公开(公告)号：US20110135948A1

公开(公告)日：2011-06-09

申请号：US10551727

申请日：2004-04-08

Applicant: Aleksander J. Pyzik ,  Ted A. Morgan ,  Terry I. Hu ,  Daniel R. Lister ,  Robert A. Newman ,  Richard Allen Lungard ,  Qin Deng

Inventor： Aleksander J. Pyzik ,  Ted A. Morgan ,  Terry I. Hu ,  Daniel R. Lister ,  Robert A. Newman ,  Richard Allen Lungard ,  Qin Deng

IPC: B32B15/04 ,  C04B35/00 ,  C04B35/14 ,  C04B35/185 ,  C04B35/10 ,  C23C16/30

CPC classification number: C23C14/223 ,  C04B35/62857 ,  C04B35/6286 ,  C04B35/62865 ,  C04B35/62873 ,  C04B35/62876 ,  C04B35/62884 ,  C04B35/62894 ,  C04B2235/3217 ,  C04B2235/3418 ,  C04B2235/3804 ,  C22C1/101 ,  C22C1/1036 ,  C22C47/04 ,  C22C47/06 ,  C22C2001/1021 ,  C23C14/0641 ,  C23C14/067 ,  Y10T428/12007 ,  Y10T428/31678

Abstract: In one embodiment, a composition (10) to be mixed with a molten metal to make a metal matrix composite, the composition characterized by: a ceramic reinforcing filler (12), the ceramic reinforcing filler not being wettable by molten aluminum and/or not being chemically stable in molten aluminum, the ceramic reinforcing filler being coated with a ceramic material, the ceramic material being wettable by and chemically stable in molten aluminum. In a related embodiment, a composition (20) to make a porous preform to be infiltrated by molten metal to make a metal matrix composite, the composition characterized by: a ceramic reinforcing filler (23), the ceramic reinforcing filler not being wettable by molten aluminum, the ceramic reinforcing filler being coated with a ceramic material (22) and optionally with a metal (21) such as nickel, the ceramic material being wettable by molten aluminum. The ceramic material can be coated on the ceramic reinforcing filler by a vacuum deposition technique such as vacuum sputtering.

Abstract translation: 在一个实施方案中，与熔融金属混合以制备金属基质复合材料的组合物（10），所述组合物的特征在于：陶瓷增强填料（12），所述陶瓷增强填料不能被熔融铝和/或不熔化 在熔融铝中化学稳定，陶瓷增强填料用陶瓷材料涂覆，陶瓷材料可在熔融铝中润湿并化学稳定。 在相关实施例中，一种组合物（20），用于使多孔预成型体浸入熔融金属中以制成金属基质复合物，该组合物的特征在于：陶瓷增强填料（23），陶瓷增强填料不能被熔融 铝，陶瓷增强填料涂覆有陶瓷材料（22）和任选地与金属（21）如镍，陶瓷材料可被熔融的铝润湿。 陶瓷材料可以通过真空沉积技术如真空溅射涂覆在陶瓷增强填料上。

公开(公告)号：US5780164A

公开(公告)日：1998-07-14

申请号：US496798

申请日：1995-06-29

Applicant: Aleksander J. Pyzik ,  Uday V. Deshmukh ,  Chan Han ,  Kevin J. Nilsen ,  Donald J. Perettie ,  Arthur R. Prunier, Jr.

Inventor： Aleksander J. Pyzik ,  Uday V. Deshmukh ,  Chan Han ,  Kevin J. Nilsen ,  Donald J. Perettie ,  Arthur R. Prunier, Jr.

IPC: C04B41/88 ,  C22C1/10 ,  C22C29/00 ,  C22C29/06 ,  C22C32/00 ,  G11B5/596 ,  G11B5/62 ,  G11B5/73 ,  G11B5/82 ,  G11B5/84 ,  G11B23/00 ,  H01L23/15 ,  B22F3/26

CPC classification number: G11B5/7315 ,  C22C1/1036 ,  C22C29/062 ,  C22C32/0057 ,  G11B23/0064 ,  G11B5/731 ,  G11B5/82 ,  G11B5/8404 ,  H01L23/15 ,  B22F2998/00 ,  G11B5/596 ,  H01L2924/0002 ,  H01L2924/09701 ,  Y10T428/12028 ,  Y10T428/12049 ,  Y10T428/12056 ,  Y10T428/12063 ,  Y10T428/12069 ,  Y10T428/249994 ,  Y10T428/256

Abstract: A hard drive disk substrate is formed of a multi-phase ceramic-based material having at least two phases with amorphous phases being present in an amount less than about 1 volume percent based on the volume of the ceramic-based material or at least one phase being free metal. A process for producing the ceramic-based disk substrate is produced by forming a flat disk of a porous ceramic and then infiltrating the porous ceramic with a metal whereby a multi-phase ceramic-based computer hard drive disk is produced. Additionally, a step of passivating the porous ceramic by elevating it to a temperature of about 1300.degree. to about 1800.degree. C. before the infiltrating step may be performed, such that the surfaces are passivated and the reaction kinetics can be controlled during the infiltrating step. A preferred composite material is made of a multi-phase boron carbide composite material including grains having peaks with an average roughness value, Ra, of between about 1 to about 200 .ANG., the roughness value being formed in situ by causing a micro hardness gradient of between about 19 and about 3200 Kg/mm.sup.2 in the various phases of the multi-phase boron carbide composite material.

Abstract translation: 硬盘驱动器盘基板由具有至少两相的多相陶瓷基材料形成，其中无定形相以基于陶瓷基材料的体积或至少一相的量存在的量小于约1体积％ 是免费金属。 通过形成多孔陶瓷的平板，然后用金属渗透多孔陶瓷来制造陶瓷基盘基板的方法，由此制造多相陶瓷基计算机硬盘驱动盘。 此外，可以在渗透步骤之前将其升高至约1300℃至约1800℃的温度来钝化多孔陶瓷的步骤，使得表面被钝化，并且可以在渗透步骤期间控制反应动力学 。 优选的复合材料由多相碳化硼复合材料制成，其包括具有平均粗糙度值Ra的峰值在约1至约200之间的晶粒，该粗糙度值通过使原位形成的微观硬度梯度 在多相碳化硼复合材料的各个相中约19至约3200Kg / mm 2。

公开(公告)号：US5298468A

公开(公告)日：1994-03-29

申请号：US960612

申请日：1992-10-13

Applicant: Aleksander J. Pyzik

Inventor： Aleksander J. Pyzik

IPC: B22F3/15 ,  C22C1/05 ,  C22C29/06 ,  C04B35/56

CPC classification number: B22F3/156 ,  C22C1/058 ,  C22C29/062 ,  B22F2998/00

Abstract: Densified boron carbide-aluminum, ceramic-metal composites that are substantially free of AlB.sub.12, AlB.sub.12 C.sub.2 and Al.sub.4 C.sub.3 result from a two stage process. Admixtures of boron carbide are densified under pressure in stage one, In stage two, the densified admixture is heat treated. In both stages, the temperature is less than 800.degree. C. If the temperatures do not exceed 600.degree. C., the resultant densified cermet has only three phases: a) boron carbide; b) Al.sub.4 BC; and c) aluminum.

Abstract translation: 基本上不含AlB12，AlB12C2和Al4C3的致密碳化硼 - 铝，陶瓷 - 金属复合材料来自两阶段工艺。 在第一阶段，碳化硼的外加剂在压力下致密化。在第二阶段中，将致密化的混合物进行热处理。 在两个阶段中，温度低于800摄氏度。如果温度不超过600摄氏度，则所得到的致密金属陶瓷只有三个阶段：a）碳化硼; b）Al4BC; 和c）铝。

公开(公告)号：US5269989A

公开(公告)日：1993-12-14

申请号：US938633

申请日：1992-09-01

Applicant: Aleksander J. Pyzik

Inventor： Aleksander J. Pyzik

IPC: C04B41/85 ,  C03C14/00 ,  C04B30/02 ,  C04B38/00 ,  C04B41/88 ,  C22C1/10 ,  C22C29/16 ,  C22C47/00 ,  C22C47/08 ,  C22C47/12 ,  C22C49/00 ,  C22C49/06 ,  C22C49/08 ,  C22C49/11 ,  C04E35/58

CPC classification number: C22C1/1015 ,  C03C14/00 ,  C04B30/02 ,  C04B38/00 ,  C22C1/10 ,  C03C2214/06 ,  C03C2214/20 ,  C03C2214/30 ,  C04B2111/00922

Abstract: Infiltrate a porous, self-reinforced .beta.-Si.sub.3 N.sub.4 preform with a metal or a crystallizable glass to yield a composite material. The preform possesses a low glass phase and has a density of from about 50 to about 70 percent of theoretical density. Prepare the .beta.-Si.sub.3 N.sub.4 preform by subjecting a porous body formed from an .alpha.-Si.sub.3 N.sub.4 powder composition to two sequential heat treatments. The first heat treatment occurs below the .alpha.- to .beta.- conversion temperature and results in a strengthened body that can be machined. The second heat treatment occurs above that temperature and yields the self-reinforced .beta.-Si.sub.3 N.sub.4 preform. Conventional infiltration procedures with an infiltrant that is a metal or a glass results in a Si.sub.3 N.sub.4 /metal or Si.sub.3 N.sub.4 /glass composite material that has 50 to 70 percent of its volume occupied by .beta.-Si.sub.3 N.sub.4 whiskers.

Abstract translation: 用金属或可结晶玻璃渗透多孔，自增强β-Si3N4预成型体，得到复合材料。 预制棒具有低玻璃相，并且具有理论密度的约50至约70％的密度。 通过将由α-Si 3 N 4粉末组合物形成的多孔体进行两次连续的热处理来制备β-Si 3 N 4预型体。 第一次热处理发生在α至β转化温度以下，并导致可加工的加强体。 第二次热处理发生在该温度以上，并产生自增强的β-Si 3 N 4预制件。 具有金属或玻璃的渗透剂的常规渗透程序导致Si3N4 /金属或Si3N4 /玻璃复合材料，其具有其β-Si 3 N 4晶须占据其体积的50％至70％。

公开(公告)号：US5120328A

公开(公告)日：1992-06-09

申请号：US657715

申请日：1991-02-19

Applicant: Aleksander J. Pyzik

Inventor： Aleksander J. Pyzik

IPC: C04B35/584 ,  C04B35/593 ,  C04B35/645 ,  C04B35/80

CPC classification number: C04B35/593 ,  C04B35/584 ,  C04B35/5935 ,  C04B35/645 ,  C04B35/806

Abstract: A dense, self-reinforced silicon nitride ceramic prepared by pressureless sintering or low pressure gas sintering. The composition comprises (a) silicon nitride, at least 20 percent of which is in the form of .beta.-silicon nitride whiskers having a high average aspect ratio, (b) from about 2 to about 10 weight percent of a glassy grain boundary phase containing magnesium oxide, yttrium oxide, silica, zirconia, and optionally, one oxide selected from the group consisting of calcium, gallium, indium and hafnium oxides, and (c) a second crystalline phase in an amount ranging from 0.5 to about 5.0 weight percent comprising zirconium oxide, and (d) optionally, crystalline phases of metal zirconium silicide and/or metal zirconium silicon nitride in a combined amount from 0.1 to 3.0 weight percent, wherein the metal is tantalum, calcium, hafnium, gallium or indium, and wherein when the metal is calcium, hafnium, gallium or indium, the same metal occurs as the metal oxide in the glassy phase. The ceramic exhibits high fracture toughness and high fracture strength and has a density of at least 98 percent of theoretical.

Abstract translation: 通过无压烧结或低压气体烧结制备的致密的自增强氮化硅陶瓷。 组合物包含（a）氮化硅，其中至少20％是具有高平均纵横比的β-硅氮化物晶须的形式，（b）约2至约10重量％的玻璃态晶界相，其含有 氧化镁，氧化钇，二氧化硅，氧化锆和任选的一种选自钙，镓，铟和铪氧化物的氧化物，和（c）含量为0.5至约5.0重量％的第二结晶相包含 氧化锆和（d）任选的，金属硅化锆和/或金属氮化硅锆的结晶相，其含量为0.1至3.0重量％，其中金属为钽，钙，铪，镓或铟，并且其中当 金属是钙，铪，镓或铟，与玻璃相中的金属氧化物发生相同的金属。 该陶瓷具有高断裂韧性和高断裂强度，其密度至少为理论值的98％。

公开(公告)号：US5118645A

公开(公告)日：1992-06-02

申请号：US572823

申请日：1990-08-24

Applicant: Aleksander J. Pyzik ,  Harold E. Rossow ,  Douglas B. Schwarz ,  Donald R. Beaman ,  Barbara M. Pyzik ,  William J. Dubensky

Inventor： Aleksander J. Pyzik ,  Harold E. Rossow ,  Douglas B. Schwarz ,  Donald R. Beaman ,  Barbara M. Pyzik ,  William J. Dubensky

IPC: B23P15/28 ,  C04B35/584 ,  C04B35/593 ,  C04B35/645 ,  C04B35/80

CPC classification number: C04B35/645 ,  C04B35/593 ,  C04B35/806

Abstract: A process for preparing a self-reinforced silicon nitride ceramic body of high fracture toughness comprising hot-pressing a powdcer mixture containing silicon nitride, a densification aid such as sodium oxide, a conversion aid such as lanthanum oxide and a compound, such as gallium oxide, which enhances growth of .beta.-silicon nitride whiskers-under conditions such that densification and the in situ formation of .beta.-silicon nitride whiskers having a high aspect ratio occur. A novel silicon nitride ceramic of high fracture toughness and high fracture strength is disclosed comprising a .beta.-silicon nitride crystalline phase wherein at least about 20 volume percent of the phase is in the form of whiskers having an average aspect ratio of at least about 2.5; a glassy second phase containing the densification aid, the conversion aid, the compound which enhances growth of .beta.-silicon nitride whiskers, and an amount of silica; and not greater than about 10 weight percent of the total weight as other phases. The glassy phase may also include a minor amount, e.g., up to 5.0 weight percentg, based upon total weight of the ceramic, of aluminum nitride or boron nitride. The glassy phase optionally includes an amount of a secondary reinforcing material such as silicon carbide whiskers.

Abstract translation: 一种制备高断裂韧性的自增强氮化硅陶瓷体的方法，包括热压含有氮化硅的粉末混合物，致密化助剂如氧化钠，转化助剂如氧化镧和化合物如氧化镓 ，其增强了β-硅氮化物晶须的生长 - 在使得具有高纵横比的β-硅氮化物晶须的致密化和原位形成的条件下。 公开了一种具有高断裂韧性和高断裂强度的新型氮化硅陶瓷，其包括β-氮化硅结晶相，其中该相的至少约20体积百分数为晶须的形式，其平均纵横比为至少约2.5; 含有致密化助剂的玻璃质第二相，转化助剂，增强β-硅氮化物晶须生长的化合物和一定量的二氧化硅; 并且不大于作为其它相的总重量的约10重量％。 玻璃相还可以包括少量，例如，至多5.0重量％，基于陶瓷的总重量，氮化铝或氮化硼。 玻璃相任选地包括一定量的第二增强材料，例如碳化硅晶须。

公开(公告)号：US5098449A

公开(公告)日：1992-03-24

申请号：US657716

申请日：1991-02-19

Applicant: Chinmau J. Hwang ,  Aleksander J. Pyzik

Inventor： Chinmau J. Hwang ,  Aleksander J. Pyzik

IPC: B23P15/28 ,  C04B35/584 ,  C04B35/593 ,  C04B35/645 ,  C04B35/80

CPC classification number: C04B35/645 ,  C04B35/593 ,  C04B35/806

Abstract: A fully densified, self-reinforced silicon nitride ceramic body of high fracture toughness and high fracture strength is disclosed comprising (a) .beta.-silicon nitride in the form of whiskers having an average aspect ratio of at least about 2.5, and (b) a crystalline grain boundary phase having an oxynitride apatite structure, as determined by X-ray crystallography.A process for preparing the above identified silicon nitride body comprising hot-pressing a powder mixture containing silicon nitride; silica; a densification aid including strontium oxide; a conversion aid, such as, yttrium oxide; and a compound, such as, calcium oxide which enhances growth of .beta.-silicon nitride whiskers, under conditions such that densification and the in situ formation of .beta.-silicon nitride whiskers having a high aspect ratio occur, and thereafter annealing the densified composition for a time sufficient to produce a crystalline grain boundary phase having an oxynitride apatite structure.

公开(公告)号：US4961778A

公开(公告)日：1990-10-09

申请号：US143560

申请日：1988-01-13

Applicant: Aleksander J. Pyzik ,  Irving G. Snyder, Jr. ,  Alexander Pechenik ,  Robert R. McDonald

Inventor： Aleksander J. Pyzik ,  Irving G. Snyder, Jr. ,  Alexander Pechenik ,  Robert R. McDonald

IPC: B22F3/15 ,  C22C1/05

CPC classification number: B22F3/156 ,  B22F3/15 ,  C22C1/051 ,  B22F2998/00

Abstract: Substantially dense, void-free ceramic-metal composites are prepared from components characterized by chemical incompatibility and non-wetting behavior. The composites have a final chemistry similar to the starting chemistry and microstructures characterized by ceramic grains similar in size to the starting powder and the presence of metal phase. A method for producing the composites requires forming a homogeneous mixture of ceramic-metal, heating the mixture to a temperature that approximates but is below the temperature at which the metal begins to flow and presssing the mixture at such pressure that compaction and densification of the mixture occurs and an induced temperature spike occurs that exceeds the flowing temperature of the metal such that the mixture is further compacted and densified. The temperature spike and duration thereof remains below that at which significant reaction between metal and ceramic occurs. The method requires pressure of 60-250 kpsi employed at a rate of 5-250 kpsi/second.

Abstract translation: 由化学不相容性和非润湿性特征的组分制备基本致密的无空隙陶瓷 - 金属复合材料。 复合材料具有类似于起始化学和微观结构的最终化学特征，其特征在于与起始粉末大小相似的陶瓷颗粒和金属相的存在。 制备复合材料的方法需要形成均匀的陶瓷 - 金属混合物，将混合物加热到接近但低于金属开始流动的温度的温度，并在混合物的压实和致密化的压力下压制混合物 发生并且发生超过金属流动温度的感应温度尖峰，使得混合物进一步压实和致密化。 温度峰值和持续时间仍然低于金属和陶瓷发生显着反应的温度峰值和持续时间。 该方法需要60-250 kpsi的压力，速率为5-250 kpsi / s。

公开(公告)号：US4834938A

公开(公告)日：1989-05-30

申请号：US185678

申请日：1988-04-25

Applicant: Aleksander J. Pyzik ,  Jack J. Ott ,  Scott J. Jankowski

Inventor： Aleksander J. Pyzik ,  Jack J. Ott ,  Scott J. Jankowski

IPC: C04B41/85 ,  B22F3/26 ,  B22F5/00 ,  B22F5/10 ,  C04B37/02 ,  C04B37/04 ,  C04B41/88 ,  C22C1/10

CPC classification number: C04B37/042 ,  B22F5/00 ,  B22F5/10 ,  C04B35/653 ,  C22C1/1036 ,  B22F2005/103 ,  C04B2235/6565 ,  C04B2237/32 ,  C04B2237/36 ,  C04B2237/368 ,  Y10S264/36

Abstract: A process is described for making a composite article without shrinkage, particularly of ceramic and metal wherein the article includes complex internal surfaces or cavities. The process requires forming an insert body that includes an external surface that corresponds to an internal cavity of the article. The insert body consists of a material having a melting temperature less than that of the article. The process further requires forming a porous compact about the insert body wherein the compact is formed into the substantially the net shape of the article. The compact is made of a material that is wetted by liquid insert material and has a sintering temperature greater than the wetting temperature of the insert material. The process further requires heating the article to a temperature such that the inserts substantially melts and infiltrates the porous compact forming the finished composite article. The process produces products including complex internal surfaces without the necessity of costly and sometimes technically difficult internal machining operations.