Synthetic
In 1902, the French chemist Auguste Verneuil developed a process for producing synthetic sapphire crystals. In the Verneuil process, named for him, fine alumina powder is added to an oxyhydrogen flame, and this is directed downward against a mantle. The alumina in the flame is slowly deposited, creating a teardrop shaped "boule" of sapphire material. Chemical dopants can be added to create artificial versions of the ruby, and all the other natural colors of sapphire, and in addition, other colors never seen in geology.
Artificial sapphire material is identical to natural sapphire, except it can be made without the flaws that are found in natural stones. The disadvantage of Verneuil process is that the grown crystals have high internal strains. Many methods of manufacturing sapphire today are variations of the Czochralski process, which was invented in 1916. In this process, a tiny sapphire seed crystal is dipped into a crucible made of the precious metal rhodium, containing molten alumina, and the slowly withdrawn upward at a rate of one to 100 mm per hour.
The alumina crystallizes on the end, creating long carrot-shaped boules of large size, up to 400 mm in diameter and weighing almost 500 kg.
In 2003, the world's production of synthetic sapphire was 250 tons (1.25 × 109 carats), mostly by the United States and Russia. The availability of cheap synthetic sapphire unlocked many industrial uses for this unique material:
The first laser was made with a rod of synthetic ruby. Titanium-sapphire lasers are popular due to their relatively rare capacity to be tuned to various wavelengths in the red and near-infrared region of the electromagnetic spectrum. They can also be easily mode-locked. In these lasers, a synthetically-produced sapphire crystal with chromium or titanium impurities is irradiated with intense light from a special lamp, or another laser, to create stimulated emission.
One application of synthetic sapphire is sapphire glass. Here glass is a layman term which refers not to the amorphous state, but to the transparency. Sapphire is not only highly transparent to wavelengths of light between 170 nm to 5.3 μm (the human eye can discern wavelengths from about 380 nm to 750 nm), but it is also five times stronger than glass and ranks a 9 on the Mohs Scale, and much tougher than tempered glass although not as much as synthetic stabilized zirconium oxide (such as yttria-stabilized zirconia).
Along with zirconia and aluminium oxynitride, synthetic sapphire is used for shatter resistant windows in armored vehicles and various military body armor suits, in association with composites. Sapphire "glass" (although being crystalline) is made from pure sapphire boules by slicing off and polishing thin wafers. Sapphire glass windows are used in high pressure chambers for spectroscopy, crystals in high quality watches, and windows in grocery store barcode scanners since the material's exceptional hardness and toughness makes it very resistant to scratching.
Cermax xenon arc lamp with synthetic sapphire output window
Synthetic sapphire is industrially produced from agglomerated aluminum oxide, sintered and fused in an inert atmosphere (hot isostatic pressing for example), yielding a transparent polycrystalline product, slightly porous, or with more traditional methods such as Verneuil, Czochralski, flux method, etc., yielding a single crystal sapphire material which is non-porous and should be relieved of its internal stress.
One type of xenon arc lamp (originally called the "Cermax" its first brand name), which is now known generically as the "ceramic body xenon lamp", uses sapphire crystal output windows that tolerate higher thermal loads - and thus higher output powers when compared with conventional Xe lamps with pure silica window.
Thin sapphire wafers are also used as an insulating substrate in high-power, high-frequency CMOS integrated circuits. This type of IC is called a silicon on sapphire or "SOS" chip. These are especially useful for high-power radio-frequency (RF) applications such as those found in cellular telephones, police car and fire truck radios, and satellite communication systems. "SOS" allows for the monolithic integration of both digital and analog circuitry all on one IC chip.
The reason for choosing wafers of artificial sapphire, rather than some of other substance, for these subtrates is that sapphire has a quite low conductivity for electricity, but a much-higher conductivity for heat. Thus, sapphire provides good electrical insulation, while at the same time doing a good job at helping to conduct away the significant heat that is generated in all operating integrated circuits.
Thus, the choice of sapphire material for these substrates was not an arbitrary one, but rather, it is a choice that is made for serious electronics engineering reasons.
Wafers of single-crystal sapphire material are also used in the semiconductor industry as a non-conducting substrate for the growth of devices based on gallium nitride (GaN). The use of the sapphire material significantly reduces the cost, because this has about one-seventh the cost of germanium. Gallium nitride on sapphire is commonly used in blue light-emitting diodes (LEDs).