Synthesis of AlN Powder by Carbothermal Reduction-Nitridation of Various Al2O3 Powders with CaF2

We investigated the effect of characteristics of raw Al₂O₃ powder on the synthesis of AlN by the carbothermal reduction-nitridation method, in which CaF₂ was added as a catalytic material. Four types of Al₂O₃ powders were selected. An Al₂O₃/C molar ratio of 0.29 was fixed, and the amount of CaF₂ was varied from 3 to 30 wt%. The carbothermal reduction-nitridation was conducted from 1350° to 1450°C in N₂ flow. The nitridation rate tended to increase with decreasing particle size of raw Al₂O₃ and was found to depend on the Al₂O₃ synthesizing method. The particle sizes of the synthesized AlN increased somewhat with increasing reaction temperatures. However, even though different particle sizes of Al₂O₃ powders were used, AlN powders synthesized under the same conditions exhibited almost the same particle size, round shape, and narrow size distribution. From XRD analysis, CaO·6Al₂O₃ and CaO·2Al₂O₃ were identified as intermediate compounds during these reactions. The above phenomena suggest that the synthesis mechanism of AlN powder by carbothermal reduction-nitridation of Al₂O₃ with CaF₂ addition was the nitridation of the intermediate compounds through the liquid phase of the system CaF₂-CaO·6Al₂O₃-CaO·2Al₂O₃.