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0955-2219(95)00146-8
Mullite-Aluminosilicate
Glassy Matrix Substrates
Obtained by Reactive Coating
J. Requena, J. F. Bartolomk, J. S. Moya, S. de Aza, F. Guitianb & G. Thomasc
Institute de Ceramica y Vidrio (CSIC), Arganda de1 Rey, Madrid, Spain
Institute de CerBmica, Universidad de Santiago, Spain
Department of Materials Science and Mineral Engineering, University of California, Berkeley, CA 94720, USA
(Accepted 22 July 1995)
Abstract
Layered kaolinite-alumina
composites
have been
obtained by a sequential slip casting technique. The
interfacial reaction as well as the microstructure of
dcrerent layers have been studied in laminates jred
at 1650C. The results are discussed on the basis of
the SiO,Al,O,-K,O
equilibrium diagram. Taking
into account these results, a new low-cost ceramic
substrate for electronic applications - reinforced
by mullite whiskers and with controlled
closed
porosity, low permittivity
value (E = 4 at I MHz)
and thermal expansion coeficient close to that of
silicon (3~9 X 1O-6 C ) - has been developed
starting from conventional kaolinite powder.
Experimental
Introduction
Recently,
250
J. Requena et al.
Table 1. Quantitative
0.1
wt%
Na,SiOJ;
Primary mullite
Secondary mullite
Glassy matrix*
SiO,
72.0 + 0.5
73.5 f 0.3
26.4 f 0.7
26.6 + 0.3
27.8 f 0.3
73.88 f 0.56
K20
1.47 f 0.05
200um
Fig. 2. SEM micrographs of the alumina-kaolinite
multilayer
composite fired at 1650C: (A) alumina layer; (B) original
kaolinite layer.
Mullite-aluminosilicate
PRIMARY
251
MULLITE
PRIMARY
MULLITE
(WHISKERS)
Al
SECONDARY MULLlTE
(REACTION LAYER)
.oo
0.00
0.00
Si
I
GLASSY
SECONDARY
MATRIX
MULLITE
?!m
4m
10.0
production
of the alumina-kaolinite
layered composite.
mullite and glassy matrix are also shown.
J. Requena
et al.
SiO,
Preheated
at 1 300C-2h.
I
\
/T
K. Caobar
AW,
Fig. 6. Substrates
processing
II
flow chart.
2020
equilibrium
diagram.
I
this work,
1600
e
f
The micrograph of an HF etched polished crosssection shows the presence of 5 pm thick coating
of a secondary mullite layer and a bulk formed
by continuous glassy matrix reinforced by primary
mullite whiskers. These are of length 20 + 5 pm
and width 2 f 0.5 pm, having an aspect ratio of
10 f 2 (Fig. 8). The content of the primary mullite
needle-like single crystals has been determined by
quantitative XRD analysis and found to be 60 wt%.
These data are in agreement with that calculated
from Fig. 4 at 1650C (60 f 5%).
The specific gravity of the fired substrate has
--
Caobar Kaolin&
t
15001400-
t;;
6
f
1300-
Inull
+ GP
:
12cQ-
IO
100
1000
Time (minutes)
Fig. 5. Time-temperature-transformation
balite nucleation for Caobar Kaolinite
of the cross-section
closed porosity.
of a substrate,
Mullite-aluminosilicate
253
SECONDARY
LAYER
MULLITE
of the cross-section
mullite
4.OE-3
3.OE-3
Z.OE-3
1 .OE-3
O.OE+O
0
200
400
600
TEMPERATURE
C
600
1000
of
J. Requena
254
c
L
t
Composite
Motoriolr
Homogoneus
I
t 200
I
f
w 150
I
c
100
n
SO
K-substrate
/
2
al.
300
250
et
MgO
Acknowledgement
n Alumino
w Mullits
n Olosr-Ceramics
10
12
Dieleckic CaMant
References
1.
2.
3.
4.
5.
6.
7.
Conclusions
8.
Layered kaolinite-alumina
ceramics obtained
by
Tummala,
packaging.