Synthesis of silicon nitride powders in a reactive atmosphere

In order to be able to manufacture cost-effective parts of advanced non-oxide ceramics, the cost of the starting powders must be lowered. Silicon nitride, Si3N4, is one such material and silicon nitride powder can be prepared by reacting silicon in a nitrogen atmosphere. As such, this is inherently a low cost process. However, subsequent comminution of the reaction product will determine the ultimate cost of the powder. This research is investigating the effect of a reactive atmosphere, HCl on the reaction of nitrogen with silicon. A reactive atmosphere can either encourage reactions in the gas phase and/or change the morphology of the reacted materials. A critical concern is the relative ease of comminution of powders produced with and without the presence of the reactive gas.