Sinterable Ceramic Powders from Laser‐Driven Reactions: I, Process Description and Modeling

Abstract

A novel process is discussed for producing a wide variety of ceramic powders with unique physical and chemical characteristics. Silicon, Si 3 N 4 , and SiC powders were produced from CO 2 laser‐heated gas‐phase reactants; a detailed description of this laser‐driven process is presented. The physical, chemical, and crystalline nature of the resultant powders and the effect of process variables are discussed in Part II. In this process, reactant gases are rapidly heated by CO 2 laser radiation and decompose, causing particles to nucleate and grow rapidly. Analytical models of fluid flow, heat transfer, heating rates, and powder‐formation mechanisms are discussed. The powders produced in this process are very fine (<0.1μm), spherical, nearly monodispersed in size, extremely pure, and loosely agglomerated.