Fused quartz

Fused quartz, fused silica or quartz glass is a glass consisting of almost pure silica (silicon dioxide, SiO2) in amorphous (non-crystalline) form. This differs from all other commercial glasses, such as soda–lime glass, lead glass, or borosilicate glass, in which other ingredients are added which change the glasses' optical and physical properties, such as lowering the melt temperature, the spectral transmission range, or the mechanical strength. Fused quartz, therefore, has high working and melting temperatures, making it difficult to form and less desirable for most common applications, but is much stronger, more chemically resistant, and exhibits lower thermal expansion, making it more suitable for many specialized uses such as lighting and scientific applications. The terms fused quartz and fused silica are used interchangeably but can refer to different manufacturing techniques, resulting in different trace impurities. However fused quartz, being in the glassy state, has quite different physical properties compared to crystalline quartz despite being made of the same substance. However, fused silica is entirely synthetic. Due to its physical properties it finds specialty uses in semiconductor fabrication and laboratory equipment, for instance. Compared to other common glasses, the optical transmission of pure silica extends well into the ultraviolet and infrared wavelengths, so is used to make lenses and other optics for these wavelengths. Depending on manufacturing processes, impurities will restrict the optical transmission, resulting in commercial grades of fused quartz optimized for use in the infrared, or in the ultraviolet. The low coefficient of thermal expansion of fused quartz makes it a useful material for precision mirror substrates or optical flats.

Manufacture Fused quartz is produced by fusing (melting) high-purity silica sand, which consists of quartz crystals. There are four basic types of commercial silica glass:

Type I is produced by electrically melting natural quartz in a vacuum or an inert atmosphere. Type II is produced by fusing quartz crystal powder in a high-temperature flame. Type III is produced by burning SiCl4 in a hydrogen-oxygen flame. Type IV is produced by burning SiCl4 in a water vapor-free plasma flame. Quartz contains only silicon and oxygen, although commercial quartz glass often contains impurities. Two dominant impurities are aluminium and titanium which affect the optical transmission at ultraviolet wavelengths. If water is present in the manufacturing process, hydroxyl (OH) groups may become embedded which reduces transmission in the infrared.

Fusion Melting is effected at approximately 2200 °C (4000 °F) using either an electrically heated furnace (electrically fused) or a gas/oxygen-fuelled furnace (flame-fused). Fused silica can be made from almost any silicon-rich chemical precursor, usually using a continuous process which involves flame oxidation of volatile silicon compounds to silicon dioxide, and thermal fusion of the resulting dust (although alternative processes are used). This results in a transparent glass with an ultra-high purity and improved optical transmission in the deep ultraviolet. One common method involves adding silicon tetrachloride to a hydrogen–oxygen flame.

Product quality Fused quartz is normally transparent. The material can, however, become translucent if small air bubbles are allowed to be trapped within. The water content (and therefore infrared transmission) of fused quartz is determined by the manufacturing process. Flame-fused material always has a higher water content due to the combination of the hydrocarbons and oxygen fueling the furnace, forming hydroxyl [OH] groups within the material. An IR grade material typically has an [OH] content below 10 ppm.

Applications

Many optical applications of fused quartz exploit its wide transparency range, which can extend well into the ultraviolet and into the near-mid infrared. Fused quartz is the key starting material for optical fiber, used for telecommunications. Because of its strength and high melting point (compared to ordinary glass), fused quartz is used as an envelope for halogen lamps and high-intensity discharge lamps, which must operate at a high envelope temperature to achieve their combination of high brightness and long life. Some high-power vacuum tubes used silica envelopes whose good transmission at infrared wavelengths facilitated radiation cooling of their incandescent anodes. Because of its physical strength, fused quartz was used in deep diving vessels such as the bathysphere and benthoscope and in the windows of crewed spacecraft, including the Space Shuttle and International Space Station. Fused quartz was used also in composite armour development.

… excerpt ends here. Continue reading the full article.