Methods for improving the wear performance of silicon nitride and/or other ceramic materials, particularly to make them more suitable for use in manufacturing biomedical implants.

A CaSiAlON ceramic with enhanced mechanical properties and a method employing micron-sized and submicron precursors to form the CaSiAlON ceramic. The CaSiAlON ceramic comprises not more than 42 wt % silicon, relative to the total weight of the CaSiAlON ceramic. The method employs submicron particles and also allows for substituting a portion of aluminum nitride with aluminum to form the CaSiAlON ceramic with enhanced mechanical properties.

A method for molding a ceramic material includes: mixing a ceramic powder, a resin, a curing agent and a solvent to obtain a raw material slurry for a ceramic material; injecting the raw material slurry into an elastic container; curing the resin in the raw material slurry injected into the elastic container to form a molded body having a desired shape; and demolding the molded body from the elastic container.

A production process for a crystal oriented ceramics includes: a first step of preparing composite particles formed of particles having magnetic anisotropy having magnetic susceptibility anisotropy and seed particles having magnetic susceptibility anisotropy less than or equal to 1/10 of the magnetic susceptibility anisotropy of the particles having magnetic anisotropy and are formed of an inorganic compound having an anisotropic shape in which a crystal axis intended to be corresponds to a minor axis or a major axis; a second step of adding raw material powder including the composite particles to a solvent to prepare a slurry a third step of preparing a green compact by disposing the slurry in a static magnetic field of 0.1 tesla and drying the slurry in a state in which crystal axes of the seed particles in a major axis direction are in one direction; and a fourth step of sintering the green compact.

The friction stir welding tool member according to the present invention is made of a silicon nitride sintered body, wherein the silicon nitride sintered body contains 15% by mass or less of additive components except silicon nitride in such a manner that the additive components include at least one element selected from lanthanoid elements and at least one element selected from Mg, Ti, Hf, and Mo. In addition, it is preferable that the additive components further include at least one element selected from Al, Si, and C. According to the above-described configuration, a friction stir welding tool member having an excellent durability can be provided.

The present invention provides a high thermal conductive silicon nitride sintered body having a thermal conductivity of 50 W/m.Math.K or more and a three-point bending strength of 600 MPa or more, wherein when an arbitrary cross section of the silicon nitride sintered body is subjected to XRD analysis and highest peak intensities detected at diffraction angles of 29.30.2, 29.70.2, 27.00.2, and 36.10.2 are expressed as I.sub.29.3, I.sub.29.7, I.sub.27.0, and I.sub.36.1, a peak ratio (I.sub.29.3)/(I.sub.27.0+I.sub.36.1) satisfies a range of 0.01 to 0.08, and a peak ratio (I.sub.29.7)/(I.sub.27.0+I.sub.36.1) satisfies a range of 0.02 to 0.16. Due to above configuration, there can be provided a silicon nitride sintered body having a high thermal conductivity of 50 W/m.Math.K or more, and excellence in insulating properties and strength.

Phosphors include a CaAlSiN.sub.3 family crystal phase, wherein the CaAlSiN.sub.3 family crystal phase comprises at least one element selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb.

An electrostatic chuck is provided. Implemented according to an embodiment of the present invention is an electrostatic chuck comprising: a silicon nitride sintered body; a surface modification layer covering at least a portion of the external surface of the silicon nitride sintered body and having corrosion resistance and plasma resistance; and an electrostatic electrode laid inside the silicon nitride sintered body. Therefore, the electrostatic chuck includes a ceramic sintered body of silicon nitride, and thus has excellent plasma resistance, chemical resistance, and thermal shock resistance while exhibiting an equivalent or similar level of heat dissipation performance compared to ceramic sintered bodies of aluminum nitride that have been conventionally widely used, so that the electrostatic chuck can be widely used in semiconductor processes.

A method for producing a composite of cubic boron nitride dispersed in a SiAlON ceramic. This method involves mixing silicon nitride nanoparticles, aluminum nitride nanoparticles, silica nanoparticles, calcium oxide nanoparticles, and cubic boron nitride microparticles to produce a mixture. The cubic boron nitride may be coated with nickel. The mixture is sintered to produce the composite, and this sintering may involve spark plasma sintering and/or sintering at a relatively low temperature. The composite may comprise a mixture of Ca--SiAlON and -SiAlON ceramic reinforced by boron nitride in either or both cubic and hexagonal phases.

A method for producing a composite of cubic boron nitride dispersed in a SiAlON ceramic. This method involves mixing silicon nitride nanoparticles, aluminum nitride nanoparticles, silica nanoparticles, calcium oxide nanoparticles, and cubic boron nitride microparticles to produce a mixture. The cubic boron nitride may be coated with nickel. The mixture is sintered to produce the composite, and this sintering may involve spark plasma sintering and/or sintering at a relatively low temperature. The composite may comprise a mixture of Ca--SiAlON and -SiAlON ceramic reinforced by boron nitride in either or both cubic and hexagonal phases.