Beall 2004
Beall 2004
Nanophase Glass-Ceramics
George H. Beall* and Linda R. Pinckney*
Corning Incorporated, Corning, New York
Future applications for glass-ceramics are likely to capital- phases. In other cases, crystallization proceeds within or from
ize on designed-in, highly specialized properties for the the surfaces of the phase-separated globules themselves.
transmission, display, and storage of information. Glass- Nucleation is followed by one or more higher-temperature
ceramics with microstructures comprised of uniformly dis- treatments to promote crystallization of the primary phase or
persed crystals <100 nm in size offer promise for many phases and development of the desired microstructure. The
potential new applications as well as provide unique attri- growth process continues until neighboring crystals impinge,
butes for many current products. This paper focuses on two creating a highly crystalline body with a small amount of re-
types of nanocrystalline glass-ceramics: transparent glass- sidual glass, or until the residual glass is depleted in the crystal-
ceramics and tough, high-modulus glass-ceramics with pre- forming components. Certain glass-ceramics are specifically
cisely engineered surfaces. Transparent glass-ceramics are designed to possess a microstructure of uniformly dispersed,
formed from certain aluminosilicate glasses capable of ef- nonimpinging crystals in a matrix of continuous residual glass.
ficient crystal nucleation and slow growth. The key crys- Glass-ceramics have several advantages over conventional
talline phases include -quartz solid solutions, character- powder-processed ceramics. In addition to the ease of flexibil-
ized by low-thermal-expansion behavior; spinel, with high ity of forming in the glassy state, glass-ceramics possess a
hardness and elastic modulus; and mullite, which shows uniformity of microstructure and subsequent reproducibility of
unique chromium-luminescence behavior. properties that result from the homogeneity of the starting
glass. Furthermore, glass-ceramics provide a wide range of
physical properties—such as coefficients of thermal expansion
I. Introduction (CTEs) from −75 × 10−7/°C to +200 × 10−7/°C—that often are
not readily obtained in glasses or ceramics. Many commercial
G LASS-CERAMIC technology is based on the controlled nucle-
ation and crystallization of glass. Although glass-ceramic
articles can be fabricated through the internal nucleation of
glass-ceramics are valued primarily for their near-zero thermal
expansion, while the combination of high mechanical strength
and zero porosity has been exploited by applications ranging
glass monoliths or via the sintering and crystallization of glass from architectural materials to tableware to bone implants. Of
frits, internal nucleation affords a much wider array of potential the many types of microstructures obtainable in glass-ceramics,
microstructures. Some glass compositions are self-nucleating, those based on uniformly dispersed crystals <100 nm in size
but, more commonly, certain components known as nucleating provide unique attributes for current products and offer prom-
agents are added to the batch to promote phase separation and ise for many potential new applications. Such microstructures
internal nucleation. The nucleating agents melt homogeneously can be termed ‘‘nanocrystalline.’’
into the glass but promote very-fine-scale phase separation on This paper focuses on two types of nanocrystalline glass-
reheating. The dispersed phase is typically structurally incom- ceramics: transparent glass-ceramics and tough, high-modulus
patible with the host glass and, therefore, precipitates tiny crys- glass-ceramics with precisely engineered surfaces. The first
talline nuclei on heating at temperatures of 30°–100°C above group has numerous consumer and technical applications,
the annealing point of the glass. These crystals serve as the while the second are of interest as magnetic memory disk sub-
sites for subsequent nucleation of the primary crystalline strates or other applications that require smooth surfaces,
chemical durability, and high use temperature.
centennialfeature
5
6 Journal of the American Ceramic Society—Beall and Pinckney Vol. 82, No. 1
c ≈ 冋冉 2
3 冊 册
× 10−3 k43 共n⌬n兲2
where x + y ⱕ 1 and z > 2. In addition, phosphatic -quartz
solid solutions can be formed where AlPO4 substitutes in part
for the SiO2. An example of a phosphatic -quartz composition
where is the mean phase width (a + W/2) and W the inter- is the commercial Schott Zerodur威. Although all of these
particle spacing. In this case, improved transparency is allowed -quartz solid solutions are believed to be metastable, with the
with particle sizes <30 nm at larger refractive index differ- exception of near the -eucryptite stoichiometry, many of the
ences, up to ⌬n ⳱ 0.3. compounds retain the -quartz structure even when heated at
The rate of nucleation must be close to optimal to achieve 1200°C for 100 h.8 Representative -quartz glass-ceramic
such small crystals. Figure 1 shows the classic diagram of compositions are given in Table I.
Tamann5,6 that illustrates the effect of temperature on the rates Crystals of stuffed -quartz typically exhibit low or negative
of homogeneous nucleation and crystal growth. The optimum volume expansion with increasing temperature. The CTE gen-
nucleation temperature lies below the optimum rate of crystal erally decreases with increasing amounts of Li+ and Zn2+ in the
growth. Both rates are limited by viscosity at low temperatures -quartz structure and increases with increasing Mg2+. It is
and by lack of thermodynamic driving forces at or near the possible to design materials with essentially zero expansion
melting temperatures. Although heterogeneous nucleation rates over fairly wide temperature intervals by tailoring the compo-
can be more complex, the general rule holds that optimal nucle- sition and amounts of -quartz crystals and positive-expansion
ation temperatures occur well below those of crystal growth residual glass. The measured CTE of various -quartz solid
January 1999 Nanophase Glass-Ceramics 7
Fig. 2. CTE of solid solution of -quartz crystallized from glasses in Fig. 4. TEM micrograph of the Zerodur威 glass-ceramic. Scale bar
the SiO2–LiAlO2 system. indicates 0.1 m.
8 Journal of the American Ceramic Society—Beall and Pinckney Vol. 82, No. 1
Radiant stovetop composed of nanocrystalline -quartz solid-solution glass-ceramic with near-zero coefficient of thermal expansion (photo-
graph courtesy of Eurokera, S.N.C.).
January 1999 Nanophase Glass-Ceramics 9
Transparent glass-ceramic cookware (VISION威) based on nanocrystals of low-thermal-expansion-coefficient -quartz solid solution (photograph
courtesy of Corning Consumer Products Company).
January 1999 Nanophase Glass-Ceramics 11
titioning in spinel glass-ceramics is readily observed when energies and broad transparency in the infrared region of the
these materials are crystallized. A Cr3+-doped spinel material is spectrum used for amplification of light in telecommunications
emerald green as a precursor glass and pink as a glass-ceramic, systems. Fluoride glasses have relatively poor chemical and
for example, whereas a Ni2+-doped material is brown and blue mechanical stability compared with oxide-based glasses, how-
before and after crystallization. Compared with the mullite ever, and, as a result, are difficult to prepare and handle. Re-
glass-ceramics, however, transparent spinel glass-ceramics cently, transparent oxyfluoride glass-ceramics, based on fluo-
have offered fewer advantages for the luminescent solar col- ride crystals dispersed throughout a continuous silicate glass,
lector application. Unlike mullite, for example, spinel glass- have been shown to combine the optical advantages of rare-
ceramics require a nucleating agent. Moreover, Cr3+-doped earth-doped fluoride crystals with the ease of forming and han-
spinel glass-ceramics do not absorb as broadly as mullite glass- dling of conventional oxide glasses. Table V gives the compo-
ceramics across the entire range of solar radiation (compare the sitions and properties of several of these oxyfluoride materials.
pink color of Cr3+-doped spinel with the gray color of Cr3+- Wang and Ohwaki25 discovered that 20 nm cadmium lead
doped mullite). It is possible that compositional and process fluoride crystals codoped with erbium and ytterbium could be
research can overcome these barriers. precipitated from aluminosilicate glasses, thereby yielding
The potential use of transparent, Cr3+-doped gahnite glass- transparent oxyfluoride glass-ceramics. They were able to use
ceramics as a laser medium has been evaluated recently using the resonant energy transfer between ytterbium and erbium to
excited-state absorption. Although the material is characterized produce upconversion and fluorescence in the blue-green. With
by a very structured and wide emission band from 685 to 750 an excitation wavelength of 0.97 m, the measured upconver-
nm, the question of its potential as an efficient laser medium sion emission intensity from the glass-ceramic was 100 times
has not been resolved.24 that of the precursor oxyfluoride glass and 2–10 times that of
(5) Transparent Oxyfluoride Glass-Ceramics
Fluoride crystals and glasses are desirable hosts for optically
active rare-earth (RE) cations because of their low phonon
Fig. 10. Thermal expansion curves of silicon and transparent spinel Fig. 11. TEM micrograph of a transparent LaF3 glass-ceramic. Scale
glass-ceramic. bar indicates 0.1 m.
January 1999 Nanophase Glass-Ceramics 13
an aluminofluoride glass, indicating excellent upconversion ef- is 7%–8% efficiency for the glass-ceramics compared with 4%
ficiency. These oxyfluoride glass-ceramics have potential ap- for ZBLAN. The quantum efficiencies have been measured
plications in blue-green laser devices. directly by Quimby et al.30 for the two glass-ceramics of Tick
Tick et al.26 subsequently described ytterbium-free oxyfluo- et al. with results of 8%–9% quantum efficiency. It is, there-
ride glass-ceramics based on praseodymium-doped nanocrys- fore, apparent that isolating the characteristic RE, in this case
tals of cadmium lead fluorides containing yttrium and zinc. praseodymium, in the fluoride crystal can produce efficiencies
Their objective was to produce materials with efficient lumi- that rival or surpass those of fluoride glasses.
nescence at 1.3 m that could be used as amplifier hosts for In addition to their interesting fluorescence properties, the
telecommunications. XRD data and TEM indicate that these glass-ceramics described by Tick et al. have unusual clarity
glass-ceramics are 15%–30% by volume crystal sizes of 9–18 and extraordinarily low optical scattering. The theoretical
nm. Fluorescence measurements indicate significant partition- losses of scattering in these materials are described in Fig. 12,
ing of the optically active RE cations into the fluoride crystals, in which particle separation is plotted against the particle ra-
with their behavior essentially determined by their local fluo- dius,26 defining several lines of volume percent crystallinity
ride, low-phonon-energy environment. Fluorescence lifetimes, radiating from the origin. There is a major difference in the
however, are only slightly better than those observed in the scattering losses according to the independent particle model
fluorozirconate glass ZBLAN, probably because of clustering. and the quasi-continuum model. The dashed lines show the
Recently, Dejneka27 described another family of transparent predicted losses in square brackets in dB/km according to the
oxyfluoride glass-ceramics, based on 15 nm crystals of LaF3 in Rayleigh–Gans model. The solid lines show much smaller
an aluminosilicate glass (Fig. 11), that provides the desirable losses using the assumptions of the quasi-continuum model.
fluoride environment for active RE ions while maintaining the The data are for a wavelength of 1300 nm and an assumed
processing advantages of an oxide glass. LaF3 is an ideal host index difference ⌬n ⳱ 0.1 between the crystals and the re-
for RE cations, because it has extensive solid solution with all sidual glass. The shaded area in the diagram indicates the typi-
RE ions. Eu3+ emission spectroscopy has demonstrated that cal microstructure—particle size and separation—as observed
active RE ions partition into the low-phonon-energy LaF3 crys- by TEM. The actual turbidity and measured scattering coeffi-
tals without clustering. Fluorescence and lifetime measure- cient for the oxyfluoride glass-ceramic as well as the parent
ments indicate that these materials are superior to ZBLAN both glass and a typical high-quality Schott optical glass are shown
for Er3+ amplifiers because of greater width and gain flatness of in Table VII. The scattering losses for the glass-ceramic range
the 1530 nm emission band and for Pr3+ amplifiers because of between 73 and 166 dB/km, which lies in the range where the
their higher quantum efficiency. quasi-continuum model is accurately predictive. The oxyfluo-
Table VI compares the quantum efficiencies of the Pr3+- ride glass-ceramic is only very slightly more scattering than the
doped oxyfluoride glass-ceramics of Tick et al. and Dejneka parent glass and the Schott optical glass.
with those of their parent glasses and that of the conventional
fluoride glass ZBLAN. The quantum efficiency can be calcu-
lated by comparison of the radiative lifetime, calculated from III. Tough Glass-Ceramics for
Judd–Ofelt theory, with the measured lifetime.28,29 The result Microengineered Surfaces
Nanocrystalline glass-ceramics with high elastic modulus
and moderate strength and toughness have been developed re-
cently for potential use as magnetic disk substrates in computer
hard drives.31 These glass-ceramics, based on spinel and en-
statite phase assemblages in the SiO2–Al2O3–MgO–ZnO–TiO2
system, have grain sizes of <100 nm and can be polished to an
average roughness of 0.5–1.0 nm. The majority of disk drives
are built with disks of NiP-plated aluminum, with chemically
strengthened glass disks also being used in certain products.32
High-modulus glass-ceramics offer many different advantages
for the disk substrate application, including improved flatness
and smoothness, better wear, resistance to flutter at high rota-
tional speeds, and the ability to be manufactured thinner than
glass or aluminum disks. They also offer excellent chemical
durability and are devoid of alkali ions that can cause contami-
nation problems under extreme use conditions.
Compositions within the cordierite liquidus field of the ter-
nary MgO–Al2O3–SiO2 system are easily nucleated with TiO2
Fig. 12. Theoretical scattering losses in nanocrystalline glass- to give a wide range of possible phase assemblages based on
ceramics. (After Tick et al., 1995.) various mixtures of cordierite, -quartz solid solution,
14 Journal of the American Ceramic Society—Beall and Pinckney Vol. 82, No. 1
9
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12
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enough in birefringence, or well matched in refractive index 13
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14
W. E. Cameron, ‘‘Mullite: A Substituted Alumina,’’ Am. Mineral., 62,
on stuffed derivatives of -quartz can meet these requirements 747–55 (1977).
and display excellent thermal shock resistance because of their 15
G. H. Beall, D. R. Cole, D. W. Hall, H. J. Holland, J. W. H. Schreurs, M.
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ceramics whose grain size is extremely fine, <50 nm. These 16
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materials have increased strain points over their parent glasses Al2O3–SiO2 Glasses,’’ J. Am. Ceram. Soc., 52, 17–25 (1969).
and selectively partition transition metals such as chromium 17
R. Reisfeld, A. Kisilev, A. Buch, and M. Ish-Shalom, ‘‘Transparent Glass-
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luminescent materials. Rare-earth ions that fluoresce farther 18
L. J. Andrews, G. H. Beall, and A. Lempicki, ‘‘Luminescence of Cr3+ in
into the infrared can be selectively partitioned into fluoride Mullite Transparent Glass-Ceramics,’’ J. Lumin., 36, 65–74 (1986).
crystals in transparent oxyfluoride glass-ceramics. Other mul- 19
L. R. Pinckney, ‘‘Transparent Glass-Ceramics Containing Gahnite,’’ U.S.
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20
N. Gotoh and M. Hayasaka, ‘‘Glass-Ceramics,’’ U.S. Pat. No. 5 028 567,
ent, possess excellent hardness and high stiffness and can be July 2, 1991.
polished to extreme smoothness. 21
C. A. Swansen, ‘‘Recommended Values for the Thermal Expansivity of
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22
clude telescope mirrors, laser gyroscopes, radiant stovetops, L. R. Pinckney, ‘‘Transparent, High Strain Point Glass-Ceramics’’; in Pro-
ceedings of the XVIII International Congress on Glass, Section E4. American
cookware, woodstove windows, and fire doors. Future appli- Ceramic Society, Westerville, OH, 1998.
cations for these materials are likely to capitalize on designed- 23
R. G. Burns, Mineralogical Applications of Crystal Field Theory; pp. 109–
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24
and storage of information. Potential products include ad- C. Koepke, K. Wisniewski, M. Grinberg, D. L. Russell, K. Holliday, and
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optoelectronic components and devices, and data storage 25
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devices. Er3+ and Yb3+ for Efficient Frequency Upconversion,’’ Appl. Phys. Lett., 63
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26
Acknowledgments: The authors would like to thank M. Dejneka and P. A. Tick, N. F. Borrelli, L. K. Cornelius, and M. A. Newhouse, ‘‘Trans-
P. Tick for helpful discussions and N. Foster for preparing many of the parent Glass-Ceramics for 1300 nm Amplifier Applications,’’ J. Appl. Phys., 78,
figures. 93–100 (1995).
27
M. J. Dejneka, ‘‘Rare-Earth Fluorescence in Novel Oxyfluoride Glasses
and Glass-Ceramics,’’ Proc. Soc. Photo-Opt. Instrum. Eng., 3280, 132–37
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16 Journal of the American Ceramic Society—Beall and Pinckney Vol. 82, No. 1