US20100304138A1

US20100304138A1 - Boron suboxide composite material

Info

Publication number: US20100304138A1
Application number: US12/596,002
Authority: US
Inventors: Anthony Andrews; Iakovos Sigalas; Mathias Herrmann
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-04-26
Filing date: 2008-04-24
Publication date: 2010-12-02
Also published as: WO2008132672A3; US8426043B2; WO2008132676A3; KR20100023819A; WO2008132672A2; EP2146942A2; WO2008132674A3; WO2008132676A2; WO2008132674A2; JP2010524838A; KR20100017357A; KR20100017361A; JP2010524840A; EP2146941A2; US20100300004A1; JP2010524839A; US8426330B2; EP2146943A2; US20100308256A1

Abstract

The invention provides a boron suboxide composite material comprising boron suboxide and a secondary phase, wherein the secondary phase contains a mixture of at least two metal oxides, neither of which is a boron-containing oxide. At least one of the oxides may be selected from oxides of elements of Groups IA, IIA, IIIA, and IVA of the periodic table. Also, at least one of the oxides may be a rare earth metal oxide selected from the oxides of scandium, yttrium, and elements of the ianthanide series. The secondary phase of the composite material may also contain a boride, and particularly a boride selected from the borides of transition metals of the fourth to eighth groups of the periodic table.

Description

BACKGROUND OF THE INVENTION

The invention relates to a boron suboxide composite material.
The development of synthetic ultrahard materials which have hardness values approaching or even exceeding that of diamond has been of great interest to material scientists. With a Vickers hardness of between 70 to 100 GPa, diamond is the hardest material known, followed by cubic boron nitride (H_V˜60 GPa) and boron suboxide herein referred to as B₆O. Hardness values of 53 GPa and 45 GPa have been determined at 0.49N and 0.98N load respectively for B₆O single crystals, which are similar to those of cubic boron nitride [9].
It is known that B₅O may also be non-stoichiometric i.e. exist as B₆O_1-x(where x is in the range 0 to 0.3). Such non-stoichiometric forms are included in the term B₆O. The strong covalent bonds and short interatomic bond length of these materials contribute to the exceptional physical and chemical properties such as great hardness, low mass density, high thermal conductivity, high chemical inertness and excellent wear resistance [1, 2]. In U.S. Pat. No. 5,330,937 to Ellison-Hayashi et al the formation of boron suboxide powders of nominal composition B₃O, B₄O, B₆O, B₇O, B₈O, B₁₂O, B₁₆O and B₁₈O was reported. Potential industrial applications have been discussed by Kurisuchiyan et al (Japan Patent No. 7,034,063) and Ellison-Hayashi et al (U.S. Pat. No. 5,456,735) and include use in grinding wheels, abrasives and cutting tools.
Several techniques have been employed for producing boron suboxide and include such procedures as reacting elemental boron (B) with boron oxide (B₂O₃) under suitably high pressure and high temperature conditions [1]. In U.S. Pat. No. 3,660,031 to Holcombe Jr. et al other methods of producing boron suboxides such as reducing boron oxide (B₂O₃) with magnesium, or by reducing zinc oxide with elemental boron are mentioned. With each of these known procedures however, there are drawbacks which retard the usefulness of the material in industry. For example, the reduction of B₂O₃with magnesium produces a solid solution of magnesium and magnesium boride contaminants in the suboxide, while the reduction of magnesium oxide with boron produces only a relatively small yield of boron suboxide and is very inefficient. Holcombe Jr. et al (U.S. Pat. No. 3,660,031) produced B₇O by reducing zinc oxide with elemental boron at temperatures of between 1200° C. to 1500° C. A hardness value of 38.2 GPa under 100 g load and density of 2.6 g.cm⁻³is reported for this material. The fracture toughness for this material is not discussed.
Petrak et al [3] investigated the mechanical and chemical properties of hot-pressed B₆O and reported micro-hardness values as high as 34-38 GPa. Ellison-Hayashi et al (U.S. Pat. No. 5,330,937) produced B₆O with a magnesium addition (approximately 6%) which yielded average KHN₁₀₀values of 34 GPa to 36 GPa.
Efforts have been made to enhance the mechanical properties of B₆O, especially its fracture toughness, by forming B₆O composites with other hard materials such as diamond [4], boron carbide [5], and ON [6]. The diamond and cBN-containing composites were made under extremely high temperature and pressure conditions. The intention was to form pseudo-binary composite systems, stronger at the grain boundaries than those of pure B₆O. Even though high hardness values were recorded for the composites (H_V˜46 GPa), again, fracture toughness values did not exceed 1.8 MPa.m^0.5. The best value here was obtained with B₆O-cBN composites.
Shabalala et al (WO 2007/029102 and [7]) produced B₈O composites with aluminium compounds which resulted in an aluminium borate phase at the grain boundary. A fracture toughness of about 3.5 MPa.m^0.5with a corresponding hardness of 29.3 GPa was obtained. The aluminium phases present in the composite are soft and although they may improve the fracture toughness of the resulting composite, they do not contribute to the overall hardness of the composite. Moreover, in addition to a crystalline aluminium borate, a boron oxide rich, chemically unstable amorphous phase and microporosity was formed, further resulting in reduced hardness [10, 11].

SUMMARY OF THE INVENTION

According to the invention there is provided a boron suboxide composite material comprising boron suboxide and a secondary phase, the secondary phase containing a mixture of at least two metal oxides, neither of which is a boron-containing oxide.
For the purpose of this specification, “secondary phase” means everything in the composite material but the boron suboxide, and may be wholly or partially crystalline or amorphous, and may include more than one thermodynamic phase.
At least one of the oxides may be selected from oxides of elements of Groups IA, IIA, IIIA, and IVA of the periodic table, and particularly may be selected from Al₂O₃, SiO₂, MgO, CaO, BaO and SrO.
In one form of the invention, at least one of the oxides may be a rare earth metal oxide. The rare earth metal oxide may be selected from the oxides of scandium, yttrium, which is preferred, and elements of the lanthanide series, and may be a mixture of rare earth metal oxides.
In addition to the metal oxides, the secondary phase also may contain a boron-containing oxide such as B₂O₃or a borate.
In one preferred form of the invention, one of the oxides is Al₂O₃and another oxide is selected from SiO₂, MgO, CaO, BaO and SrO.
In yet a further preferred form of the invention, one of the oxides is a rare earth metal oxide and another oxide is selected from Al₂O₃, SiO₂, MgO, CaO, BaO and SrO.
The amount of oxide present in the composite material of the invention will vary according to the properties desired for the composite material, particularly hardness and fracture toughness, and the type of oxide. Generally the mixture of oxides will be present in amount of up to 20 volume % of the composite. For many oxides, the oxides will generally be present in an amount of up to 10 volume % of the composite material and for yet other oxides the oxides will generally be present in an amount of up to 5 volume % of the composite material.
The secondary phase of the composite material may also contain a boride, and particularly a boride selected from the borides of transition metals of the fourth to eighth groups of the periodic table. Any reference to “boride” includes a reference to a monoboride, diboride and any other form of boride. More particularly, the boride may be selected from the borides of iron, cobalt, nickel, titanium, tungsten, tantalum, hafnium, zirconium, rhenium, molybdenum and chromium. The boride may also be a platinum group metal boride, preferably palladium boride. Hard borides like TiB₂, W₂B₅and ReB₂may be present in the composite material in a larger amount than the relative soft borides, such as those borides formed from Fe, Ni and Co.
The boron suboxide may be particulate or granular boron suboxide. The mean grain size of the boron suboxide particles or granules themselves is preferably fine and may range from 100 nm to 100 μm, preferably 100 nm to 10 μm.
Finely particulate boron suboxide may be produced, for example, by subjecting a source of boron suboxide to milling. If milling takes place in the presence of an iron or cobalt containing milling medium, some iron and/or cobalt will be introduced into the material which is sintered. For an iron-free material, the milled powder can be washed with hydrochloric acid, or the milling can be carried out with alumina pots and milling balls. It has been found to be advantageous to wash the milled powder in warm water or alcohols to remove any excess of B₂O₃or H₃BO₃.
The composite material of the invention comprises boron suboxide, generally in particulate or granular form, and the secondary phase in a bonded, coherent form. The secondary phase will preferably be present in a volume percent less than that of the boron suboxide and will be uniformly dispersed among the boron suboxide. The secondary phase can be amorphous or partially crystalline.
The invention provides a composite material containing boron suboxide and a mixture of metal oxides, of which at least two oxides do not contain boron, and which has both high fracture toughness and high hardness. In particular, the composite material generally has a fracture toughness greater than 3.5 MPa.m^0.5in combination with a Vickers Hardness (H_V) greater than 25 GPa. Preferably the fracture toughness of the composite material is greater than 3.5 MPa.m^0.5, and more preferably at least 4.0 MPa.m^0.5and still more preferably at least 5.0 MPa.m^0.5. The fracture toughness (K_IC), as used herein, was measured at indentations generally with a load of 5 kg. The average of five measured was used to determine the properties of the B₆O samples discussed hereinafter. The K_ICwas measured via the DCM method, using Anstis' equation [8]:
$\begin{matrix} K_{C} = {δ (\frac{E}{H})}^{\frac{1}{2}} \frac{P}{c^{\frac{3}{2}}} & (1) \end{matrix}$
where E is the Young's modulus, H the hardness and δ is a constant, which only depends on the geometry of the indenter. A value of 470 GPa was used for the Young's modulus value in this equation. For the standard Vickers diamond pyramid indenter, Anstis et al established a value of δ=0.016±0.004 as the calibration constant which was also used for these measurements.
The hardness of the composite material is preferably greater than 25 GPa and more preferably at least 30 GPa. The Vickers hardness was measured using an indentation load of 5 kg. The average of five measured hardness values was used to determine the properties of the B₆O composite samples.
FIG. 1 shows the preferred lower thresholds for the region of hardness and fracture toughness of composite materials of this invention in relation to the prior art boron suboxide materials. It is postulated that the improved toughness of these types of composite could be due to multiple factors such as crack deflection due to the generation of internal stresses, crack arrest mechanisms occurring in the generated secondary phases, and changes in the nature of the composition and properties of the grain boundaries between the B₆O particles. Further, it has been found that the effective densification of the composite material during manufacture is enhanced by the use of a secondary phase which contains a mixture of at least two oxides, neither of which is a boron-containing oxide. Densification in excess of 95 percent of the theoretical densities is possible during liquid phase densification, and can be achieved under milder temperature and pressure conditions with the addition of an oxide, than that which can be achieved when there is no oxide present in the secondary phase. In particular, densification of 98%-99% has been obtained.
The composite material of the invention may be made by providing a source of boron suboxide, preferably as particles or granules; contacting the source of boron suboxide with a mixture of oxides, wherein at least two of the oxides do not contain boron, to create a reaction mass; and sintering the reaction mass to produce the boron suboxide composite material. This method forms another aspect of the invention.
Sintering preferably takes place at a relatively low temperature and pressure, i.e. a pressure of less than 200 MPa and a temperature of not exceeding 1950° C. Low pressure sintering processes such as hot pressing (HP), gas pressure sintering, hot isostatic pressing (HIP) or spark plasma sintering (SPS) are preferred. The SPS process is characterised by very fast heating and short isothermal holding times, in particular with heating rates of 50-400 K/minute and isothermal holding times of 5 minutes or less. The hot pressing process is characterised by heating rates of 10-20 K/minute, and isothermal holding times of 15 to 25, typically 20 minutes.
Consistent with this oxide-based approach is the formation of a stable oxide liquid phase during sintering which then cools to form crystalline and/or amorphous oxide secondary phases in the final product. The oxides, especially if they are a mixture of Al₂O₃and SiO₂, react with the remaining B₂O₃and form amorphous phases between the boron suboxide particles or granules.
The addition of mixed oxides chemically stabilizes the amorphous grain boundary, and makes the composite material more wear resistant. This amorphous grain boundary results from a reaction between the oxides and B₂O₃during the liquid phase of densification. To increase wear resistance, chemically stability and high temperature stability of the material, it is preferable that the B₂O₃content in the grain boundary is low. A mol ratio of B₂O₃/(B₂O₃+ other oxides) of less than 60 is preferable, more preferably a mol ratio of less than 30, and even more preferably a mol ratio of less than 20.
The boron suboxide may be mixed with the components necessary to produce the secondary phase prior to the sintering step. The boron suboxide may alternatively be coated with the secondary phase components prior to sintering.
Whilst it may be preferable to introduce these secondary phase components in their oxidised form prior to sintering, the secondary phase components may also be present in the reaction mass in another form (e.g. nitrates, carbonates or oxalates forming oxides during decomposition or in their metallic state) and be allowed to oxidise within the reaction mass during sintering.
The composite material according to the invention may be used in cutting applications and in wear parts. It may also be crushed to grit form and used in grit applications. Moreover, the composite material may be used in armour applications, such as ballistic armour, and particularly body armour.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph showing the relative hardness and fracture toughness values for B₆O composite materials of this invention; and similar types of materials from the prior art.

FIG. 2 is a SEM image of a sintered composite material produced from B₆O admixed with 2.62% by weight of Al₂O₃and 2.65% by weight of Y₂O₃.

FIG. 3 is a SEM image of a sintered composite material produced from B₆O admixed with 10% by weight of TiB₂, 2.0% by weight of Al₂O₃and 2.0% by weight of Y₂O₃.

FIG. 4 is a SEM image of a sintered composite material produced from B₆O admixed with 4% by weight of WO₃, 2.0% by weight of Al₂O₃, and 0.53% MgO (from the powder), showing the sub-μm W₂B₅precipitates (white phase) and the partially polished out oxide grain boundary.

FIG. 5 is SEM images of Al—Y—Si-doped B₆O hot pressed composites showing grain growth in higher SiO₂content.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The invention will now be illustrated by the following examples. Table 1 summarises these materials and their measured hardness and toughness properties for comparative purposes. In these examples the terms “secondary phase” and “grain boundary phase” are both used. The terms are used interchangeably and refer to the same phase.
For the purpose of this specification, “secondary phase” means everything in the composite material but the boron suboxide, and may be wholly or partially crystalline or amorphous, and may include more than one thermodynamic phase.

Example 1

B₆O starting powder was milled using an attritor mill with steel balls for 50 hours. The iron contaminants were removed by washing in HCl. The powder was subsequently washed in methanol to remove any B₂O₃present. The average particle size after milling was 500 nm.
The milled powder was admixed with 2% by weight of Al₂O₃and 2.65% by weight of Y₂O₃in methanol and milled for two hours using a planetary mill. The milled mixture was dried using a rotary evaporator and then placed in a boron nitride cell (inside a graphite die) and sintered using a hot press at a temperature of 1800° C. and a pressure of 50 MPa, under an argon atmosphere for about 20 minutes. A fully densified composite material comprising boron suboxide particles was produced within which a secondary phase was uniformly dispersed. No crystalline phase in the secondary phase was identified by XRD. The grain boundary was an amorphous grain boundary phase containing Y₂O₃, Al₂O₃and remaining B₂O₃.
A cross-section of the sample was polished and then tested for hardness and fracture toughness with Vickers indenter. The hardness was found to be about 33.2 GPa at a load of 5 kg and a fracture toughness of about 6.3 MPa.m^0.5.
Table 1 summarises the measured properties of this boron suboxide composite material. The hot pressed B₆O composite of the invention had a higher hardness and fracture toughness compared to both pure B₆O and the composite material produced by Shabalala et al (WO 2007/029102).

Example 2

A boron suboxide composite material was produced using the same components and conditions set out in Example 1, save that the amount of Y₂O₃and Al₂O₃components was reduced by half, with the ratio between the two being kept the same. The composite material produced was fully densified and was also found to contain Y₂O₃, Al₂O₃and remaining B₂O₃. It had a hardness of 30.4 GPa and a fracture toughness of 6.0 MPa.m^0.5.

Example 3

A boron suboxide composite material was produced using the same components and conditions set out in Example 1, save that the components for the secondary phase included an additional 1.0 weight % SiO₂. The composite material produced was fully densified and was found to contain an amorphous grain boundary phase containing Y₂O₃, Al₂O₃and remaining B₂O₃. It had a hardness of 33.5 GPa and a fracture toughness of 5.0 MPa.m^0.5.

Example 4

B₆O starting powder was milled using an attritor mill with alumina balls, in an ethanol solvent. After milling the suspension was dried using a rotation evaporator. The wear of the alumina balls was included in the overall composition of the materials in Table 1.
The milled powder was admixed with 2.62% by weight of Al₂O₃and 2.65% by weight of Y₂O₃in isopropanol and milled for two hours using a planetary mill. The milled mixture was dried using a rotary evaporator, after which fast spark plasma sintering was carried out using graphite dies with graphite foils. The graphite foils were coated with a BN suspension to prevent interaction with the graphite. The milled mixture was sintered using the SPS method with a heating rate of 50 K/min, a temperature of 1740° C. and a pressure of 115 MPa, under an argon atmosphere for about 5 minutes. The heating rate was 50 K/min. Since a nonconductive hBN lining or coating was used, the densification was more a fast hot pressing than a SPS-process, which is characterized by a current going through the powder.
A fully densified composite material was produced comprising boron suboxide particles within which a secondary phase was uniformly dispersed. A cross-section of the sample was polished and then tested for hardness and fracture toughness with a Vickers indenter. The hardness was found to be about 33.4±0.6 GPa at a load of 0.4 kg and a fracture toughness of about 4.3 MPa.m^0.5.

Example 5

A boron suboxide composite material was produced using the same components and conditions set out in Example 4, save that the milled mixture was sintered using a temperature of 1800° C. and a pressure of 80 MPa, using the same SPS method as in example 4. The composite material produced was fully densified. It had a hardness of 33 GPa at 0.4 kg and a fracture toughness of 4 MPa.m^0.5.

Example 6

A boron suboxide composite material was produced using the same components and conditions set out in Example 4, except that the milled powder was admixed with 2.0% by weight of Al₂O₃and 2.0% by weight of Y₂O₃, and sintered at a temperature of 1850° C. and a pressure of 50 MPa. The composite material produced was fully densified and was also found to contain Y₂O₃, Al₂O₃and some residual B₂O₃. It had a hardness of 32.1 GPa and a fracture toughness of 4 MPa.m^0.5.

Example 7

B₆O starting powder was milled using a jet mill. The average particle size after milling was 2.3 μm. The milled B₆O powder was admixed with 2% by weight of Al₂O₃, 2% by weight of Y₂O₃and 2% by weight of ZrO₂(i.e. TZP stabilised with 3 mol % yttria) in isopropanol and milled for six hours using an attrition mill with Al₂O₃balls. The milled mixture was dried using a rotary evaporator and then placed in a graphite die coated with hexagonal BN, and sintered using the SPS method with a heating rate of 50 K/minute and a holding time of 5 minutes, under an argon atmosphere.
In addition to the sample containing Y₂O₃(example 7a), a sample without Y₂O₃was produced (example 7b). A fully densified composite material comprising boron suboxide particles was produced within which a secondary phase was uniformly dispersed. In the sample with Y₂O₃an amorphous oxide grain boundary phase was observed, in addition to ZrB₂and partially ZrB₁₂. A crystalline oxide phase (Al₁₈B₄O₃₃) was detected by XRD in the secondary phase in the material of example 7b without Y₂O₃additions. The MgO together with the remaining B₂O₃and some Al₂O₃formed an amorphous grain boundary phase. This amorphous grain boundary phase is more stable than that formed with only Al₂O₃(Shabalala). The typical feature of formation of micropores was not observed, resulting in higher hardness values. The ZrO₂transforms into ZrB₂and partially ZrB₁₂. It has to be mentioned that the peaks of ZrB₁₂are slightly shifted in comparison to the standard values, indicating that there may be some yttrium or aluminum dissolved in the lattice.
A cross-section of the sample was polished and then tested for hardness and fracture toughness with Vickers indenter. The hardness was found to be about 36.9 GPa (sample 7b) and 34.2 GPa (sample 7a) at a load of 0.4 kg and a fracture toughness of about 4 MPa.m^0.5.

Examples 8-10

Boron suboxide composite materials were produced using the same conditions set out in Example 7, but replacing the ZrO₂with HfO₂, WO₃and TiB₂respectively in the ratios provided in Table 1. Densification was carried out at 1850° C. and 1900° C. At 1850° C. densities of 96-98% were observed. At 1900° C. densities of more than 98% were observed. In example 7b, the same densities were observed for both temperatures, indicating slightly better densification behaviour with ZrO₂additions than what is achieved with the addition of HfO₂or WO₃.
In the samples without Y₂O₃additions, some Al₁₈B₄O₃₃and a boride was also formed. There was no formation of microporosity as in Shabalala et al (WO 2007/029102 and [9]) indicating a more stable grain boundary phase (FIG. 4). In addition to the oxide phase, borides (HfB₂, W₂B₅, which is a composition with a homogeneity range and sometimes is named also as WB₂-W₂B₅and WB₂are both used because a detailed determination of the lattice constants was not carried out) were also formed in all the examples. The addition of Y₂O₃suppresses the crystallization of Al₁₈B₄O₃₃in the oxide amorphous grain boundary or secondary phase.

Examples 11-13

A boron suboxide composite material of example 11 was produced using the same conditions set out in Example 1, save that the Y₂O₃of Example 1 was replaced with SiO₂, Examples 12-13 were produced in the same way as Example 7. The composite material produced was fully densified.
The materials, densities, phase compositions and properties of all composites produced are given in Table 1. The data showed that the addition of Y₂O₃/Al₂O₃increases densification substantially. The densification at 1850° C. can be completed for the compositions with the additives, whereas the pure B₆O powders can only be densified to 95% of theoretical densities at this temperature. The same density as for the pure material can be reached at 50-100° C. lower temperatures. Fast densification starts at 1350-1370° C. for the material with the Y₂O₃/Al₂O₃additives whereas the densification of the pure material starts only at 1450° C. The microstructures of the materials with addition of Y₂O₃/Al₂O₃reveal the existence of such a liquid, because no crystalline grain boundary phases (secondary phase) are found. SEM figures show a homogeneous distribution of the Y₂O₃/Al₂O₃additives in the triple junctions. The grain size of the material cannot be determined, but from the SEM micrographs it can be concluded that the grain size is less than 1 μm, i.e. no grain growth occurs.
The addition of 10 wt % TiB₂to the composition of the B₆O+Y₂O₃/Al₂O₃does not change the densification behaviour.
FIG. 3 shows the microstructure of the material of example 10, showing that the TiB₂particle is in the range of 1-2 μm and the oxide grain boundary is visible.
The microstructure of the material with WO₃(example 9c) additions are given in FIG. 4. The material is nearly 100% dense and the formation of borides is visible. The particle size of the precipitated borides is less than 1 μm.
The results show the possibility of producing dense superhard B₆O materials without high pressure. The improved densification of these materials in comparison to pure B₆O is connected with the formation of a liquid phase during densification.

TABLE 1

		Additive			Phases
	Material components	Ratio	H_v(5 kg),	K_IC,	(after	Density
No.	(sintering temp, ° C.)	(weight %)	(GPa)	(MPa · m^0.5)	sintering)	(g/cm³)

Ref*	B₆O	—	30.1	Brittle	B₆O	2.5
			(1 kg Load)
Prior art*	B₆O + Al₂O₃	—	29.3	3.5	B₆O
					Al₄B₂O₉
Ex 1	B₆O + Al₂O₃+ Y₂O₃	2:2.65	33.2 ± 2.79	6.3 ± 0.99	B₆O	2.53
	(1800° C.)				amorphous
					secondary
					phase
Ex 2	B₆O + Al₂O₃+ Y₂O₃	1:1.32	30.4 ± 1.8	6.0 ± 0.4	B₆O	2.41
	(1800° C.)				amorphous
					secondary
					phase
Ex 3	B₆O + Al₂O₃+ Y₂O₃+ SiO₂	2:2.65:1	33.5 ± 2.2	5.0 ± 1.0	B₆O	2.46
	(1800° C.)				amorphous
					secondary
					phase
Ex 4	B₆O + Al₂O₃+ Y₂O₃	2.62:2.65	33.4 ± 0.6**	4.3 ± 0.7	B₆O	2.56
	(1740° C.)				amorphous
					secondary
					phase
Ex 5	B₆O + Al₂O₃+ Y₂O₃	2.62:2.65	33.0 ± 0.7**	4.0 ± 0.4***	B₆O	2.60
	(1800° C.)				amorphous
					secondary
					phase
Ex 6	B₆O + Al₂O₃+ Y₂O₃	2:2	32.1 ± 0.7**	4.0 ± 0.4***	B₆O	2.53
	(1850° C.)				amorphous
					secondary
					phase
Ex 7a	B₆O + Al₂O₃+ Y₂O₃+ ZrO₂+ MgO	2:2:2:0.53	34.2 ± 0.6**	4	B₆O, ZrB₂,	2.60
	(1850° C.)				ZrB₁₂
					amorphous
					secondary
					phase
Ex 7b	B₆O + Al₂O₃+ ZrO₂+ MgO	2:2:0.53	36.9 ± 0.6**	4	B₆O, ZrB₂,	2.60
	(1850° C.)				ZrB₁₂,
					Al₁₈B₄O₃₃
					amorphous
					secondary
					phase
Ex 8a	B₆O + Al₂O₃+ Y₂O₃+ HfO₂+ MgO	2:2:2:0.53	34.2 ± 0.6**	4	B₆O, HfB₂	2.52
	(1900° C.)				amorphous
					secondary
					phase
Ex 8b	B₆O + Al₂O₃+ HfO₂+ MgO	2:2:0.53	36.1 ± 0.6**	4	B₆O, HfB₂	2.56
	(1850° C.)				Al₁₈B₄O₃₃
					amorphous
					secondary
					phase
Ex 9a	B₆O + Al₂O₃+ Y₂O₃+ WO₃+ MgO	2:2:4:0.53	35.6 ± 0.4**	4	B₆O, W₂B₅	2.61
	(1900° C.)				amorphous
					secondary
					phase
Ex 9b	B₆O + Al₂O₃+ Y₂O₃+ WO₃+ MgO	2:2:4:0.53	34.2 ± 0.5**	4	B₆O, W₂B₂	2.61
	(1850° C.)				amorphous
					secondary
					phase
Ex 9c	B₆O + Al₂O₃+ WO₃+ MgO	2:4:0.53	34.0 ± 0.6**	4	B₆O, W₂B₂	2.61
	(1850° C.)				amorphous
					secondary
					phase
Ex 10a	B₆O + Al₂O₃+ Y₂O₃+ TiH₂+ MgO	2:2:5:0.53	36.1 ± 0.6**	4	B₆O, TiB₂	2.49
	(1900° C.)				amorphous
					secondary
					phase
Ex 10b	B₆O + Al₂O₃+ Y₂O₃+ TiB₂+ MgO	2:2:10:0.53	36.8 ± 0.5**	4	B₆O, TiB₂	2.68
	(1900° C.)				amorphous
					secondary
					phase
Ex 10c	B + TiO₂+ 0.4% MgO + 0.5%	65.44:34.55:0.4:0.5	28.2 ± 0.6**	4	B₆O, TiB₂	2.79
	Al₂O₃(wear of balls)				amorphous
	(1850° C.)				secondary
					phase
Ex 11	B₆O + Al₂O₃+ SiO₂	2:1	29.5 ± 1.60	4.8 ± 0.65	B₆O	2.42
	(1800° C.)				Al₁₈B₄O₃₃
					amorphous
					secondary
					phase
Ex 12	B₆O + Al₂O₃+ Sc₂O₃+ MgO	2:2:0.53	36.7 ± 0.6**	4	B₆O	2.57
	(1900° C.)				amorphous
					secondary
					phase
Ex 13	B₆O + Al₂O₃+ Y₂O₃+ BN	2:2:2	31.3 ± 0.8**	3.6	B₆O	2.45
	(1900° C.)				amorphous
					secondary
					phase

*Data for reference and prior art sample taken from Shabalala et al. (WO2007/029102)
**measured under 0.4 Kg load
***measured by SENB (notch radius 30 μm)

REFERENCES

- 1. H. Hubert, L. Garvie, B. Devouard, P. Buseck, W. Petuskey, P. McMillan, Chem. Mater.; 10; (1998); pp. 1530-1537
- 2. H. Itoh, I. Maekawa, H. Iwahara, J. Soc. Mat. Sci., Japan; 47(10); (1998); pp. 1000-1005
- 3. R. R Petrak, R. Ruh, G. R. Atkins, Cer. Bull.; 53(8); (1974); pp. 569-573
- 4. R. Sasai, H. Fukatsu, T. Kojima, and H. Itoh, J. Mater. Sci.; 36; (2001); pp. 5339-5343
- 5. H. Itoh, I. Maekawa, and H. Iwahara; J. Mater. Sci.; 35; (2000); pp. 693-698
- 6. H. Itoh, R. Yamamoto, and H. Iwahara; J. Am. Ceram. Soc.; 83(3); (2000); pp. 501-506
- 7. T. C. Shabalala, D. S. McLachlan, I. J. Sigalas, M. Herrmann; Advances in Sci and Tech.; 45; (2006); pp. 1745-1750
- 8. G. Anstis, P. Chantikul, B. Lawn and D. Marshall; “A critical evaluation indentation techniques for measuring fracture toughness: I, Direct crack measurements”, J. Am. Ceram. Soc.; 64; (1981); pp 533-538
- 9. He, D., Zhao, Y., Daemen, L., Qian, J., Shen, T. D. & Zerda, T. W. Boron suboxide: As hard as cubic boron nitride, Appl. Phys. Lett. Vol. 81, 4, 643-645(2002)
- 10. A. Andrews, M. Herrmann, T. C. Shabalala, and I. Sigalas, “Liquid phase assisted hot pressing of boron suboxide materials”, J. Europ. Ceram. Soc. 28, 1613-1621 (2008)
- 11. H.-J. Kleebe, S. Lauterbach, T. C. Shabalala, M. Herrmann and I. J. Sigalas, “B₆O: A Correlation Between Mechanical Properties and Microstructure Evolution Upon Al₂O₃Addition During Hot-Pressing”, J. Amer. Ceram. Soc., 91 [2] 569-575 (2008))
- 12. Rutz H. L., Day D. E. and Spencer C. F., J. Am. Ceram. Soc., 1990, vol. 73, No. 6, p. 1788.

Claims

1. A boron suboxide composite material comprising boron suboxide and a secondary phase, the secondary phase containing a mixture of at least two metal oxides, neither of which is a boron-containing oxide.

2. A composite material according to claim 1 wherein at least one of the oxides is selected from the oxides of elements of the Groups IA, IIA, IIIA, and IVA of the periodic table.

3. A composite material according to claim 1 wherein at least one of the oxides is a rare earth metal oxide.

4. A composite material according to claim 3 wherein the rare earth metal oxide is selected from yttrium oxide, scandium oxide and oxides of elements of the lanthanide series.

5. A composite material according to claim 1 wherein at least one of the oxides is selected from Al2O3, SiO2, MgO, CaO, BaO and SrO.

6. A composite material according to claim 1 wherein one of the oxides is Al2O3 and another oxide is selected from SiO2, MgO, CaO, BaO and SrO.

7. A composite material according to claim 1 wherein one of the oxides is a rare earth metal oxide and another oxide is selected from Al2O3, SiO2, MgO, CaO, BaO and SrO.

8. A composite material according to claim 1 wherein the secondary phase also contains a boron-containing oxide.

9. A composite material according to claim 1 wherein the secondary phase also contains a boride.

10. A composite material according to claim 9 wherein the boride is selected from the borides of transition metals of the fourth to eighth groups of the periodic table.

11. A composite material according to claim 10 wherein the boride is selected from a boride of iron, cobalt, nickel, titanium, tungsten, tantalum, hafnium, zirconium, rhenium, molybdenum and chromium.

12. A composite material according to claim 9 wherein the boride is a platinum group metal boride.

13. A composite material according to claim 12 wherein the platinum group metal boride is palladium boride.

14. A composite material according to claim 1 wherein the mixture of oxides is present in an amount of up to 20 volume % of the composite material.

15. A composite material according to claim 1 wherein the mixture of oxides is present in an amount of up to 10 volume % of the composite material.

16. A composite material according to claim 1 wherein the mixture of oxides is present in an amount of up to 5 volume % of the composite material.

17. A composite material according to claim 1 wherein the boron suboxide is particulate or granular boron suboxide.

18. A composite material according to claim 1 wherein the mean grain size of the boron suboxide particles or granules range from 100 nm to 100 μm.

19. A composite material according to claim 18 wherein the mean grain size of the boron suboxide particles or granules range from 100 nm to 10 μm.

20. A composite material according to claim 9 wherein the boron suboxide is present in an amount of at least 50 volume % of the composite material.

21. A composite material according to claim 1 wherein the fracture toughness of the composite material is greater than 3.5 MPa.m0.5.

22. A composite material according to claim 1 wherein the hardness of the composite material is greater than 25 GPa.

23. A method of producing a boron suboxide composite material according to claim 1 comprising the steps of providing a source of boron suboxide; contacting the source of boron suboxide with a mixture of oxides, wherein at least two of the oxides do not contain boron, or compounds or metals capable of producing such a mixture of oxides, to create a reaction mass; and sintering the reaction mass to produce the boron suboxide composite material.

24. A method according to claim 23 wherein the reaction mass is sintered at a pressure of less than 200 MPa and a temperature of not exceeding 19500C.

25. A method according to claim 23 wherein the reaction mass is sintered by a heating rate of 50-400 K/minute and an isothermal holding time of 5 minutes or less.

26. A method according to claim 23 wherein the reaction mass is sintered by heating rates of 10-20 K/minute and isothermal holding times of 15-60 minutes.

27. A method according to claim 23 wherein contacting the boron suboxide with the mixture of oxides or compounds or metals is done by way of mixing.