Abstract:
This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds and sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat.
Abstract:
A silicon carbide ceramic having crystalline grain boundary phases is prepared by heating a composition comprising silicon carbide, a silicate glass and a high metal content transition metal silicide, to a temperature of 1300 DEG to 2100 DEG C under vacuum until oxygen is removed from the glass as SiO gas, and the glass that remains within the silicon carbide ceramic crystallizes.
Abstract:
The present invention relates to an improved filler material for use in forming metal matrix composites. Particularly, the filler has specific characteristics which enhance formation processes and/or improve the mechanical and/or physical properties of resultant metal matrix composite bodies.
Abstract:
This invention relates to a novel method for producing self-supporting composite bodies, formed by the oxidation reaction of a parent metal and a solid-phase oxidant to produce at least one oxidation reaction product comprising, in most cases, at least one intermetallic phase, and, optionally, having at least one metallic component introduced during formation of the body to impart certain properties to the formed body. The invention also relates to formation of, in some cases, ceramic phases in addition to the intermetallic phase(s).
Abstract:
The present invention relates to a novel process 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 molten matrix metal is provided in a unique manner which enhances the spontaneous infiltration process.
Abstract:
The present invention relates to a novel process for forming metal matrix composite bodies by using a barrier material. 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 up to the barrier material. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vaccum. Accordingly, shaped metal matrix composite bodies can be produced having superior surface finish.
Abstract:
The present invention relates to the use of a gating means (3) in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform (2) is spontaneously infiltrated by molten matrix metal (5) to form a metal matrix composite body. A gating means (3) is provided which controls or limits the areal contact between molten matrix metal (5) and the filler material or preform (2). The use of a gating means (3) provides for control of the amount of matrix metal (5) which can contact the preform (2) or filler material, which may result in less machining of a formed metal matrix composite body compared with a similar metal matrix composite body made without a gating means (3). Moreover, the use of a gating means (3) ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.