Containment of molten materials having silicon

Abstract

Silicon eutectic alloy compositions and methods for making the same are disclosed. In one approach, a method may include using a glass carbon container to restrict contamination of the eutectic alloy melt. In an alternative approach, a method may include using a container having aluminum. The aluminum in the container may provide aluminum that is incorporated into the silicon eutectic alloy. Silicon eutectic bodies made by such methods are also disclosed.

What is claimed is: 
     
         1 . A method of making a silicon eutectic alloy body, the method comprising:
 heating a mixture in a container thereby forming a eutectic alloy melt, wherein the mixture includes silicon and a metallic element M a , where portions of the container in contact with the eutectic alloy melt comprise glassy carbon; and   removing heat from the eutectic alloy melt to solidify the eutectic alloy melt, thereby forming a silicon eutectic alloy body comprising having a eutectic aggregation including a first phase comprising the silicon and a second phase comprising the metallic element a, wherein the second phase has a formula M a Si 2 .   
     
     
         2 . The method of  claim 1 , wherein the mixture comprises a third phase comprising the metallic element M b , and wherein, after the removing step, the body comprising the eutectic aggregation comprises a third phase comprising the metallic element M b , wherein the third phase has a formula M b Si 2 , and wherein the second and third phases are immiscible. 
     
     
         3 . The method of  claim 2 , wherein the metallic element M a  comprises chromium and the metallic element M b  comprises vanadium 
     
     
         4 . The method of  claim 1 , wherein a carbide phase forms between the eutectic alloy melt and the container. 
     
     
         5 . The method of  claim 4 , wherein the carbide phase comprises silicon carbide. 
     
     
         6 . The method of  claim 1 , wherein the glassy carbon substantially does not contaminate the eutectic alloy melt. 
     
     
         7 . The method of  claim 1 , wherein the eutectic alloy melt is substantially free of carbon. 
     
     
         8 . The method of  claims 1 , wherein the heating the mixture comprises resistive or inductive heating. 
     
     
         9 . A silicon eutectic alloy composition comprising:
 a body comprising a eutectic alloy including silicon, aluminum, a metallic element M a , a metallic element M b , and a eutectic aggregation including a first phase comprising the silicon, a second phase comprising the metallic element M a  and the metallic element M b , wherein the second phase is a disilicide comprising a solid solution of the metallic element M a  and the metallic element M b , and having a formula of M a     x   M b     1-x   Si 2 , where 0<x<1, and wherein the body comprises greater than 0.1 wt. % of the aluminum.   
     
     
         10 . The silicon eutectic alloy composition of  claim 9 , wherein M a Si 2  and M b Si 2  phases are miscible in the eutectic alloy. 
     
     
         11 . The silicon eutectic alloy composition of  claim 9 , wherein the eutectic alloy comprises only one silicide phase. 
     
     
         12 . A method of making a silicon eutectic alloy, the method comprising:
 heating a mixture including silicon, a metallic element M a , and a metallic element M b , to form a eutectic alloy melt in a container where portions of the container in contact with the eutectic alloy melt comprises a composition having aluminum; and   removing heat from the eutectic alloy melt to solidify the eutectic alloy melt, thereby forming a body comprising a eutectic alloy including the silicon, aluminum, the metallic element M a , the metallic element M b , and a eutectic aggregation including a first phase comprising the silicon, a second phase comprising the metallic element M a  and the metallic element M b , wherein the second phase is a disilicide comprising a solid solution of the metallic element M a  and the metallic element M b , and having a formula of M a     x    M b     1-x   Si 2 , where 0<x<1, and wherein the body comprises greater than 0.1 wt. % of the aluminum.