C - Chemistry – Metallurgy – 09 – K
Patent
C - Chemistry, Metallurgy
09
K
31/116, 204/197,
C09K 3/00 (2006.01) C01B 35/00 (2006.01) C01B 35/04 (2006.01) C04B 35/46 (2006.01) C04B 35/58 (2006.01) C25C 3/08 (2006.01)
Patent
CA 1048257
Abstract of the Disclosure Sub-micron carbon-containing titanium diboride powder and other hard, refractory metal boride powders, such as zirconium diboride and hafnium diboride powders, are prepared by vapor phase reaction of the corresponding metal halide, e.g., titanium halide, vaporous carbon source, and boron source reactants in the presence of hydrogen in a reaction zone and in the substantial absence of oxygen, either combined or elemental. In a preferred embodiment, the metal halide, e.g., titanium tetrachloride, carbon source, e.g., halogenated hydrocarbon, and boron source, e.g., boron trichloride, reactants are mixed with a hot stream of oxygen produced by heating hydrogen in a plasma heater. The reaction zone is maintained at metal boride forming temperatures and submicron solid, carbon-containing metal boride powder is removed promptly from the reactor and permitted to cool. The preponderant number metal boride particles comprising the preponderant number of metal boride particles comprising the powder product have a particle size in the range of between 0.05 and 0.7 microns. The metal boride powder product contains a minor amount of carbon, e.g., from above 0.1 to about 5 percent by weight total carbon, probably as submicron refractory metal carbide. Alternatively, submicron metal carbide powders, e.g., titanium, zirconium, hafnium or boron carbide powders, or finely-divided carbon can be blended physically with submicron metal boride powder prepared as described above but in the absence of the carbon source reactant to provide metal borides containing a minor concentration of carbon in the amounts previously indicated. Titanium diboride powder compositions containing minor amounts of carbon can be hot pressed, or cold pressed and sintered to densities of at least 95 percent of theoretical.
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