Abstract:
A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix embedding a filler (38) includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal with an oxidant and, optionally, one or more metallic constituents, and the filler (38) embedded by the matrix. The method includes heating the parent metal to provide a first source (36) of molten parent metal and a reservoir (34) of molten parent metal and contacting the first source (36) of molten parent metal with a permeable bedding of filler (38). The first source (36) of molten parent metal is reacted with the oxidant to form the oxidation reaction product and is replenished from the reservoir (34) as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired boundary and thereby embed at least a portion of the bedding of filler (38) within the oxidation reaction product to form the ceramic composite structure. The bedding of filler (38) may have any suitable shape, including that of a hollow body, the interior of which is contacted by the first source (36) of molten parent metal to grow the oxidation reaction product through the shaped, hollow body of filler.
Abstract:
A method of producing self-supporting ceramic bodies (12) having a polymer component, which includes first providing a self-supporting ceramic body (12) comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal with an oxidant, and (ii) interconnected porosity (13) at least partially accessible from one or more surfaces of said ceramic body. The polymer is disposed or formed within the interconnected porosity (13). The polymer is situated so as to alter, modify or contribute to the properties of the ceramic body (12) originally formed.
Abstract:
A method for producing a self-supporting ceramic composite which comprises preparing a polycrystalline material as the oxidation reaction product of a parent metal with a vapor-phase oxidant, comminuting the resulting material to a particulate, forming a permeable mass of said particulate as filler, and infiltrating said particulate with an oxidation reaction product of a parent metal with a vapor-phase oxidant, thereby forming said ceramic composite.
Abstract:
A method of producing self-supporting ceramic composite bodies of desired shaped by infiltrating a permeable preform with polycrystalline matrix material consisting essentially of an oxidation reaction product obtained by oxidation of a parent metal precursor, such as aluminum, and optionally containing therein metallic constituents. The composite body is formed by contacting a zone of a permeable preform, having at least one defined surface boundary spaced from said contacting zone, with a body of molten metal which is reacted with a suitable vapor-phase oxidant to form an oxidation reaction product. Within a certain temperature region, and optionally with one or more dopants in or on the parent metal or said permeable preform, molten parent metal migrates through previously formed oxidation reaction product into contact with the oxidant, causing the oxidation reaction product to grow into the preform toward said defined surface boundary so as to infiltrate the preform up to said defined surface boundary, and provide the composite structure of desired geometry.
Abstract:
A method for producing a self-supporting ceramic composite body having a negative pattern which inversely replicates the positive pattern of a parent metal precursor (2) having thereon a positive pattern section (4,6,8,9) which is emplaced in conforming engagement with a bed of conformable filler (14). The parent metal precursor (2), which also has a non-replicating section, is melted and reacted with an oxidant to form a polycrystalline oxidation reaction product which grows primarily only from the positive pattern section of the parent metal precursor (2) and through the filler (14). The molten parent metal is drawn through the growing polycrystalline material and oxidized at the interface between the oxidant and previously formed oxidation reaction product. The reaction is continued for sufficient time to at least partially embed the filler (14) within the oxidation reaction product and form the ceramic composite body containing a negative pattern which inversely replicates the positive pattern of the parent metal precursor (2).
Abstract:
A method of producing self-supporting ceramic bodies (12) having a polymer component, which includes first providing a self-supporting ceramic body (12) comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal with an oxidant, and (ii) interconnected porosity (13) at least partially accessible from one or more surfaces of said ceramic body. The polymer is disposed or formed within the interconnected porosity (13). The polymer is situated so as to alter, modify or contribute to the properties of the ceramic body (12) originally formed.