Abstract:
This invention relates generally to a novel method for forming a self-supporting body. Specifically, the formed self-supporting body has a higher volume percent of metallic constituent relative to a body formed by similar techniques. A first porous self-supporting body is formed by reactively infiltrating a molten parent metal into a bed or mass containing a boron donor material and a carbon donor material (e.g., boron carbide) and/or a boron donor material and a nitrogen material (e.g., boron nitride) and, optionally, one or more inert fillers. Additionally, powdered parent metal may be admixed with a mass to be reactively infiltrated to form additional porosity therein. The porous self-supporting body which is formed by the reactive infiltration process according to this invention should contain at least some interconnected porosity which is capable of being filled in a subsequent step with additional metal, thus increasing the volume percent of parent metal in the body at the expense of porosity.
Abstract:
This invention relates generally to a reaction which occurs on the surface of a substrate body. Particularly, at least one solid oxidant is contacted with at least one parent metal to result in a reaction therebetween and the formation of a reaction product on the surface of a substrate body.
Abstract:
This invention broadly relates to methods for producing self-supporting silicon carbide and silicon carbide composite bodies. More particularly, this invention relates to silicon carbide and silicon carbide composites, grown by the oxidation reaction of a silicon metal with a gas comprising at least one gas selected from the group consisting of fluorinated hydrocarbon gases, chlorohydrocarbon gases and chlorofluorocarbon gases.
Abstract:
The present invention relates to the formation of bodies having graded properties. Particularly, the invention provides a method for forming a metal matrix composite body having graded properties. The graded properties are achieved by, for example, locating differing amounts of filler material in different portions of a formed body and/or locating different compositions of filler material in different portions of a formed body and/or locating different sizes of filler materials in different portions of a formed body. In addition, the invention provides for the formation of macrocomposite bodies wherein, for example, an excess of matrix metal can be integrally bonded or attached to a graded metal matrix composite portion of a macrocomposite body.
Abstract:
This invention relates generally to a novel process for making self-supporting polymer matrix composite bodies, and the novel products produced thereby. More specifically, an appropriate filler material is caused to be placed within a particular polymer material, whereby the polymer material functions as a matrix and the filler material synergistically interacts with the polymer to form a novel composite body. By combining specific polymer matrix materials with specific filler or reinforcing materials, very desirable wear parts can be fabricated.
Abstract:
This invention relates generally to the fabrication of materials for use as tools (22) in various applications. Specific emphasis is placed upon certain ceramic matrix composite materials and metal matrix composite materials for use as tools as well as certain ceramic matrix composite and/or metal matrix composite coatings on substrate materials, also for use as tools. This invention makes specific reference to a number of different materials for use as tools in the molding of thermoplastic materials (e.g., polymers, plastics, ceramics, glasses, metals) with particular emphasis being directed to the thermoplastic molding of plastics or polymers.
Abstract:
This invention relates generally to a novel method for joining at least one first self-supporting body to at least one second self-supporting body which is similar in composition to or different in composition from said at least one first self-supporting body and to novel products which result from such joining. In some of its more specific aspects, this invention relates to different techniques for joining ceramic matrix composite bodies to other ceramic matrix composite bodies of similar characteristics and for joining ceramic matrix composite bodies to bodies which have different characteristics (e.g., metals). The ceramic matrix composite bodies of this invention are produced by a reactive infiltration of a molten parent metal into a bed or mass containing at least one of a boron source material, a carbon source material, and a nitrogen source material and, optionally, one or more inert fillers.
Abstract:
The present invention relates to a novel process for forming a filler material which can be used in various metal matrix composite formation processes for forming metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. The amount of matrix metal provided is sufficient only to coat, to a desired thickness, substantially all of the filler material. The coated filler material is thereafter comminuted for use in any desired metal matrix composite formation process.
Abstract:
The present invention relates to the formation of a macrocomposite body for use as an electronic package or container. The macrocomposite body is formed by spontaneously infiltrating a permeable mass of filler material (247) or a preform with molten matrix metal (250) and bonding the spontaneously infiltrated material to at least one second material such as a ceramic or ceramic containing body and/or a metal or metal containing body. Moreover, prior to infiltration, the filler material or preform is placed into contact with at least a portion of a second material such that after infiltration of the filler material or preform by molten matrix metal, the infiltrated material is bonded to said second material, thereby forming a macrocomposite body. The macrocomposite body may then be coated by techniques according to the present invention to enhance its perfomance and/or bonding capabilities.
Abstract:
The present invention relates to coated optical devices, such as optical fibers and optical wave guides, and methods for forming coated optical devices. Methods for forming coated optical devices comprise providing at least one optical device and contacting at least a portion of at least one optical device with at least one coating composition comprising at least one metal-nitrogen polymer. The at least one coating composition may further comprise at least one multifunctional organic electrophile comprising at least one monomer, oligomer, or polymer comprising a plurality of organic electrophilic substituents. The coating composition contacting at least a portion of an optical device is at least partially crosslinked, thereby forming coated optical devices which exhibit enhanced resistance to, for example, deterioration resulting from, among other things, exposure to chemicals and environmental factors.