free of silicon-carbide bonds.
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45. A superabrasive composite material having the general formula SixCyNz such that X is from about 0.05Y to about 0.35Y and is substantially free of silicon-carbide bonds.
Specification