Sapphires can be treated by several methods to enhance and improve their clarity and color. The inclusions in natural stones are easily seen with a
jeweler's loupe. Evidence of sapphire and other gemstones being subjected to heating goes back at least to Roman times. Un-heated natural stones are somewhat rare and will often be sold accompanied by a certificate from an independent gemological laboratory attesting to "no evidence of heat treatment".
Yogo sapphires do not need heat treating because their
cornflower blue color is attractive out of the ground; they are generally free of
inclusions, and have high uniform clarity. When Intergem Limited began marketing the Yogo in the 1980s as the world's only guaranteed untreated sapphire, heat treatment was not commonly disclosed; by the late 1980s, heat treatment became a major issue. At that time, much of all the world's sapphires were being heated to enhance their natural color. Intergem's marketing of guaranteed untreated Yogos set them against many in the gem industry. This issue appeared as a front-page story in
The Wall Street Journal on 29 August 1984 in an article by Bill Richards,
Carats and Schticks: Sapphire Marketer Upsets The Gem Industry. It was later applied to natural sapphire. Today, titanium diffusion often uses a synthetic colorless sapphire base. The color layer created by titanium diffusion is extremely thin (less than 0.5 mm). Thus repolishing can and does produce slight to significant loss of color. Chromium diffusion has been attempted, but was abandoned due to the slow diffusion rates of chromium in corundum. In the year 2000, beryllium diffused "padparadscha" colored sapphires entered the market. Typically
beryllium is diffused into a sapphire under very high heat, just below the melting point of the sapphire. Initially () orange sapphires were created, although now the process has been advanced and many colors of sapphire are often treated with beryllium. Due to the small size of the beryllium ion, the color penetration is far greater than with titanium diffusion. In some cases, it may penetrate the entire stone. Beryllium-diffused orange sapphires may be difficult to detect, requiring advanced chemical analysis by gemological labs (e.g., Gübelin,
SSEF,
GIA, American Gemological Laboratories (AGL), and
Lotus Gemology There are several ways of treating sapphire. Heat-treatment in a reducing or oxidizing atmosphere (but without the use of any other added impurities) is commonly used to improve the color of sapphires, and this process is sometimes known as "heating only" in the gem trade. In contrast, however, heat treatment combined with the deliberate addition of certain specific impurities (e.g. beryllium, titanium, iron, chromium or nickel, which are absorbed into the crystal structure of the sapphire) is also commonly performed, and this process can be known as "diffusion" in the gem trade. However, despite what the terms "heating only" and "diffusion" might suggest, both of these categories of treatment actually involve diffusion processes. The most complete description of corundum treatments extant can be found in Chapter 6 of ''Ruby & Sapphire: A Gemologist's Guide'' (chapter authored by John Emmett, Richard Hughes and Troy R. Douthit). In the flame-fusion (
Verneuil process), fine
alumina powder is added to an
oxyhydrogen flame, and this is directed downward against a ceramic pedestal. Following the successful synthesis of ruby, Verneuil focused his efforts on sapphire. Synthesis of blue sapphire came in 1909, after chemical analyses of sapphire suggested to Verneuil that iron and titanium were the cause of the blue color. Verneuil patented the process of producing synthetic blue sapphire in 1911.
Dopants 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
geological samples. 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 the 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 by Polish chemist
Jan Czochralski. In this process, a tiny sapphire seed crystal is dipped into a crucible made of the precious metal
iridium or
molybdenum, containing molten alumina, and then slowly withdrawn upward at a rate of 1 to 100 mm per hour. The alumina crystallizes on the end, creating long carrot-shaped boules of large size up to 200 kg in mass. One popular variant of the Czochralski method is the
Kyropoulos method which has the advantage of using all of the feedstock material such as aluminum oxide to create sapphire and crucibles do not have to be replaced. This is one of the main production methods for synthetic sapphire. However, the original Czochralski method can also be used.
Other growth methods Synthetic sapphire is also produced industrially from agglomerated aluminum oxide, sintered and fused (such as by
hot isostatic pressing) in an inert atmosphere, yielding a transparent but slightly
porous polycrystalline product. Another popular method is the Heat Exchanger Method (HEM), in which aluminum oxide is placed in a molybdenum crucible and heated until melting at 2200°C. It allows for very large crystals over 30 cm wide to be produced. The process takes place in a vacuum. A sapphire seed crystal sits at the bottom of the crucible and is kept from melting by heat exchange (cooling) with helium gas or liquid helium which is shielded from the vacuum. The furnace is kept at a temperature just above melting, but the heat exchanger is at a temperature just below melting. Then the heat exchanger temperature is lowered to start crystalization, and then the aluminum oxide is cooled over a period of at least 72 hours to 17 days to crystalize it into sapphire. The crucibles are single use, the process is similar to the
Bridgman technique and the Stöber methods for crystal growth, and was used for iPhone screens. The crystal grows upward from the bottom of the crucible. Another method is the Edge-defined Film-fed Growth (EFG) method, very similar to the Czochralski method but the material passes through a die before cooling, which shapes the crystal. The crystal does not rotate. Chemical Vapor Deposition (CVD), gradient furnace or vertical bridgman processes can be used for sapphire crystal growth. In 2003, the world's production of synthetic sapphire was 250 tons (1.25 billion carats), mostly by the United States and Russia. The availability of cheap synthetic sapphire unlocked many industrial uses for this unique material.
Applications Equipment windows with synthetic sapphire watch crystal Synthetic sapphire—also referred to as
sapphire glass—is commonly used for small windows, because it is both highly transparent to wavelengths of light between 150 nm (
UV) and 5500 nm (
IR) (the visible
spectrum extends about 380 nm to 750 nm), and extraordinarily scratch-resistant. The key benefits of sapphire windows are: • Very wide optical transmission band from
UV to
near infrared (0.15–5.5 μm) • Significantly stronger than other optical materials or standard glass windows • Highly resistant to scratching and abrasion (9 on the
Mohs scale of mineral hardness scale, the third-hardest natural substance next to
moissanite and diamonds) Approximately in diameter, weighing approximately . (A second boule is visible in the background.) Some sapphire-glass windows are made from pure sapphire boules that have been grown in a specific crystal orientation, typically along the optical axis, the
c axis, for minimum
birefringence for the application. The boules are sliced up into the desired window thickness and finally polished to the desired surface finish. Sapphire optical windows can be polished to a wide range of surface finishes due to its crystal structure and its hardness. The surface finishes of optical windows are normally called out by the scratch-dig specifications in accordance with the globally adopted MIL-O-13830 specification. Sapphire windows are used in both high-pressure and vacuum chambers for
spectroscopy, crystals for
watches, and windows in grocery-store
barcode scanners, since the material's exceptional hardness and toughness makes it very resistant to scratching. Several attempts have been made to make sapphire screens for smartphones viable. Apple contracted GT Advanced Technologies, Inc. to manufacture sapphire screens for iPhones, but the venture failed, causing the bankruptcy of GTAT. The
Kyocera Brigadier was the first production smartphone with a sapphire screen. Sapphire is used for end windows on some high-powered laser tubes, as its wide-band transparency and thermal conductivity allow it to handle very high power densities in the infrared and UV spectrum without degrading due to heating. One type of
xenon arc lamporiginally called the "Cermax" and now known generically as the "ceramic-body xenon lamp"uses sapphire crystal output windows that tolerate higher thermal loads and consequently can provide higher output powers than conventional Xe lamps with pure
silica windows. Sapphire was used for the
F-35 Lightning 2 Electro Optical Targeting System window, due to its high strength. Along with
zirconia and
aluminum oxynitride, synthetic sapphire is used for shatter-resistant windows in armored vehicles and various military
body armor suits, in association with composites.
As substrate for semiconducting circuits Thin sapphire wafers were the first successful use of an insulating
substrate upon which to deposit silicon to make the
integrated circuits known as
silicon on sapphire or "SOS"; now other substrates can also be used for the class of circuits known more generally as
silicon on insulator. Besides its excellent electrical insulating properties, sapphire has high
thermal conductivity.
CMOS chips on sapphire are especially useful for high-power radio-frequency (RF) applications such as those found in
cellular telephones,
public-safety band radios, and
satellite communication systems. "SOS" also allows for the monolithic integration of both
digital and
analog circuitry all on one IC chip, and the construction of extremely low power circuits. Wafers of single-crystal sapphire are also used in the
semiconductor industry as
substrates for the growth of devices based on
gallium nitride (GaN). The use of sapphire significantly reduces the cost, because it has about one-seventh the cost of
germanium. Gallium nitride on sapphire is commonly used in blue
light-emitting diodes (LEDs).
In lasers The first
laser was made in 1960 by
Theodore Maiman 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.
In endoprostheses Monocrystalline sapphire is fairly biocompatible and the exceptionally low wear of sapphire–metal pairs has led to the introduction (in Ukraine) of sapphire monocrystals for hip joint
endoprostheses. ==Historical and cultural references==