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precursor fiber that is later pyrolyzed into sili- fibers with a minimum of surface flaws, the
con, carbon and nitrogen-based continuous rod’s surface should be flame polished with an
fiber and the reaction between silica and car- oxy-hydrogen flame, as is done in optical fiber
bon to make discontinuous whiskers. manufacturing (Blyler and DiMarcello, 1991).
The manufacturing processes are summa-
rized in Table 8.1.
8.3.3 CONTINUOUS FIBERS BY CHEMICAL
VAPOR DEPOSITION
8.3 CONTINUOUS FIBERS Producing silicon carbide fibers by chemical
8.3.1 HIGH SILICA FIBERS vapor deposition (CVD) begins by pulling a
melt-spun carbon fiber through a mercury seal
Amorphous high silica fibers can be manufac- and into a tubular reactor. The carbon fiber is
tured by leaching sodium oxide from sodium heated by coupling the mercury seals on the
silicate glass fibers. The glass fibers, made by top and bottom of the reactor to a source of
using conventional glass fiber production tech- electricity. The melt-spun carbon fiber is called
niques, are composed primarily of 74.5%)silica a substrate or a core because silicon carbide is
and 24.2% sodium oxide. The fibers are held in vapor deposited onto it. The deposited silicon
a perforated basket, which is suspended within carbide is produced by the reaction of a gas
a cylindrical tank. A solution of HC1 and water mixture of silanes and hydrogen that enters
is pumped from the bottom of the tank up to the reactor through a port. Details of produc-
and over the glass fibers for several hours. The ing silicon fibers by CVD are found in
HCl/water/fiber mixture is stirred periodi- Wawner, Jr. (1988) and Textron Specialty
cally. The HCl and water are drained away, the Materials (1993b). Producing boron fibers by
fibers rinsed and a second leaching and rinsing CVD is a similar process (Tsirlin, 1985;
cycle is performed. The fibers are dried at a low Wawner, Jr., 1988; DeBolt, 1982).
temperature (Price and Kielmeyer, 1980).Other
techniques used to make high silica fibers
include spinning from solutions and spinning 8.3.4 PYROLYSIS OF POLYMERIC PRECURSOR
from a gel (Cooke, 1991). FIBER
Several ceramic fibers composed of various
combinations of silicon, carbon, nitrogen,
8.3.2 DRAWING CONTINUOUS FUSED
boron and titanium have been produced by
QUARTZ FIBERS
the pyrolysis of polymeric precursor fiber. The
Amorphous fused quartz fibers are made from process consists of four major steps: synthesize
preforms of fused quartz rods. The end of a a spinnable polymer, spin the polymer into
fused quartz rod is heated with an oxy-hydro- precursor fiber, cross-link (cure) the precursor
gen flame and the fiber is drawn, sized and fiber and pyrolyze the cured precursor fiber
either taken up on a spool or combined with into ceramic fiber.
other simultaneously drawn fibers to form a The synthesis of a polymeric precursor is
strand. Fused quartz rods are made by fusing known as Preceramic Polymer Chemistry.
chemically purified ground quartz crystal or Many spinnable polymers have been synthe-
quartz sand. Fused quartz rods are classified sized, including polycarbosilane as a
as Type I or Type I1 vitreous silica depending precursor for silicon carbide fiber (Yajima,
on the fusion technique. Type I signifies that 1985),polytitanocarbosilane as a precursor for
fusing was done in an electrically heated cru- Si-Ti-C-0 fiber (Yamamura et al., 1988) and
cible, while Type I1 implies fusing with an hydridopolysilazane as a precursor for silicon
oxy-hydrogen flame. To obtain fused quartz carbonitride fiber (LeGrow et al., 1987). In
158 Boron, high silica, quartz and ceramicfibers
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general, the polymeric precursor is melt spun. operation. They claimed that the fiber proper-
But other spinning methods, such as dry spin- ties were improved due to uniform heating and
ning, have been used. even fiber tensioning (Koba et al., 1989).
The spun precursor fiber is cross-linked to Sumitomo Chemical Co invented a fiber
prevent melting during the subsequent pyroly- with 85% gamma or delta-alumina and 15%sil-
sis step. Yajima cross-linked his polycarbosilane ica by calcining dry-spun fibers. The spinnable
precursor fiber by heating it in air to 200°C. mixture was formed by mixing an aluminum
Later research showed that silicon carbide fiber compound in a solvent and adding water to
properties were improved after curing the poly- get polyaluminoxane. A silica containing com-
carbosilane precursor fiber with electron beam pound, an organic polymer to improve
radiation (Takeda et al., 1992). spinnability and a compound such as lithium
The pyrolysis step consists of heating the to improve fiber properties were added. The
cured precursor fiber to a temperature gener- solvent was removed by distillation. The mix-
ally above 800°C in order to create a ceramic ture is spun into fiber and the fiber is calcined
fiber. (Kadokura, Harakawa and Matumoto, 1991).
Minnesota Mining and Mfg. Co. (3M)
makes fibers composed of alumina, boria and
8.3.5 ALUMINA BASED FIBER
silica by drying and sintering fiber that is spun
E.I. du Pont de Nemours patented a process to from concentrated aqueous solutions. The
make continuous alumina fibers that involved aqueous solution can be composed of an alu-
spinning a viscous slurry. One slurry composi- mina and boria precursor such as a basic
tion was prepared by dissolving an alumina aluminum acetate, silica sol and water. The
precursor such as aluminum chlorohydroxide 14%boria in 3M’s Nextel 312 fiber mhibits the
in water and then adding solid alumina parti- formation of alumina crystals and aluminum
cles. An organic polymer might be added to borosilicate is the predominant crystalline
the slurry to aid its spinnability by modifying species. The 2% boria in Nextel 440, however,
its viscosity. The viscous slurry was extruded is not enough to inhibit alumina, with eta-
through a spinneret and the green (unfired) alumina being the predominant crystalline
fibers were wound onto a bobbin. The fibers species (Sowman, 1988).
were fired at a temperature below the sinter-
ing temperature (calcining) to remove water
8.4 STAPLE
and volatile material. The calcined fibers were
sintered (densified) to remove porosity and The process to make alumina staple is similar
convert the alumina precursor to the stable to the processes that are used in making alu-
alpha-alumina structure. mina-based continuous fibers. An aqueous
This slurry-spinning process was advanced and viscous solution of an alumina precursor,
by Mitsui Mining Co. where the fiber was spun, silica and an organic polymer is extruded
dried, calcined and sintered in a continuous through apertures into a high velocity gas
stream, creating green (unfired) staple. The
green staple is sintered. The silica is added to
toughen the resultant staple by inhibiting alu-
Footnotes for Table 8.1
mina crystal growth while the green staple is
a Most of the trade names are registered trademarks. Each
from the catalytic grade with an eta-alumina the end of a polycrystalline feed rod is melted
structure, to an aerospace grade with a delta + with a CO, laser, a grain free seed crystal is
alpha-alumina or an alpha + delta-alumina + brought in contact with the melt and a whisker
mullite structure. is drawn. The LHFZ process can be used to
Alumina-silica staple, also called alumi- produce whiskers with diameters as low as
nosilicate staple, is made by atomizing a 10 pm or as high as 10 pm (Haggerty,Wills and
molten ceramic stream. The raw material for Sheehan, 1991).
the melt is a clay mineral or a blend of alumina
and silica. The melt is atomized by pouring it 8.5.2 DISCONTINUOUS WHISKERS BY THE VLS
into the path of a high velocity air stream or by PROCESS
feeding it onto a rotating wheel that throws
out the melt by centrifugal force. The former is VLS stands for vapor feed gases-liquid cata-
called the blowing process, while the latter is lyst-solid crystalline whisker growth. In a
called centrifugal spinning. One commercial particular VLS process to make single crystal
alumina-silica staple called Fiberfrax ranges Sic whiskers, uniformly sized catalyst particles
in length from 70-1000 pm and is made by The are applied to carbon substrates. The carbon
Carborundum Co. substrates and catalyst are placed within a
growth chamber. Also within the chambers are
Si0 generators, made by impregnating porous
8.5 WHISKERS brick with carbon and SiO,. The chamber is
placed within a furnace and heated to a growth
8.5.1 CONTINUOUS WHISKERS
temperature of 1300-1450°C. During t h s time,
Single crystal continuous alumina whiskers can gases such as CO, CH,, N, and H, are fed into
be grown from a pure melt by using a modifi- the chamber. The catalyst particles melt and
cation of the Czochralski method. The modified become supersaturated with material supplied
method is still classified as a moving crystal from the vapor and carbon from the substrate.
techruque, but, unlike Czochralslu’s technique, Solid Sic precipitates from the liquid catalyst
uses a die to shape the growing whisker. A cap- onto the growth substrate. As precipitation con-
illary tube draws the melt up to and over a die. tinues, the whisker grows, lifting the catalyst
The melt flows to the die’s vertical edges and ball from the substrate (Petrovic and Hurley
stops; so the die’s vertical edges control the 1990; Milewski et al., 1985).
shape of the subsequently drawn whisker. A The time necessary to produce Sic whiskers
grain free seed crystal is brought in contact with by the VLS process can be reduced by under-
the melt surface and a whisker is drawn. A lin- cooling or pre-alloying the catalyst balls. After
ear temperature distribution is maintained reaching the growth temperature, the catalyst
along the axis of the growing crystal to avoid balls are undercooled by 150”C,initiating pre-
defects by lowering thermal stresses (LaBelle, cipitation. The chamber is brought back up to
Jr, 1980; Antonov, 1990). Saphikon Inc. grows the growth temperature and held there until
whiskers in many shapes using a similar whisker growth is completed. Another tech-
process that they call EFG (edge-defined,film- nique to reduce the growth time is to pre-alloy
fed growth). One of the shapes is a hollow tube the catalyst particles with carbon and silicon
that may be used as a waveguide (Harrington so that whisker growth occurs immediately
and Gregory 1990). upon reaching the growth temperature
Another moving crystal technique to make (Shalek, 1987; Shalek, Katz and Hurley, 1988).
continuous alumina whiskers is called the Other whiskers produced by the VLS
laser heated floating zone directional solidifi- process include A1,0,, boron, MgO and Si
cation process (LHFZ). In the LHFZ process,
Forms 161
diameter Sic fiber (KO, 1989). Fine diameter and two diagonal directions. Figure 8.1 shows
(less than 20 pm) continuous ceramic fiber is the 3D and 5D fabrics. See Ngai (1990) for dia-
more flexible, can be formed into nontwisted grams of 4D, 7D and 11D fabrics.
strands (sometimes called nontwisted yarn) Continuous boron fibers are supplied in the
and braided or woven into two- or three- form of borodepoxy prepreg tape and
dimensional shapes. The quartz fibers, being boron/aluminum preform sheets. The
the most flexible, can be twisted into filament boron/aluminum preform sheets are made by
yarn and braided or woven into two- or three- resin bonding the boron fibers to the side of
dimensional shapes. aluminum foil. The fibers can be aligned in
Figure 8.1 shows some of the many forms any direction. These preform sheets are used
that fibers can take. Each strand of the fine in solid state (low temperature, high pressure)
diameter ceramic fibers can contain anywhere diffusion bonding processes (TextronSpecialty
from 250 to 1000 filaments per strand, depend- Materials, 1993a).
ing on the product. The strands may be Continuous Sic fibers with a core are
bundled to form roving. Fused quartz formed into plasma-sprayed aluminum or
untwisted strands are formed into roving that titanium preform sheets for hot molding (a
contains either 2880 or 4800 filaments per rov- low pressure, hot pressing process) and into
ing. As mentioned earlier, fused quartz fibers ’woven fabric’ for investment casting or diffu-
may be twisted into yarn at 4 turns per inch, sion bonding. In diffusion bonding, the fabric
with 120, 240, 480, 960, or 1920 filaments per is placed between two metal foils prior to con-
yarn and in a variety of yarn constructions. solidation. The ’woven fabric’ is similar to
Fine diameter ceramic and fused quartz fibers nonwoven roving because the fibers are
can be formed into many multidimensional aligned in one direction and held together by a
structures, such as orthogonal nonwoven fab- cross-weave of metallic ribbons (Textron
rics (Fiber Materials, Inc., 1993; KO, 1989). Specialty Materials, 199313; Mittnick 1990).
Orthogonal nonwoven fabrics are so-called Continuous high silica fibers are processed
because there is no interlacing of fibers. Other into a variety of forms such as cloth, tape,
names for these fabrics are xyz fabrics, multi- sleeving, yarn, cordage, rope, nonwoven mat,
directional preforms and 3D, 4D, 5D, 7D or blanket, felt, rigid tile and sewing thread.
11D woven blocks. The 5D, 7D and 11D blocks Alumina-silica staple fibers are made into
have strands going in the three orthogonal paper, rigid board and cylinders, other rigid
directions and in diagonal directions. The 4D three-dimensional shapes and into most of the
blocks have strands going in two orthogonal high silica fiber forms. Alumina staple fibers
are processed into paper, mat, felt, blanket,
rigid board and cylinders and other rigid
Footnotes for Table 8.2 three-dimensional shapes.
aAll values, except those for silicon carbide whiskers, are
from the manufacturers’ product literature.
Test methods may varv between manufacturers.
i ,
8.8 APPLICATIONS
All values are averages, are for reference only and are
not to be taken as a specification. Table 8.3 provides a sampling of the many
Most fibers are under continual development. Contact applications for boron, high silica, fused
the manufacturers for the most up to date property values.
DNA = Data Not Available.
quartz and ceramic fibers. For other applica-
The silicon carbide whisker values are from Petrovic and tions, see Bracke, Schurmans and Verhoest
Hurley (1990). (1984), Mortensen and Koczak (1993),
This value in metric units was converted from a value
that was given in English units.
Schwartz (1992) and the other chapters within
Most of the tradenames are registered trademarks. Each this handbook.
trademark belongs to the manufacturer listed to its left
164 Boron, high silica, quartz and ceramicfibers
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4 812 271. Mar. 14, 1989. Assigned to Mitsui Price, G.B. and Kielmeyer, W.H. 1980. Method for
Mining Co Ltd. Making I-ligh Purity, Devitrification Resistant,
LaBelie, Jr., H.E.1980. EFG, The Invention and Amorphous Silica Fibers. US Patent 4 200 485.
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L,asday, S.B. 1993. Ceramic/Ceramic Composite 2nd edn. New York: Marcel Dekker, Inc.
Components Advance Furnace Systems and Schwartz, M.M. 1992. Composite Materials I$andbook,
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LeGrow, G.E., et al. 1987. Ceramics from McGr a w-Hill , Inc .
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