公开(公告)号：ES2033915T3

公开(公告)日：1993-04-01

申请号：ES87630176

申请日：1987-09-03

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： NEWKIRK, MARC S. ,  DWIVEDI, RATNESH K. ,  LESHER, H. DANIEL ,  KANTNER, ROBERT C.

IPC: B22D19/14 ,  B28B7/34 ,  C04B35/10 ,  C04B35/622 ,  C04B35/65 ,  C04B35/653 ,  C04B35/71

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.

公开(公告)号：ES2000418T3

公开(公告)日：1993-02-16

申请号：ES87630075

申请日：1987-04-30

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： NEWKIRK, MARC S. ,  ZWICKER, SHIRLEY L.

IPC: C04B35/10 ,  C04B35/565 ,  C04B35/622 ,  C04B35/65 ,  C04B35/71 ,  C04B35/80

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.

公开(公告)号：ES2031923T3

公开(公告)日：1993-01-01

申请号：ES87630179

申请日：1987-09-03

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： LUSZCZ, STANLEY J. ,  URQUHART, ANDREW W. ,  NEWKIRK, MARC S.

IPC: C04B35/65 ,  C04B37/00

Abstract: Ceramic bodies are bonded by providing a first body formed of polycrystalline material and interconnected residual metal formed by the oxidn. reaction of molten metal and a vapour phase oxidant and grown as molten metal is transported through and then oxidised on the surface of its own oxidn. reaction prod.; holding a second ceramic body against a surface of the first; and heating so that the residual metal content of the first body is transported to the interface where an oxidn. reaction prod. continues to grown as above and forms a bond. - Specifically the metal is Al, oxidant is air and oxidn. reaction prod. is Al2O3. The first body may be formed by infiltrating a filler with oxidn. reaction prod. A barrier material, pref. Ca sulphate, silicate or phosphate or Portland cement, is used to embed and surround all surfaces of the first body except the contacting surface. A body of metal may be placed in contact with another surface of the first body embedded in the barrier material, so that the metal melts and is transported to the bonding interface during the heating step. The second body may have the same ceramic compsn. as the first; it may be made by a different method; or may be of a different compsn. but made by the same method. Pref. the reaction prod. is an oxide, nitride or carbide and the metal is Ti, Si, Zr, Hf or Sn.

公开(公告)号：ES2038201T3

公开(公告)日：1993-07-16

申请号：ES87630133

申请日：1987-07-28

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： NEWKIRK, MARC S. ,  URQUHART, ANDREW W. ,  ZWICKER, HARRY R.

IPC: C04B35/622 ,  C04B35/10 ,  C04B35/65 ,  C04B41/51 ,  C04B41/88 ,  C22C1/10 ,  C22C29/12 ,  C23C10/22

Abstract: A method of producing self-supporting ceramic bodies (10) having a modified metal-containing component includes first providing a self-supporting ceramic body (10) comprising (i) a polycrystalline oxidation reaction product (12) formed upon oxidation of a molten parent metal precursor with an oxidant, and (ii) an interconnected metal-containing component (14) at least partially accessible from one or more surfaces (15) of said ceramic body (10). The surface or surfaces (15) of the ceramic body (10) is contacted with a quantity of foreign metal different from said interconnected metal-containing component (14) at a temperature and for a time sufficient to allow for interdiffusion, whereby at least a portion of said metal-containing component (14) is displaced by said foreign metal. The resulting ceramic body, having an altered metal-containing component, exhibits modified or improved properties.

公开(公告)号：ES2036595T3

公开(公告)日：1993-06-01

申请号：ES87630183

申请日：1987-09-10

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： KENNEDY, CHRISTOPHER R. ,  URQUHART, ANDREW W. ,  WHITE, DANNY R. ,  NEWKIRK, MARC S.

IPC: C04B35/622 ,  C04B35/10 ,  C04B35/65 ,  C22C1/10 ,  C22C29/12 ,  C22C29/16

Abstract: A method is disclosed for producing a ceramic body by oxidation of a parent metal, the ceramic body having a graded microstructure characterized by a plurality of zones differing from each other in one or more properties. The zones in the ceramic body are attained by altering the process conditions during formation of said ceramic body such that a zone of the oxidation reaction product formed posterior to said altering has one or more properties different from a zone of the oxidation reaction product formed anterior to said altering.

公开(公告)号：ES2032854T3

公开(公告)日：1993-03-01

申请号：ES87630178

申请日：1987-09-03

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： NEWKIRK, MARC S. ,  WEINSTEIN, JERRY

IPC: C04B35/622 ,  B22F3/26 ,  C04B35/10 ,  C04B35/65 ,  C04B41/87 ,  C22C1/10 ,  C22C29/12

Abstract: A method of producing self-supporting ceramic structures includes providing a first self-supporting ceramic body (10) comprising (i) a polycrystalline oxidation reaction product (12) formed upon oxidation of a first molten parent metal with a first oxidant, and (ii) interconnected porosity (13) at least partially accessible from one or more surfaces (15) of said first ceramic body (10). A second ceramic body is used to form, by reaction with a vapor-phase oxidant, a second polycrystalline material which is infiltrated into the porosity of at least a zone of said first ceramic body (10).

公开(公告)号：ES2028061T3

公开(公告)日：1992-07-01

申请号：ES87300409

申请日：1987-01-19

Applicant: LANXIDE TECHNOLOGY COMPANY, LP.

Inventor： NEWKIRK, MARC S. ,  URQUHART, ANDREW W. ,  LESHER, H. DANIEL

IPC: C04B35/622 ,  C04B35/117 ,  C04B35/65

Abstract: A method of producing a self-supporting ceramic composite body having therein at least one cavity which inversely replicates the geometry of a positive mold of parent metal, includes embedding the mold of parent metal within a conformable bed of filler to provide therein a cavity shaped and filled by the mold. The assembly is heated to melt the parent metal mold, e.g., an aluminum parent metal mold, and contacted with an oxidant to oxidize the molten parent metal to form a polycrystalline material which grows through the surroundings of filler, the molten metal being drawn through the growing polycrystalline material to be oxidized at the interface between the oxidant and previously formed oxidation reaction product whereby the cavity formerly filled by the mold of parent metal is eventually evacuated by the metal. There remains behind a cavity whose shape inversely replicates the original shape of the mold. The method provides ceramic composite articles having therein at least one cavity inversely replicating the shape of the mold which supplied the parent metal for oxidation.