U.S. patent application number 10/493222 was filed with the patent office on 2005-03-17 for boron carbide based sintered compact and method for preparation thereof.
Invention is credited to Hirao, Kiyoshi, Kanzaki, Shuzo, Sakaguchi, Shuji, Yamada, Suzuya, Yamauchi, Yukihiko.
Application Number | 20050059541 10/493222 |
Document ID | / |
Family ID | 26624380 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050059541 |
Kind Code |
A1 |
Hirao, Kiyoshi ; et
al. |
March 17, 2005 |
Boron carbide based sintered compact and method for preparation
thereof
Abstract
A boron carbide based sintered body having a four-point flexural
strength of at least 400 MPa and a fracture toughness of at least
2.8 MPa.multidot.m.sup.1/2, which has the following two preferred
embodiments. (1) A boron carbide-titanium diboride sintered body
obtained by sintering a mixed powder of a B.sub.4C powder, a
TiO.sub.2 powder and a C powder while reacting them under a
pressurized condition and comprising from 95 to 70 mol % of boron
carbide and from 5 to 30 mol % of titanium diboride, wherein the
boron carbide has a maximum particle diameter of at most 5 .mu.m.
(2) A boron carbide-chromium diboride sintered body containing from
10 to 25 mol % of CrB.sub.2 in B.sub.4C, wherein the sintered body
has a relative density of at least 90%, boron carbide particles in
the sintered body have a maximum particle diameter of at most 100
.mu.m, and the abundance ratio (area ratio) of boron carbide
particles of from 10 to 100 .mu.m to boron carbide particles having
a particle diameter of at most 5 .mu.m, is from 0.02 to 0.6.
Inventors: |
Hirao, Kiyoshi; (Nagoya-shi,
JP) ; Sakaguchi, Shuji; (Nagoya-shi, JP) ;
Yamauchi, Yukihiko; (Nagoya-shi, JP) ; Kanzaki,
Shuzo; (Nagoya-shi, JP) ; Yamada, Suzuya;
(Nagoya-shi, JP) |
Correspondence
Address: |
OBLON, SPIVAK, MCCLELLAND, MAIER & NEUSTADT, P.C.
1940 DUKE STREET
ALEXANDRIA
VA
22314
US
|
Family ID: |
26624380 |
Appl. No.: |
10/493222 |
Filed: |
October 20, 2004 |
PCT Filed: |
November 6, 2002 |
PCT NO: |
PCT/JP02/11577 |
Current U.S.
Class: |
501/87 ; 264/625;
501/96.3 |
Current CPC
Class: |
C04B 2235/658 20130101;
C04B 2235/5436 20130101; C04B 2235/5454 20130101; C04B 35/645
20130101; C04B 2235/3813 20130101; C04B 2235/94 20130101; C04B
2235/528 20130101; C04B 2235/3231 20130101; C04B 2235/3821
20130101; C04B 2235/656 20130101; C04B 2235/6581 20130101; C04B
2235/80 20130101; C04B 35/64 20130101; C04B 2235/661 20130101; B82Y
30/00 20130101; C04B 2235/3232 20130101; C04B 35/563 20130101; C04B
2235/5409 20130101; C04B 2235/424 20130101; C04B 2235/5445
20130101; C04B 2235/422 20130101; C04B 2235/786 20130101; C04B
2235/6562 20130101; C04B 2235/96 20130101; C04B 2235/77 20130101;
C04B 2235/604 20130101 |
Class at
Publication: |
501/087 ;
501/096.3; 264/625 |
International
Class: |
C04B 035/563; C04B
035/58 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 6, 2001 |
JP |
2001-341205 |
May 7, 2002 |
JP |
2002-131272 |
Claims
1. A boron carbide based sintered body characterized by having a
four point flexural strength of at least 400 MPa as measured in
accordance with JIS R1601 and a fracture toughness of at least 2.8
MPa.multidot.m.sup.1/2 as measured in accordance with JIS
R1607-SEPB method.
2. The boron carbide based sintered body according to claim 1,
which is a boron carbide-titanium diboride sintered body obtained
by sintering a mixed powder of boron carbide (B.sub.4C) powder,
titanium dioxide (TiO.sub.2) powder and carbon (C) powder while
reacting them under a pressurized condition and which comprises
from 95 to 70 mol % of boron carbide and from 5 to 30 mol % of
titanium diboride, wherein the boron carbide has a maximum particle
diameter of at most 5 .mu.m.
3. The boron carbide based sintered body according to claim 1 or 2,
wherein the four point flexural strength is at least 700 MPa.
4. The boron carbide based sintered body according to claim 1, 2 or
3, wherein the four point flexural strength is at least 800 MPa,
and the fracture toughness is at least 3.0
MPa.multidot.m.sup.1/2.
5. A boron carbide based sintered body which is a boron
carbide-chromium diboride sintered body containing from 10 to 25
mol % of chromium diboride (CrB.sub.2) in boron carbide (B.sub.4C),
characterized in that the sintered body has a relative density of
at least 90%, boron carbide particles in the sintered body have a
maximum particle diameter of at most 100 .mu.m, and the abundance
ratio (area ratio) of boron carbide particles of from 10 to 100
.mu.m to boron carbide particles having a particle diameter of at
most 5 .mu.m, is from 0.02 to 0.6.
6. The boron carbide based sintered body according to claim 5,
which has an electric conductivity of at least 5.times.10.sup.2
S/m.
7. The boron carbide based sintered body according to claim 6,
which has a four point flexural strength of at least 400 MPa and a
fracture toughness of at least 3.0 MPa.multidot.m.sup.1/2.
8. A process for producing a boron carbide based sintered body,
characterized by mixing a titanium dioxide powder having an average
particle diameter of less than 1 .mu.m and a carbon powder having
an average particle diameter of less than 1 .mu.m to a boron
carbide powder having a maximum particle diameter of at most 5
.mu.m, an average particle diameter of at most 1 .mu.m and a
specific surface area of at least 10 m.sup.2/g, and sintering the
mixture within a temperature range of from 1900 to 2100.degree. C.
while reacting them under a pressurized condition.
9. The process for producing a boron carbide based sintered body
according to claim 8, wherein the specific surface area of the
boron carbide powder is at least 16 m.sup.2/g, and the average
particle diameter of each of the titanium dioxide powder and the
carbon powder is less than 0.1 .mu.m.
10. A process for producing a boron carbide based sintered body,
characterized by molding a raw material powder having from 10 to 25
mol % of a chromium diboride powder added and mixed to a boron
carbide powder having an average particle diameter (D.sub.50) of at
most 2 .mu.m and a specific surface area of at least 10 m.sup.2/g,
followed by heating from 1950 to 2100.degree. C. in a non-oxidizing
atmosphere under a non-pressurized condition.
11. A shock absorber made of the boron carbide based sintered body
as defined in any one of claims 1 to 7.
12. The shock absorber according to claim 11, wherein the shock
absorber is for a high velocity missile.
13. An abrasion resistant component made of the boron carbide based
sintered body as defined in any one of claims 1 to 7.
Description
TECHNICAL FIELD
[0001] The present invention relates to a boron carbide based
sintered body, such as a boron carbide-titanium diboride sintered
body or a boron carbide-chromium diboride sintered body, having
high density, four-point flexural strength and fracture toughness,
and a process for its production.
BACKGROUND ART
[0002] In general, a boron carbide sintered body is expected to
have a wide range of applications as a material having a light
weight and high hardness and being excellent in abrasion resistance
or corrosion resistance. At present, it is used, for example, for a
sandblast nozzle, a wire drawing die or an extrusion die. However,
on the other hand, such a boron carbide sintered body has a
drawback that it has low strength. For example, K. A. Schwetz, J.
Solid State Chemistry, 133, 177-81 (1997) discloses preparation of
boron carbide sintered bodies by HIP treatment under various
sintering conditions, but a boron carbide sintered body having a
flexural strength of at least 600 MPa has not yet been
obtained.
[0003] Further, V. Skorokhod, J. Material Science Letter, 19,
237-239 (2000) discloses that a mixture comprising a boron carbide
(B.sub.4C) powder, a titanium dioxide (TiO.sub.2) powder and a
carbon (C) powder, is sintered under a pressurized condition
employing a hot press method while reacting a part of boron carbide
with titanium dioxide and carbon (see the following reaction
formula), to obtain a boron carbide-titanium diboride sintered
body, whereby a four-point flexural strength of 621 MPa is
obtained.
Reaction formula: B.sub.4C+2TiO.sub.2+3C.fwdarw.2TiB.sub.2+4CO
[0004] However, in order to make it practically possible to use a
boron carbide based sintered body in a wide range of applications,
it is desired to develop a boron carbide based sintered body having
a still higher four-point flexural strength. However, as mentioned
above, according to the conventional methods, a boron carbide based
sintered body having a high four-point flexural strength exceeding
621 MPa has not yet been obtained.
[0005] Further, a boron carbide based sintered body is hardly
sinterable and accordingly, it is usually prepared by a hot press
method. This production method hinders a common application of a
boron carbide based sintered body, since its production cost is
high. Accordingly, it is being studied to prepare a boron carbide
sintered body by heating (sintering) under a non-pressurized
condition (a normal pressure method) instead of the hot press
method. For example, in the above-mentioned prior art reference K.
A. Schwetz, J. Solid State Chemistry, 133, 177-81 (1997), carbon is
added as a sintering-assisting agent, and a boron carbide sintered
body is prepared under a non-pressurized condition. However, such a
method is not practically preferred, since it is necessary to carry
out sintering at an extremely high temperature of at least
2150.degree. C.
[0006] Further, a boron carbide sintered body has an extremely high
hardness, whereby it can hardly be processed by a usual
grinding/polishing method, and further, the electric conductivity
of the boron carbide sintered body is low at a level of from 10 to
300 S/m, whereby there has been a problem that the discharge
processing is difficult.
[0007] As mentioned above, a boron carbide sintered body is hardly
sinterable and hardly processable, and at present, it is
practically used only in an extremely limited application.
[0008] Under these circumstances, the present inventors have
conducted an extensive research with an aim to develop a new boron
carbide based sintered body which has a four-point flexural
strength higher than the above-mentioned four-point flexural
strength of 621 MPa and which makes it possible to realize a wide
range of applications, and as a result, have found it possible to
accomplish the desired object by selecting a specific material and
by carrying out sintering treatment with a specific composition and
under a specific temperature condition.
[0009] Further, the present inventors have found it possible to
obtain a boron carbide based sintered body having excellent
characteristics by preparing a sintered body having a specific
microstructure wherein a highly electrically conductive chromium
diboride phase forms a three dimensional network structure, by
adding a predetermined amount of chromium diboride to a boron
carbide powder having a specific physical property and carrying out
liquid phase sintering under a non-pressurized condition to form a
liquid phase of chromium diboride.
[0010] The present invention has been accomplished on the basis of
the above discoveries.
[0011] Namely, it is an object of the present invention to provide
a novel boron carbide based sintered body having a four-point
flexural strength of at least 400 MPa and a fracture toughness of
at least 2.8 MPa.multidot.m.sup.1/2.
[0012] Further, it is an object of the present invention to provide
a boron carbide-titanium diboride sintered body having a four-point
flexural strength of at least 700 MPa, preferably at least 800 MPa
and a fracture toughness of at least 3.0
MPa.multidot.m.sup.1/2.
[0013] Further, it is an object of the present invention to provide
a novel process for producing a boron carbide material which makes
it possible to produce a boron carbide based sintered body which
has a high density and having the fracture toughness improved,
wherein the maximum particle diameter of boron carbide is at most 5
.mu.m, the titanium diboride particles are uniformly dispersed in
the boron carbide matrix, and the agglomerated/dispersed state of
titanium diboride particles is uniform and good.
[0014] Further, it is an object of the present invention to provide
a boron carbide based sintered body which has a relative density of
at least 90%, an electrical conductivity of at least
5.times.10.sup.2 S/m, a four-point flexural strength of at least
400 MPa and a fracture toughness of at least 3.0
MPa.multidot.m.sup.1/2, and a process for producing it by sintering
under a non-pressurized condition.
DISCLOSURE OF THE INVENTION
[0015] The gist of the present invention to solve the above
problems, is as follows.
[0016] (1) A boron carbide based sintered body characterized by
having a four point flexural strength of at least 400 MPa as
measured in accordance with JIS R1601 and a fracture toughness of
at least 2.8 MPa.multidot.m.sup.1/2 as measured in accordance with
JIS R1607-SEPB method.
[0017] (2) The boron carbide based sintered body according to the
above (1), which is a boron carbide-titanium diboride sintered body
obtained by sintering a mixed powder of boron carbide (B.sub.4C)
powder, titanium dioxide (TiO.sub.2) powder and carbon (C) powder
while reacting them under a pressurized condition and which
comprises from 95 to 70 mol% of boron carbide and from 5 to 30 mol%
of titanium diboride, wherein the boron carbide has a maximum
particle diameter of at most 5 .mu.m.
[0018] (3) The boron carbide based sintered body according to the
above (1) or (2), wherein the four point flexural strength is at
least 700 MPa.
[0019] (4) The boron carbide based sintered body according to the
above (1), (2) or (3), wherein the four point flexural strength is
at least 800 MPa, and the fracture toughness is at least 3.0
MPa.multidot.m.sup.1/2.
[0020] (5) A boron carbide based sintered body which is a boron
carbide-chromium diboride sintered body containing from 10 to 25
mol% of chromium diboride (CrB.sub.2) in boron carbide (B.sub.4C),
characterized in that the sintered body has a relative density of
at least 90%, boron carbide particles in the sintered body have a
maximum particle diameter of at most 100 .mu.m, and the abundance
ratio (area ratio) of boron carbide particles of from 10 to 100
.mu.m to boron carbide particles having a particle diameter of at
most 5 .mu.m, is from 0.02 to 0.6.
[0021] (6) The boron carbide based sintered body according to the
above (5), which has an electric conductivity of at least
5.times.10.sup.2 S/m.
[0022] (7) The boron carbide based sintered body according to the
above (6), which has a four point flexural strength of at least 400
MPa and a fracture toughness of at least 3.0
MPa.multidot.m.sup.1/2.
[0023] (8) A process for producing a boron carbide based sintered
body, characterized by mixing a titanium dioxide powder having an
average particle diameter of less than 1 .mu.m and a carbon powder
having an average particle diameter of less than 1 .mu.m to a boron
carbide powder having a maximum particle diameter of at most 5
.mu.m, an average particle diameter of at most 1 .mu.m and a
specific surface area of at least 10 m.sup.2/g, and sintering the
mixture within a temperature range of from 1900 to 2100.degree. C.
while reacting them under a pressurized condition.
[0024] (9) The process for producing a boron carbide based sintered
body according to the above (8), wherein the specific surface area
of the boron carbide powder is at least 16 m.sup.2/g, and the
average particle diameter of each of the titanium dioxide powder
and the carbon powder is less than 0.1 .mu.m.
[0025] (10) A process for producing a boron carbide based sintered
body, characterized by molding a raw material powder having from 10
to 25 mol% of a chromium diboride powder added and mixed to a boron
carbide powder having an average particle diameter (D.sub.50) of at
most 2 .mu.m and a specific surface area of at least 10 m.sup.2/g,
followed by heating from 1950 to 2100.degree. C. in a non-oxidizing
atmosphere under a non-pressurized condition.
[0026] (11) A shock absorber made of the boron carbide based
sintered body as defined in any one of the above (1) to (7).
[0027] (12) The shock absorber according to the above (11), wherein
the shock absorber is for a high velocity missile.
[0028] (13) An abrasion resistant component made of the boron
carbide based sintered body as defined in any one of the above (1)
to (7).
BEST MODE FOR CARRYING OUT THE INVENTION
[0029] Now, the present invention will be described in further
detail.
[0030] The present invention is a boron carbide based sintered body
having a four-point flexural strength of at least 400 MPa as
measured in accordance with JIS R1601 and a fracture toughness of
at least 2.8 MPa.multidot.m.sup.1/2, preferably at least 3.0
MPa.multidot.m.sup.1/2, as measured in accordance with JIS
R1607-SEPB method, which is a novel boron carbide based sintered
body. Such a boron carbide based sintered body having a high
four-point flexural strength and a high fracture toughness is
useful in a wide range of applications for e.g. sliding components,
cutting tools, bulletproof plates or novel abrasion resistant
components by virtue of its properties and thus is industrially
useful.
[0031] A boron carbide based sintered body according to a preferred
embodiment of the present invention is a boron carbide-titanium
diboride sintered body obtained by mixing a boron carbide powder
having a specific property with a titanium dioxide powder and a
carbon powder in a specific composition and sintering them in a
specific temperature range under a pressurized condition while
reacting a part of the boron carbide powder with the titanium
dioxide powder and the carbon powder in accordance with the
following reaction formula.
B.sub.4C+2TiO.sub.2+3C.fwdarw.2TiB.sub.2+4CO
[0032] The present inventors have conducted various experimental
studies on a process for sintering boron carbide while utilizing
the above reaction and as a result, have found that when specific
materials are selected for use and sintering treatment is carried
out with a specific composition and under a specific temperature
condition, it is possible to obtain a boron carbide-titanium
diboride sintered body which has a high density and a specific
microstructure, wherein the maximum particle diameter of boron
carbide is at most 5 .mu.m, titanium diboride particles are
uniformly dispersed in the boron carbide matrix, and the
agglomerated/dispersed state of titanium diboride particles is
uniform and good and that the sintered body has a four-point
flexural strength of at least 700 MPa which has not been obtained
heretofore, and has high strength characteristics.
[0033] The boron carbide-titanium diboride sintered body is a boron
carbide-titanium diboride sintered body obtained by sintering a
mixed powder comprising a boron carbide (B.sub.4C) powder, a
titanium dioxide (TiO.sub.2) powder and a carbon (C) powder while
reacting them in a specific temperature range under a pressurized
condition, and it comprises from 95 to 70 mol% of boron carbide and
from 5 to 30 mol% of titanium diboride and yet, the maximum
particle diameter of the boron carbide is at most 5 .mu.m.
[0034] The reason for specifying the compositional ratio of boron
carbide and titanium diboride in the above range, is that if
titanium diboride present in the boron carbide-titanium diboride
sintered body is less than 5 mol%, no adequate effect for improving
the strength can be obtained, and if it exceeds 30 mol%, the
density of the sintered body tends to be higher than 3.0
g/cm.sup.3, whereby the light weight feature of the boron carbide
based sintered body will be lost, and at the same time, the
hardness will be low.
[0035] Further, even in the range of the above compositional ratio,
if the maximum particle diameter of boron carbide in the sintered
body exceeds 5 .mu.m, it will be difficult to obtain one having a
high strength. When the above-mentioned specific compositional
range and the specific microstructure are satisfied at the same
time, it will be possible for the first time to obtain a boron
carbide-titanium diboride sintered body having a sufficiently high
strength.
[0036] The sintered body of the present invention shows a high
strength with a four-point flexural strength of at least 700 MPa
when the above conditions are satisfied. Further, according to a
result of the studies made by the present inventors, by selecting
preferred conditions with respect to the particle sizes of the
boron carbide powder, the titanium dioxide powder and the carbon
powder to be used as the starting materials, such as selecting
those having finer particle sizes, it becomes possible to obtain a
boron carbide-titanium diboride sintered body which has a
four-point flexural strength of at least 800 MPa and yet has a high
strength characteristic with a fracture toughness of at least 3.0
MPa.multidot.m.sup.1/2.
[0037] The boron carbide-titanium diboride sintered body of the
present invention is effective for prolonging the useful life when
it is applied to a conventional sandblast, a wire drawing die, an
extrusion die, etc., and has a remarkable characteristic which can
not be expected with a conventional boron carbide based sintered
body, such that it can be suitably applied to a wide range of
applications which has heretofore been impossible.
[0038] In the process for producing a boron carbide-titanium
diboride sintered body of the present invention, a boron carbide
powder, a titanium dioxide powder and a carbon powder having
specific properties are used as the starting materials, and they
are mixed and sintered while reacting them in a specific
temperature range under a pressurized condition of e.g. a hot
pressing method. It is thereby possible to obtain a boron
carbide-titanium diboride sintered body having the above-mentioned
characteristics, which has a high density and wherein the maximum
particle size of boron carbide is at most 5 .mu.m, titanium
diboride particles are uniformly dispersed in the boron carbide
matrix, the agglomerated/dispersed state of titanium diboride
particles is uniform and good, and the fracture toughness is
improved, by controlling the particle sizes, the maximum particle
sizes, the agglomerated states, and the dispersed state, of boron
carbide particles and titanium diboride particles in the boron
carbide-titanium diboride sintered body.
[0039] The boron carbide powder to be used in the present invention
is one having an average particle diameter (D50) is at most 1 .mu.m
and a maximum particle diameter of at most 5 .mu.m, as measured by
a laser diffraction scattering analyzer (Microtrac). If the average
particle diameter (D50) is larger than 1 .mu.m, the sinterability
tends to be poor, and it becomes impossible to obtain a dense
sintered body within a temperature range of from 1900 to
2100.degree. C., and in order to densify such a material, it will
be required to adopt a higher sintering temperature so that grain
growth is likely to take place. Consequently, the maximum diameter
of the boron carbide particles in the obtainable sintered body
tends to exceed 5 .mu.m, whereby it tends to be difficult to obtain
a sintered body having a high four-point flexural strength.
Further, with respect to the specific surface area (BET) of the
boron carbide powder, a boron carbide powder having a specific
surface area of at least 10 m.sup.2/g is preferably selected for
use, since its sinterability is good.
[0040] With respect to the titanium dioxide powder and the carbon
powder to be used in the present invention, it is necessary to use
fine powders in order to carry out a uniform reaction during
sintering, and they are ones having an average particle diameter
(D50) of less than 1 .mu.m as measured by a laser diffraction
scattering analyzer (Microtrac). If the average particle diameter
(D50) is at least 1 .mu.m, large titanium diboride particles will
be formed in the sintered body, and such large particles will be
starting points for fracture, whereby it becomes impossible to
obtain a sintered body having a high four-point flexural
strength.
[0041] Further, in a case where the average particle diameter is
less than 0.1 .mu.m, it tends to be difficult to carry out the
measurement accurately, since the powder tends to agglomerate
during the measurement by a laser diffraction scattering analyzer.
Therefore, a BET average particle diameter calculated from the
specific surface area may be employed. Further, titanium dioxide
has crystal systems of rutile type, anatase type and brookite type,
and any type may be employed.
[0042] The boron carbide powder, the titanium dioxide powder and
the carbon powder having the above-mentioned physical properties
may respectively be obtained by such a means as sieving, separation
by sedimentation, pulverization, etc. Commercial products may be
used so long as they have the above-mentioned physical
properties.
[0043] In the present invention, a titanium dioxide powder having
an average particle diameter of less than 1 .mu.m and a carbon
powder having an average particle diameter of less than 1 .mu.m are
blended to a boron carbide powder having an average particle
diameter of at most 1 .mu.m, a maximum particle diameter of at most
5 .mu.m and a specific surface area of at least 10 m.sup.2/g,
preferably in a blend ratio of from 4.5 to 19 mol% of the titanium
dioxide powder, and the molar ratio of carbon powder/titanium
dioxide powder being from 1.4 to 1.7, followed by mixing, so that
the composition of the boron carbide-titanium diboride sintered
body to be prepared would be from 95 to 70 mol% of boron carbide
and from 5 to 30 mol% of titanium diboride. Then, if necessary,
this mixture is molded and then the above mixed powder or molded
product is sintered in a temperature range of from 1900 to
2100.degree. C. in vacuum or in an inert gas atmosphere of e.g. Ar
while reacting them under a pressurized condition to let titanium
diboride particles form among boron carbide particles, to prepare a
dense boron carbide-titanium diboride sintered body having a
relative density of at least 98%.
[0044] Here, in the method for obtaining the boron carbide-titanium
diboride sintered body by sintering the mixed powder comprising the
boron carbide powder, the titanium dioxide powder and the carbon
powder, in the specific temperature range while reacting them under
a pressurized condition, according to the study by the present
inventors, there is a technical problem that titanium diboride
particles in the prepared boron carbide-titanium diboride sintered
body, tend to agglomerate in the reaction process and are likely to
form large agglomerated masses, and if titanium diboride
agglomerated masses or coarse boron carbide particles larger than 5
.mu.m, are present, they serve as fracture starting points and
bring about deterioration of the four-point bending strength.
[0045] According to the present invention, a boron carbide powder
having a specific physical property is used, whereby sinterability
of the boron carbide powder itself is good, and as compared with
formation of titanium diboride particles, sintering among the boron
carbide particles will preferentially proceed, whereby titanium
diboride particles will be uniformly dispersed in the boron carbide
matrix, whereby the agglomerated/dispersed state of titanium
diboride particles will be uniform and good. As a result, it is
possible to make that there will be no substantial presence of
coagulated particles of titanium diboride. Further, the maximum
particle diameter of boron carbide is at most 5 .mu.m, and
accordingly, coarse boron carbide particles are not present from
the beginning. As a result, the obtainable boron carbide-titanium
diboride sintered body has a four point flexural strength as high
as at least 700 MPa, as mentioned above.
[0046] In addition, according to the present invention, when a
boron carbide powder having an average particle size of at most 1
.mu.m, a maximum particle size of at most 5 .mu.m and a specific
surface area of at least 16 m.sup.2/g is used, and a titanium
dioxide powder having an average particle size of less than 0.1
.mu.m and a carbon powder having an average particle size of less
than 0.1 .mu.m are employed, the agglomerated/dispersed state of
titanium diboride particles becomes more uniform and good. And,
even if particles of the titanium dioxide powder are joined during
the process wherein sintering of the boron carbide powder proceeds
for a grain growth to from 2 to 3 .mu.m, titanium diboride
particles of from 2 to 3 .mu.m will form, and the titanium diboride
particles will be uniformly dispersed without being coagulated at
all. As a result, boron carbide-titanium diboride sintered body can
be obtained, which has a specific microstructure having titanium
diboride uniformly dispersed and which has high strength.
[0047] Namely, in a boron carbide-titanium diboride sintered body,
the thermal expansion coefficient of titanium diboride is larger
than boron carbide. Accordingly, in a case where titanium diboride
particles having a size of from 2 to 3 .mu.m are present in the
boron carbide matrix, crack propagation detour or microcracking
takes place in the vicinity of the interface between the boron
carbide matrix and the titanium diboride particles during the
progress of fracture, whereby the fracture toughness will be
improved. And, in the process for producing a boron
carbide-titanium diboride sintered body, the agglomerated/dispersed
state of titanium diboride particles will be good, and the fracture
toughness will be improved. Its strength will further be improved,
and it is possible to prepare a boron carbide-titanium diboride
sintered body having a high flexural strength of at least 800 MPa
and having a fracture toughness of at least 3.0
MPa.multidot.m.sup.1/2.
[0048] In the present invention, the titanium dioxide powder having
an average particle size of less than 0.1 .mu.m, may be any one so
long as the above-mentioned requirements are satisfied. However, a
spherical powder prepared by a vapor phase method will suitably be
employed. Further, as the carbon powder, any one may be used so
long as the average particle diameter is less than 0.1 .mu.m, and
carbon black or acetylene black can be preferably employed.
[0049] In the present invention, with respect to the sintering
conditions, if the sintering temperature is lower than 1900.degree.
C., it will be difficult to prepare a sufficiently dense boron
carbide-titanium diboride sintered body. On the other hand, if the
sintering temperature is higher than 2100.degree. C., a fine
sintered structure can not be obtained due to an abnormal grain
growth, whereby the flexural strength is likely to be low.
Accordingly, it is preferred to select the temperature within a
range of from 1900 to 2100.degree. C.
[0050] Further, the pressure during the sintering is usually from
20 MPa to 100 MPa, preferably from 30 MPa to 60 MPa. However, in a
case where the pressure during the sintering is lower than 20 MPa,
no adequately dense sintered body can be obtained. Further, in a
case where the pressure exceeds 100 MPa, discharge of a carbon
monoxide gas to the exterior will be prevented, whereby formation
of titanium diborate is likely to be impaired.
[0051] Another preferred boron carbide based sintered body of the
present invention is a boron carbide-chromium diboride sintered
body containing from 10 to 25 mol% of chromium diboride (CrB.sub.2)
in boron carbide (B.sub.4C), characterized in that the sintered
body has a relative density of at least 90%, boron carbide
particles in the sintered body have a maximum particle diameter of
at most 100 .mu.m, and the abundance ratio (area ratio) of boron
carbide particles of from 10 to 100 .mu.m to boron carbide
particles having a particle diameter of at most 5 .mu.m, is from
0.02 to 0.6.
[0052] In order to prepare a dense boron carbide based sintered
body by sintering under a non-pressurized condition, grain growth
of boron carbide to some extent is required, and if no grain growth
takes place, a sintered body having a high density can not be
obtained. On the other hand, if grain growth proceeds too much,
coarse grains will hinder densification, whereby the density of the
sintered body tends to rather decrease, and coarse particles will
be starting points for fracture, whereby the flexural strength
tends to decrease.
[0053] In the present invention, by using a boron carbide powder
having specific physical properties, sintering is carried out under
a specific non-pressurized condition in a temperature range where a
liquid phase containing chromium diboride (CrB.sub.2) as the main
component will form, whereby it is possible to obtain a boron
carbide-chromium diboride sintered body characterized in that the
maximum particle diameter of boron carbide particles is at most 100
.mu.m, the abundance ratio (area ratio) of boron carbide particles
of from 10 to 100 .mu.m to boron carbide particles having a
particle diameter of at most 5 .mu.m, is within a range of from
0.02 to 0.6, the relative density is at least 90%, a highly
electrically conductive chromium diboride phase forms a network
structure three dimensionally, and the body has an electrical
conductivity of at least 5.times.10.sup.2 S/m, a four-point
flexural strength of at least 400 MPa and a fracture toughness of
at least 3.0 MPa.multidot.m.sup.1/2.
[0054] The boron carbide powder to be used in the present invention
may preferably one having an average particle diameter (D.sub.50)
of at most 2 .mu.m as measured by a laser diffraction scattering
method or a Doppler method. If the average particle diameter
(D.sub.50) is larger than 2 .mu.m, the sinterability tends to be
poor, a dense sintered body can hardly be obtainable within a
temperature range of from 1950 to 2100.degree. C., and in order to
densify it, it will be required to sinter it at a higher
temperature at which grain growth is more likely to take place,
whereby deterioration of the flexural strength is likely to be
brought about. With respect to the specific surface area (BET), it
is preferred to employ a boron carbide powder having a specific
surface area of at least 10 m.sup.2/g, more preferably at least 15
m.sup.2/g, which has good sinterability.
[0055] The boron carbide powder having the above physical
properties can be prepared by a means such as sieving, separation
by sedimentation, pulverization, etc., but a commercial product
having such physical properties may be available for use.
[0056] To the boron carbide powder having the above physical
properties, from 10 to 25 mol% of a chromium diboride powder is
added and molded, followed by heating (sintering) in vacuum or
under a non-pressurized condition under a non-oxidizing atmosphere
such as Ar within a sintering temperature range of from 1950 to
2100.degree. C. in a state where a chromium diboride based liquid
phase is formed.
[0057] The chromium diboride powder will react and melt with a part
of the boron carbide powder during the sintering to form a chromium
diboride based liquid phase, which will penetrate among boron
carbide particles, and as compared with the boron carbide powder,
it may be used even in the form of a starting material powder
having a large particle size. Preferably, a chromium diboride
powder having an average particle size (D.sub.50) of at most 8
.mu.m may be used, and more preferably, one having an average
particle diameter (D.sub.50) of at most 4 .mu.m may be used.
[0058] In a case where the sintering temperature is lower than
1950.degree. C., a chromium diboride based liquid phase will not be
formed, whereby a sufficiently dense boron carbide sintered body
can not be prepared, and a three dimensional network structure of
the chromium diboride phase can not be formed, whereby high
electrical conductivity can not be obtained. On the other hand, at
a sintering temperature higher than 2100.degree. C., coarse boron
carbide particles will be formed by grain growth, thus leading to
deterioration of the flexural strength.
[0059] If the amount of chromium diboride is less than 10 mol%, a
sufficient amount of the chromium diboride based liquid phase will
not be formed, whereby a dense sintered body can hardly be
obtained, and the effects for improving the electrical conductivity
and the fracture toughness tend to be inadequate. On the other
hand, if the amount of chromium diboride exceeds 25 mol%, the
density of the sintered body will be higher than 3.0 g/cm.sup.3,
whereby the feature of light weight of the boron carbide type
sintered body will be impaired, and the hardness will also be
low.
[0060] The boron carbide-chromium diboride sintered body of the
present invention has excellent properties and is useful as an
abrasion resistant component. In the present invention, the
abrasion resistant component means to include every type of a
component such as a sliding component, a cutting tool, an abrasion
resistant part, etc.
[0061] Effects
[0062] The effect mechanism with the boron carbide-titanium
diboride sintered body as a preferred embodiment of the present
invention, is as follows. Usually, in a process for producing a
boron carbide-titanium diboride sintered body by sintering a mixed
powder comprising a boron carbide powder, a titanium dioxide powder
and a carbon powder while reacting them under a pressurized
condition, titanium diboride particles are likely to agglomerate to
form large agglomerated blocks in the reaction process, and if
titanium diboride agglomerated blocks or coarse boron carbide
particles larger than 5 .mu.m, are present, they are likely to act
as starting points for fracture and bring about deterioration of
the four-point flexural strength.
[0063] However, in the present invention, the boron
carbide-titanium diboride sintered body is prepared by using raw
material powders having prescribed properties in a prescribed blend
ratio to obtain a prescribed compositional ratio, whereby titanium
diboride particles will be uniformly dispersed in the boron carbide
matrix, and their agglomerated/dispersed state is uniform and good,
and as a result, a boron carbide-titanium diboride sintered body
having high strength and a specific microstructure wherein titanium
diboride particles are uniformly dispersed in the boron carbide
matrix, can be obtained.
[0064] Further, in the present invention, when a boron carbide
powder having an average particle diameter of at most 1 .mu.m, a
maximum particle diameter of at most 5 .mu.m and a specific surface
area of at least 16 m.sup.2/g, is used, and a titanium dioxide
powder having an average particle diameter of less than 0.1 .mu.m
and a carbon powder having an average particle diameter of less
than 0.1 .mu.m are used, the agglomerated/dispersed state of
titanium diboride particles will be more uniform and good, and
consequently, a boron carbide-titanium diboride sintered body
having a high strength can be obtained which has a microstructure
wherein titanium diboride is uniformly dispersed and which has its
strength further improved.
[0065] The effect mechanism with the boron carbide-chromium
diboride sintered body as another preferred embodiment of the
present invention, is as follows. By carrying out liquid phase
sintering under a non-pressurized condition to form a liquid phase
of chromium diboride, to prepare a sintered body having a specific
microstructure wherein a highly electrically conductive chromium
diboride phase forms a network structure three dimensionally, it is
possible to prepare a boron carbide-chromium diboride sintered body
having excellent characteristics.
[0066] With the boron carbide-chromium diboride sintered body of
the present invention, since the thermal expansion coefficient of
chromium diboride is larger than boron carbide, cracking
propagation detour or microcracking takes place in the vicinity of
the interface between the boron carbide particles and the chromium
diboride phase during the progress of the fracture, whereby the
fracture toughness will be improved. Further, the maximum particle
size is at most 100 .mu.m, protruded portions of boron carbide
particles will be diminished by the dissolution/precipitation
mechanism of the chromium diboride based liquid phase, whereby the
stress concentration will be relaxed, and boron carbide particles
will be bonded by the chromium diboride phase, whereby falling off
of boron carbide particles during processing will be suppressed,
and the fracture toughness will be improved, whereby the strength
will be improved, and a high flexural strength of at least 400 MPa
can be obtained.
[0067] Now, the present invention will be described in further
detail with reference to Examples and Comparative Examples.
However, it should be understood that the present invention is by
no means restricted by the following Examples, etc. The four-point
flexural strength and the fracture toughness of the boron carbide
based sintered bodies were measured by JIS R1601 and JIS R1607,
respectively.
EXAMPLES 1 to 40
[0068] As boron carbide powders, specific boron carbide powders A,
B and C having the physical properties as identified in Table 1,
were employed. As a submicron-size titanium dioxide powder, one
having an average particle diameter (D50 as measured by a laser
diffraction scattering analyzer) of 0.3 .mu.m and a crystal phase
of rutile type, was used. Further, as a nano-size titanium dioxide
powder, a spherical powder prepared by a gas phase method and
having a specific surface area (BET) of 48.5 m.sup.2/g, an average
particle diameter (BET method) of 31 nm and a crystal phase of 80%
anatase and 20% rutile, was used. As a carbon powder, carbon black
having a specific surface area (BET) of 88.1 m.sup.2/g and an
average particle diameter (BET method) of 30 nm, was used.
1TABLE 1 Physical properties of boron carbide powders B.sub.4C
starting Average Maximum material particle particle BET powder
diameter .mu.m diameter .mu.m m.sup.2/g A 0.50 2.4 21.5 B 0.44 3.3
15.5 C 0.41 2.3 22.5 D 0.55 5.7 18.7 E 1.20 5.9 8.6
[0069] To the boron carbide powder, 14.5 mol% of the submicron-size
or nano-size titanium dioxide powder and 21.5 mol% of carbon black
were incorporated, and using a methanol solvent, mixing was carried
out by a planetary ball mill made of silicon carbide (SiC) at a
rotational speed of 270 rpm for 1 hour, followed by drying by a
evaporator and further by drying at 150.degree. C. for 24 hours.
Then, the mixture was sieved through a sieve with an opening of 250
.mu.m to obtain a boron carbide-titanium dioxide-carbon mixed
powder.
[0070] Then, in a die made of graphite, the boron carbide-titanium
dioxide-carbon mixed powder was filled and molded under 7.5 MPa and
then placed in a firing furnace. In a pressurized state at 5 MPa,
heating was carried out at a temperature raising rate of 40.degree.
C./min while vacuuming to a pressure of from 2.0.times.10.sup.-1 to
2.0.times.10.sup.-2 Pa by means of a diffusion pump. When the
temperature reached 1000.degree. C., vacuuming was terminated, and
Ar gas was introduced at a flow rate of 2 liters/min to an
atmosphere with a gas pressure of 0.103 MPa, followed by heating to
1500.degree. C. From 1500.degree. C. to 2000.degree. C., the
temperature was raised at a rate of 10.degree. C./min. After the
temperature reached 2000.degree. C., the pressure was raised to 50
MPa and maintained for 1 hour to obtain a boron carbide-20 mol%
titanium diboride sintered body.
[0071] The surface of a test piece was finished by a surface
grinding machine No. 400. Further, the density of the test piece
was measured by an Archimedes method, and the relative density was
calculated. The surface of the test piece was subjected to lapping
and etching treatment, whereupon SEM observation was carried out to
obtain the maximum particle diameter of boron carbide. Further, by
the X-ray diffraction method, identification of the crystal phase
in the sintered body was carried out. The results of such
measurements are shown in Table 2.
2TABLE 2 Examples and Comparative Examples Maximum Four- particle
B.sub.4C TiO.sub.2 Density of Relative point diameter starting
starting sintered density of flexural Fracture of boron material
material body sintered strength toughness carbide No. powder powder
g/cm.sup.3 body % MPa MPa .multidot. m.sup.1/2 .mu.m Example 1 A
Submicron 2.82 100 720 3.1 3.5 Example 2 B Nano size 2.82 100 720
2.8 3.4 Example 3 A Nano size 2.82 100 870 3.4 3.8 Example 4 C Nano
size 2.82 100 815 3.2 3.9 Comparative E Submicron 2.75 97.8 475 2.8
6.4 1 Comparative D Nano size 2.82 100 585 2.8 6.1 2
[0072] Each of the boron carbide-titanium diboride sintered bodies
prepared in Examples 1 to 4 had a high density and a maximum
particle diameter of boron carbide of at most 5 .mu.m and a high
four-point flexural strength of at least 700 MPa. Especially, in
Examples 3 and 4, a four-point flexural strength of at least 800
MPa and a high fracture toughness of at least 3
MPa.multidot.m.sup.1/2 were obtained. Further, in each sintered
body, a crystal phase was detected with respect to boron carbide
and titanium diboride, and unreacted titanium dioxide was not
detected.
Comparative Examples 1 and 2
[0073] Then, as Comparative Examples, boron carbide-20 mol%
titanium diboride sintered bodies were prepared in the same manner
as in Examples 1 to 4 except that the composition was changed to a
combination of the boron carbide powder E as identified in Table 1
and the submicron-size titanium dioxide powder as used in Examples
1 to 4, and a combination of the boron carbide powder D as
identified in Table 1 and the nano-size titanium dioxide
powder.
[0074] Further, in the same manner as in Examples 1 to 4,
evaluation of the four-point flexural strength, the fracture
toughness, the density of the sintered body and the maximum
particle diameter of boron carbide, was carried out. The results of
measurements thereof are shown in Table 2. The four-point flexural
strength of the sintered body in each of Comparative Examples 1 and
2, was low at a level of not more than 600 MPa, and the maximum
particle diameter of boron carbide was larger than 5 .mu.m.
EXAMPLE 5
[0075] To a boron carbide powder I having the physical properties
as identified in Table 3, 20 mol% of a chromium diboride powder
having an average particle diameter (D.sub.50) of 3.5 .mu.m was
blended, and using a methanol solvent, the blend was mixed by a
planetary ball mill made of SiC at a rotational speed of 275 rpm
for 1 hour. The slurry was dried by an evaporator and further dried
at 150.degree. C. for 24 hours, and then it was sieved through a
sieve of 250 mesh to obtain a boron carbide-chromium diboride mixed
powder.
[0076] This powder was molded in a mold under 20 MPa, followed by
CIP molding under 200 MPa to obtain a molded product. The molded
product was put into a graphite container and placed in a
resistance heating type firing furnace. Heating was carried out at
a temperature-raising rate of 40.degree. C./min while vacuuming to
a pressure of from 2.0.times.10.sup.-1 to 2.0.times.10.sup.-2 Pa by
means of a diffusion pump. When the temperature reached
1000.degree. C., vacuuming was terminated, and Ar gas was
introduced, followed by heating to 1500.degree. C. From
1500.degree. C. to 2030.degree. C., heating was carried out at a
temperature raising rate of 10.degree. C./min. After the
temperature reached 2030.degree. C., sintering was carried out for
1 hour under a non-pressurized condition to obtain a boron
carbide-chromium diboride sintered body.
3TABLE 3 Physical properties of B.sub.4C starting material powders
Average B.sub.4C starting particle BET material powder diameter
.mu.m m.sup.2/g I 0.43 15.3 II 1.60 17.5 III 2.90 8.6
[0077] The surface of a test piece was finished by a surface
grinding machine No. 400. Further, the density of the test piece
was measured by an Archimedes method, and the relative density was
calculated. The surface of the test piece was subjected to lapping
and etching treatment, whereupon SEM observation was carried out,
and image treatment was carried out to measure the maximum particle
diameter of boron carbide and the abundance ratio (area ratio) of
boron carbide particles of from 10 to 100 .mu.m to boron carbide
particles having a particle diameter of at most 5 .mu.m. The
electrical conductivity was measured by means of a four terminal
method.
[0078] The results of evaluation are shown in Table 4. The sintered
body had a relative density of at least 90%, a maximum particle
diameter of at most 100 .mu.m, an abundance ratio (area ratio) of
the boron carbide particles being within a range of from 0.02 to
0.6, and had an electrical conductivity of at least
5.times.10.sup.2 S/m, a four-point flexural strength of at least
400 MPa and a fracture toughness of at least 3.0
MPa.multidot.m.sup.1/2.
4TABLE 4 Examples and Comparative Examples Density Relative
Abundance B.sub.4C of density ratio of Maximum Electric CrB.sub.2
starting Sintering sintered of B.sub.4C particle Flexural Fracture
conduc- amount material temp. body sintered particles diameter
strength toughness tivity No. mol % powder .degree. C. g/cm.sup.3
body % % .mu.m MPa MPa .multidot. m.sup.1/2 S/m Ex. 1 20 I 2030
2.86 98.1 0.09 32 528 3.7 2.1 .times. 10.sup.4 Ex. 2 20 II 2030
2.84 97.2 0.08 35 460 3.6 1.2 .times. 10.sup.4 Ex. 3 15 I 2050 2.75
97.6 0.40 75 457 3.1 7.3 .times. 10.sup.3 Ex. 4 22.5 I 2020 2.85
95.8 0.26 58 436 3.5 8.6 .times. 10.sup.3 Comp. 20 III 2030 2.57
87.9 0.01 32 320 2.4 5.5 .times. 10.sup.2 Ex. 1 Comp. 7.5 I 2030
2.11 79.5 0.01 16 175 2.3 7.5 .times. 10 Ex. 2
EXAMPLE 6
[0079] To a boron carbide powder II having the physical properties
as identified in Table 3, 20 mol% of a chromium diboride powder
having an average particle diameter (D.sub.50) of 3.5 .mu.m was
blended, and using a methanol solvent, the blend was mixed by a
planetary ball mill made of SiC at a rotational speed of 275 rpm
for 1 hour. The slurry was dried by an evaporator and further dried
at 150.degree. C. for 24 hours, whereupon it was sieved through a
sieve of 250 mesh to obtain a boron carbide-chronium diboride mixed
powder.
[0080] This powder was molded in a mold under 20 MPa, followed by
CIP molding under 200 MPa to obtain a molded product. The molded
product was put into a graphite container and placed in a
resistance heating type firing furnace. Heating was carried out at
a temperature-raising rate of 40.degree. C./min while vacuuming to
a pressure of from 2.0.times.10.sup.-1 to 2.0.times.10.sup.-2 Pa by
means of a diffusion pump. When the temperature reached
1000.degree. C., vacuuming was terminated, and Ar gas was
introduced, followed by heating to 1500.degree. C. From
1500.degree. C. to 2030.degree. C., the temperature was raised at a
rate of 10.degree. C./min. After the temperature reached
2030.degree. C., sintering was carried out for 1 hour under a
non-pressurized condition to obtain a boron carbide-chromium
diboride sintered body.
[0081] The surface of a test piece was finished by a surface
grinding machine No. 400. Further, the density of the test piece
was measured by an Archimedes method, and the relative density was
calculated. The surface of the test piece was subjected to lapping
and etching treatment, whereupon SEM observation was carried out
and image treatment was carried out to measure the maximum particle
diameter of boron carbide and the abundance ratio (area ratio) of
boron carbide particles of from 10 to 100 .mu.m to boron carbide
particles having a particle diameter of at most 5 .mu.m. The
electric conductivity was measured by a four-terminal method.
[0082] The results of evaluation are shown in Table 4. The sintered
body had a relative density of at least 90%, a maximum particle
diameter of at most 100 .mu.m, the abundance ratio (area ratio) of
boron carbide particles being within a range of from 0.02 to 0.6,
and had an electrical conductivity of at least 5.times.10.sup.2
S/m, a four-point flexural strength of at least 400 MPa and a
fracture toughness of at least 3.0 MPa.multidot.m.sup.1/2.
Comparative Example 3
[0083] Sintering was carried out under a non-pressurized condition
in the same manner as Examples 5 and 6 except that a boron carbide
powder III having the physical properties as identified in Table 3
was used, to obtain a boron carbide-chromium diboride sintered
body, and evaluation was carried out.
[0084] In Table 4, the results of evaluation are shown. In
Comparative Example 3, a boron carbide powder having an average
particle diameter (D.sub.50) larger than 2 .mu.m and a specific
surface area (BET) smaller than 10 m.sup.2/g, was used whereby a
dense sintered body was not obtained, and the abundance ratio (area
ratio) of boron carbide particles was outside the range of from
0.02 to 0.6, whereby the flexural strength and the fracture
toughness had low values.
EXAMPLE 7
[0085] To a boron carbide powder I, 15 mol% of the same chromium
diboride powder as in Examples 5 and 6, was blended, and in the
same manner as in Examples 5 and 6, a boron carbide-chromium
diboride mixed powder was prepared. Sintering was carried out under
a non-pressurized condition in the same manner as in Examples 5 and
6, except that the sintering temperature was changed to
2050.degree. C., to obtain a boron carbide-chromium diboride
sintered body, and evaluation was carried out.
[0086] The results of evaluation are shown in Table 4. The sintered
body had a relative density of at least 90%, a maximum particle
diameter of at most 100 .mu.m, an abundance ratio (area ratio) of
boron carbide particles being within a range of from 0.02 to 0.6,
and had an electric conductivity of at least 5.times.10.sup.2 S/m,
a four-point flexural strength of at least 400 MPa and a fracture
toughness of at least 3.0 MPa.multidot.m.sup.1/2.
EXAMPLE 8
[0087] To a boron carbide powder I, 22.5 mol% of the same chromium
diboride powder as in Examples 5 and 6, was blended, and in the
same manner as in Examples 5 and 6, a boron carbide-chromium
diboride mixed powder was prepared. Sintering was carried out under
a non-pressurized condition in the same manner as in Examples 5 and
6 except that the sintering temperature was changed to 2020.degree.
C., and evaluation was carried out.
[0088] The results of evaluation are shown in Table 4. The sintered
body had a relative density of at least 90%, a maximum particle
diameter of at most 100 .mu.m, an abundance ratio (area ratio) of
boron carbide particles being within a range of from 0.02 to 1.6,
and had an electric conductivity of at least 5.times.10.sup.2 S/m,
a four-point flexural strength of at least 400 MPa, and a fracture
toughness of at least 3.0 MPa.multidot.m.sup.1/2.
Comparative Example 4
[0089] Sintering was carried out under a non-pressurized condition
in the same manner as in Examples 5 and 6 except that the amount of
the chromium diboride powder was changed to 7.5 mol%, to obtain a
boron carbide-chronium diboride sintered body, and evaluation was
carried out.
[0090] The results of evaluation are shown in Table 4. The amount
of the chromium diboride powder was small, and no adequate amount
of the chromium diboride based liquid phase was formed, whereby a
dense sintered body was not obtained, and the abundance ratio (area
ratio) of the boron carbide particles was not within the range of
from 0.02 to 0.6, the electrical conductivity was not improved, and
the flexural strength and the fracture toughness had low
values.
[0091] Industrial Applicability
[0092] According to the present invention, the following
industrially useful effects can be obtained.
[0093] (1) It is possible to prepare a boron carbide-titanium
diboride sintered body having a high four-point flexural strength
of at least 700 MPa.
[0094] (2) It is possible to obtain a boron carbide-titanium
diboride sintered body which has a high density and a maximum
particle diameter of boron carbide of 5 .mu.m, wherein titanium
diboride particles are uniformly dispersed in the boron carbide
matrix, the agglomerated/dispersed state of titanium diboride
particles is uniform and good, and the fracture toughness is
improved.
[0095] (3) The boron carbide-titanium diboride sintered body has a
four-point flexural strength as high as at least 700 MPa which has
not been obtained by a conventional method, and it is useful in a
wide range of applications for e.g. sliding components, cutting
tools, bullet-proof plates and new abrasion resistant components,
and is thus industrially useful.
[0096] (4) It is possible to obtain a sintered body wherein a
highly electrically conductive chromium diboride phase forms a
network structure three dimensionally.
[0097] (5) The boron carbide-chromium diboride sintered body of the
present invention can be prepared by heating (sintering) under a
non-pressurized condition at a low sintering temperature.
[0098] (6) The sintered body has a high density and good electric
conductivity and is processable by discharge processing.
[0099] (7)A novel abrasion resistant component can be provided.
[0100] (8) The boron carbide-chromium diboride sintered body has
high strength and toughness and is excellent in mechanical
properties, and thus, it is useful for various applications for
e.g. sliding components, cutting tools and new abrasion resistant
components and is thus industrially useful.
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