United States Patent [191 [11] 4,409,193 Sato Et Al

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United States Patent [191 [11] 4,409,193 Sato Et Al United States Patent [191 [11] 4,409,193 Sato et al. [45] Oct. 11, 1983 [54] PROCESS FOR PREPARING CUBIC BORON shi Endo, Osamu' Fukunga, Minoru Iwata (1979) NITRIDE 1676-1680. [75] Inventors: Tadao Sato; Tadashi Endo; Osamu Journal of Material Science 16 (1981) 2227-2232, “The Fukunaga, all of Sakura; Minoru Synthesis of cBN Using Ca3B2N4”, Tadashi Endo, Iwata, Matsudo, all of Japan Osamu Fukunga, Minoru Iwata. [73] Assignee: National Institute for Researches in Primary Examiner-Brian E. Hearn Inorganic Materials, Ibaraki, Japan Assistant Examiner—Jackson Leeds Attorney, Agent, or Firm—Oblon, Fisher, Spivak, [21] Appl. No.: 354,354 McClelland & Maier [22] Filed: Mar. 3, 1982 [57] ABSTRACT [30] Foreign Application Priority Data A process for preparing cubic boron nitride comprises Mar. 6, 1981 [JP] Japan ................................ .. 56-32139 heating hexagonal boron nitride and magnesium boron Mar. 20, 1981 [JP] Japan ................................ .. 56-40563 nitride at a temperature of at least 1350“ C. under a [51] Int. Cl.3 ............................................ .. C01B 21/06 pressure at which the cubic boron nitride is thermody namically stable, whereby the cubic boron having high [52] U.S. C]. .. 423/290; 423/279 [58] Field of Search .............................. .. 423/290, 276 strength and high purity can readily be obtainable. Also disclosed is a process for the preparation of magnesium [56] References Cited boron useful as a starting material for the above process. FOREIGN PATENT DOCUMENTS This process comprises mixing hexagonal boron nitride and magnesium nitride or metal magnesium in a molar 506438 6/1971 Switzerland ...................... .. 423/290 ratio of hexagonal boron nitride/magnesium being at OTHER PUBLICATIONS least 0.6, and heating the mixture thus obtained, at a DeVries, R. C. et al., “Journ. Cryst. Growth” 1972, pp. temperature of from 950° to 1250° C. under atmospheric 88-92. pressure in a non-oxidizing atmosphere, eg a nitrogen Chem Abst., vol. 93, 1980, 978240. atmosphere. Journal of Material Science 14, “Precipitation Mecha nism of BN in the Ternary System of B-Mg-N” Tada 10 Claims, 7 Drawing Figures U.S. Patent 0a. 11, 1983 Sheet 1 of 3 4,409,193 (aim)PRESSURE U1 1 I200 I400 I600 I800 TEMPERATURE (°C) US Patent 00:. 11, 1983 Sheet 3 of 3 4,409,193 I27 , 3/ o o 0/240 1 o .ZI/O, ' (2,22 0 I o O \ \ / O O I 1 7 ' o _ O Q .. T 2 f T I 26 F I G. ,7 MAGNESIUM BORONNITRIDE (29=29.6°) I00 INTENS/TIES0F-RAYDIFFRACTIONLINESX 01 O O |000° | I 00° |200° ROOM TEMPERATURE HEATING TEMPERATURE ("c1 4,409,193 1 2 sure required to establish a thermodynamically stable PROCESS FOR PREPARING CUBIC BORON phase of the cubic boron nitride at the temperature. NITRIDE However, calcium boron nitride (Ca3B2N4) has a drawback that it is relatively unstable against moisture. BACKGROUND OF THE INVENTION For instance, when exposed in the air, it will be decom posed into a hydroxide by the moisture in the air. Ac 1. Field of the Invention cordingly, in order to maintain its desired function as The present invention relates to a process for prepar the solvent, it is necessary to take special cares for its ing cubic boron nitride. It relates further to a process for storage or at the time of ?lling it to the high pressure preparing magnesium boron nitride which is useful as a 10 cell. starting material for the production of the cubic boron Now, with respectto a process for the preparation of nitride. magnesium boron nitride useful as a starting material for 2. Description of the Prior Art the production of the cubic boron nitride, it has been Cubic boron nitride, i.e. boron nitride having a cubic reported to form magnesium boron nitride by heating crystal structure, is superior in its chemical stability to 15 boron nitride and metal magnesium at a temperature of diamond, although it is inferior in its hardness to 1150° C. under pressure of 2.5 GP. The magnesium diamond. For instance, it is durable in an oxidizing boron nitride obtained by the reported method, has the atmosphere at a high temperature, and its reactivity following X-ray diffraction peaks. ‘ with an iron group element is extremely small. Accord ingly, it exhibits substantially superior mechanical prop TABLE 1 erties to those of diamond when used for grinding a heat Lattice spacings and intensities obtained from the major resistant high strength material containing nickel or X-ray diffraction lines of the magnesium boron nitride prepared by the conventional method. cobalt as the basic component, or a high speed steel. Lattice Lattice Thus, the cubic boron nitride is a quite useful substance. spacings Intensities spacings Intensities It has been common to prepare the cubic boron ni 25 7.76 weak 1.68 strong tride by treating hexagonal boron nitride at a high tem 3.88 weak 1.65 moderate perature under high pressure in the presence of a cata 3.02 moderate 1.57 moderate - lyst. As the catalyst, there have been known (1) ele 2.69 weak 1.55 moderate ments belonging to Groups Ia and Ila, (2) rare earth 2.59 strong 1.49 moderate 2.44 strong 1.46 moderate elements, actinide elements, tin, antimony, lead, etc. (in 30 2.38 weak 1.32 weak practice, these elements are used in the form of their 2.21 ‘strongest 1.31 weak _ nitrides or alloys), and (3) urea and ammonium salts. 2.12 strong 1.27 weak However, when the above-mentioned metals or al 1.94 moderate 1.22 weak loys are used as the catalyst, unstable boron compounds 1.89 weak 1.19 weak 1.82 moderate 1.10 weak and free boron are likely to form as by-products and 35 1.75 weak they tend to be included in the cubic boron nitride crys In the above relative intensities, strongest = 100, strong = 70 to 30, moderate = 30 tals thereby obtained. The crystals thereby obtained to 10 and weak = 10 to 3. have drawbacks such that they are blackish and opaque, and the strength of the particles is rather low. This method has drawbacks such that high pressure is In the case where the above-mentioned nitrides are required and the productivity is poor. used as the catalyst, unreacted nitrides will remain in the system, and they are likely to be trapped in the cubic SUMMARY OF THE INVENTION boron nitride. Accordingly, it is thereby dif?cult to Accordingly, it is an object of the present invention obtain cubic boron nitride crystals having high quality. to provide a process for preparing cubic boron nitride, Besides, the chemical reaction system is rather compli 45 which is capable of readily producing high strength cated, and it is difficult to properly set the conditions to cubic boron nitride containing little impurities without obtain the desired crystals. the production of chemically complexed reaction prod In the case where the above-mentioned urea or am ucts. monium salts are used as the catalyst, the cubic boron As a result of an extensive research, the present in nitride thereby obtained tends to have an extremely ventors have found that the above object can be small particle size at a level of from 0.1 to 0.5 micron. Its achieved by subjecting hexagonal boron nitride and usefulness as grinding particles will thereby be limited. magnesium boron nitride to heat treatment at a tempera Further, the mechanisms of the chemical reaction and ture of at least 1350° C., i.e. a temperature suf?ciently the product formation are not yet been clearly known, high to dissolve both reactants, under pressure at and accordingly, it is not possible to set the reaction which the cubic boron nitride is thermodynamically conditions to increase the particle size. stable. Other than the methods using such catalysts, it is Thus, the present invention provides a process for known to prepare the cubic boron nitride with use of preparing cubic boron nitride, which comprises heating calcium boron nitride as a solvent. The cubic boron hexagonal boron nitride and magnesium boron nitride at nitride thereby obtained has a high quality with a mini 60 a temperature of at least 1350” C. under pressure at mal content of impurities, and it is also superior in its which the cubic boron nitride is thermodynamically mechanical strength. Namely, during the process of stable. conversion of the hexagonal boron nitride to the cubic Another object of the present invention is to provide boron nitride, the calcium boron nitride serves as a a process for preparing magnesium, boron nitride which solvent for the hexagonal boron nitride, and accord 65 is useful for the production of the cubic boron nitride. ingly, it is possible to crystallize the cubic boron nitride As a result of a research with an aim to obtain magne from the liquid phase by the treatment at a temperature sium boron nitride suitable as a catalyst for the synthesis suf?ciently high to solubilize both reactants, i.e. to es of the cubic boron nitride, the present inventors have tablish a co-solubilization condition, and under a pres found that magnesium boron nitride having X-ray dif 4,409,193 3 4 fraction peaks are different from those of the magne The precipitation or crystallization of the cubic boron sium boron nitride obtained by the above-mentioned nitride is facilitated by the solubilization of the hexago conventional method. nal boron nitride in the molten state of the high pressure Thus, the present invention also provides a process phase. for preparing magnesium boron nitride, which com To obtain single crystals of the cubic boron nitride prises mixing hexagonal boron nitride and magnesium from the magnesium boron nitride and the hexagonal nitride or metal magnesium in a molar ratio of hexago boron nitride, it is necessary to heat the magnesium nal boron nitride/magnesium being at least 0.6, and boron nitride and the hexagonal boron nitride at a tem» heating the mixture thus obtained, at a temperature of perature of at least 1350“ C., preferably from 14000 to from 950° to 1250” C.
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