Strict process control, combined with proprietary process enhancements have enabled the production of large-scale single-crystal sapphire that demonstrates crystalline quality in excess of what has previously been possible. Extremely low defect densities, narrow rocking-curves, and very low stress gradients in the material are demonstrated through various X-ray diffraction techniques.

As sensor technology and applications have advanced over the years, the size of sensor windows has grown substantially to satisfy current and future demands. Rubicon Technology, with their strong history in scaling sapphire crystal growth and large scale production processes, has successfully produced large sapphire blanks using a highly modified horizontal directional solidification process. Several prototypes have been synthesized up to 1.75 inches thick, 14 inches wide and 20 inches long. Crystal properties and optical characteristics such as transmission and refractive index homogeneity will be presented on several polished bubble-free windows with excellent results. This research sets the standard for high quality monolithic sapphire sheets large enough for use as seamless integrated optical windows in both military and civilian applications.

The lattice strain behavior of osmium diboride—a member of a group of third-row transition metal borides associated with hard/superhard behavior—has been studied using radial diffraction in a diamond anvil cell under high pressure and non-hydrostatic stress. We interpret the average values of the measured lattice strains as a lower-bound to the lattice-plane dependent yield strengths using existing estimates for the elastic constants of OsB2, with a yield strength of 11 GPa at 27.5 GPa of hydrostatic pressure. The measured differential lattice strains show significant plane-dependent anisotropy, with the (101) lattice plane showing the largest differential strain and the (001) lattice plane showing the least strain. At the highest pressure, the a-axis develops a larger compressive strain and supports a larger differential strain than either the b or c axes. This causes an increase in the c/a ratio and a decrease in the a/b ratio especially in the maximum stress direction. The large strength anisotropy of this material points to possible ways to modulate directional mechanical properties by taking advantage of the interplay between aggregate polycrystalline texture with directional mechanical properties.

The five independent moduli required to construct the complete monocrystal elastic modulus tensor of the hexagonal-symmetry superhard compound ReB2 were measured from 308 to 5 K using resonant ultrasound spectroscopy on a special-texture polycrystal. This is possible because, confirmed by X-ray diffraction, the specimen measured was composed of grains with hexagonal axes parallel so that its polycrystal elastic response is identical to a monocrystal and because hexagonal-symmetry solids are elastically isotropic in the plane perpendicular to the hexagonal axis. Along the hexagonal (c) axis, C330=1021 GPa, nearly equal to C11 of diamond, and consistent with the superhard properties. However, in the (softer) isotropic plane, C110=671 GPa, much lower than diamond. The changes of Cij with temperature are very small and smooth. The Debye temperature was computed to be 738 K, and using a high-temperature approximation, the Grüneisen parameter is γ=1.7.

Interest in new ultraincompressible hard materials has prompted studies of transition metal diboride solid solutions. We have synthesized pure RuB2 and solid solutions of Os1−xRuxB2. The mechanical properties of these materials are investigated using in situ high-pressure X-ray diffraction and Vickers hardness testing techniques. Both bulk moduli and hardness vary linearly with composition in accordance with Vegard’s law, whereas the differing behavior among end-members can be explained by relativistic effects, core electron density, and differences in the cohesive energy of the parent metals. The results provide a refinement of the rules previously reported for the design of new superhard materials.

Surface Brillouin specotroscopy of a densified powder compact of rhenium diboride (see scanning electron microscopy image) results in a determined shear modulus of 223 GPa. This value is comparable to the shear modulus of c-BC2N and provides evidence for the superhard nature of ReB2.

Dense transition metal borides have recently been identified as superhard materials that offer the possibility of ambient pressure synthesis compared to the conventional high pressure, high temperature approach. This feature article begins with a discussion of the relevant physical properties for this class of compounds, followed by a summary of the synthesis and properties of several transition metal borides. A strong emphasis is placed on correlating mechanical properties with electronic and atomic structure of these materials in an effort to better predict new superhard compounds. It concludes with a perspective of future research directions, highlighting some recent results and presenting several new ideas that remain to be tested.

Dense transition metal borides have recently been identified as superhard materials that offer the possibility of ambient pressure synthesis compared to the conventional high pressure, high temperature approach. This feature article begins with a discussion of the relevant physical properties for this class of compounds, followed by a summary of the synthesis and properties of several transition metal borides. A strong emphasis is placed on correlating mechanical properties with electronic and atomic structure of these materials in an effort to better predict new superhard compounds. It concludes with a perspective of future research directions, highlighting some recent results and presenting several new ideas that remain to be tested.

Single crystals of ReB(2) have been prepared from an aluminum flux under inert gas flow. The crystals are typically 1-3 mm in diameter and 500 microm thick, growing along the [002] direction with a distinct hexagonal morphology. Vickers microhardness and nanoindentation testing indicate that the (002) plane possesses the highest hardness with measured values of 40.5 and 36.4 GPa, respectively. The elastic anisotropy was examined and the indentation moduli of the basal plane and an (hk0) plane of unknown indices are 675 and 510 GPa, respectively. Four-probe electrical resistivity measurements demonstrate that ReB(2) is the hardest material known to exhibit metallic behavior. Thermogravimetric analysis indicates that the crystals are stable in air up to 1000 degrees C due to the formation of a protective boron oxide coating.

Dubrovinskaia et al . question our demonstration that rhenium diboride (ReB 2 ) is hard enough to scratch diamond. Here, we provide conclusive evidence of a scratch through atomic force microscopy depth profiling and elemental mapping. With high hardness, high-bulk modulus, and the ability to withstand extreme differential stress, ReB 2 and related materials should be investigated regardless of their cost, which is not prohibitive.