Abstract:
A method for producing an article including a refractory compound by infiltrating a preform (10) with a liquid infiltrant (18) and initiating a reaction between the preform and the liquid infiltrant to establish a reaction front (20) which propagates in a direction opposite to the direction of flow of the liquid infiltrant (22) is provided, as are the articles prepared according to this method.
Abstract:
The present invention broadly relates to novel aluminum nitride matrix ceramic composite bodies for use as refractory materials and methods for making the same. The refractory materials are useful in environments which are corrosive, erosive, abrasive and/or which generate thermal shock. Such environments include furnaces, and associated apparatus which house or contact molten masses including, for example, molten metals, molten glasses, etc. The preferred method for making the aluminum nitride matrix ceramic composites comprises a directed oxidation of molten metal.
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:
An additive manufacturing process includes providing a powder mixture having a ceramic constituent and a reactive metal constituent, and reacting and fusing the powder mixture with a directed energy source to form a geometry.
Abstract:
The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the composite body such that any undesirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. The getterer material(s) may form at least one compound which acts as a passivation layer, and/or is able to move by bulk transport (e.g., by viscous flow as a glassy material) to a crack, and sealing the crack, thereby further enhancing the oxidation protection of the composite body. One or more ceramic filler materials which serve as reinforcements may have a plurality of superimposed coatings thereon, at least one of which coatings may function as or contain an oxidation protection mechanism. Specifically, a coating comprising boron nitride which has been engineered or modified to contain some silicon exhibits improved corrosion resistance, specifically to oxygen and moisture. The coated materials may be useful as reinforcing materials in high performance composites to provide improved mechanical properties such as fracture toughness. The present invention also relates to improved composites which incorporate these materials, and to their methods of manufacture.
Abstract:
This invention relates generally to a novel directed metal oxidation process which is utilized to produce self-supporting bodies. In some of the more specific aspects of the invention, a parent metal (e.g., a parent metal vapor) is induced to react with at least one solid oxidant-containing material to result in the directed growth of a reaction product which is formed from a reaction between the parent metal (46) and the solid oxidant-containing material (47). The inventive process can be utilized to form bodies having substantially homogeneous compositons, graded compositions, and macrocomposite bodies.
Abstract:
This invention is directed to a process for forming an interwoven composite product, particularly a thin interwoven composite multilayer film product. In the case of the interwoven composite multilayer film product, a substantially noninterwoven multilayer film is first formed having a plurality of discrete thin layers. This noninterwoven film comprises at least one discrete thin layer of a first material and at least one discrete thin layer of a second material. The thin discrete layers, which are substantially unreactive with each other at ambient temperature, are arranged in alternative adjacent layers. At least one component of a first material in one discrete thin layer undergoes a solid state displacement reaction with at least one component of a second material in an alternate adjacent thin discrete layer thereby producing the requisite thin interwoven composite film product.
Abstract:
The present invention relates to a novel process for removal of at least a portion of at least one metallic component of a metallic constituent from a multi-phase composite body. Particularly, by providing at least one of an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere to be in communication with a permeable mass, which contacts at least a portion of a composite body, said metallic component of the composite body, when made molten, is caused to spontaneously infiltrate the permeable mass. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.
Abstract:
This invention relates generally to a novel method for removing metal from a formed self-supporting body. A self-supporting body is made 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 donor material (e.g., boron nitride) and, optionally, one or more inert fillers. Once the self-supporting body is formed, it is then subjected to appropriate conditions which causes metallic constituent contained in the self-supporting body to be at least partially removed.