Compositions: ceramic – Ceramic compositions – Refractory
Patent
1993-12-21
1997-06-10
Group, Karl
Compositions: ceramic
Ceramic compositions
Refractory
501 971, 501 984, 266266, 428689, 428698, 428699, C04B 35582
Patent
active
056375417
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
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.
BACKGROUND ART
Ceramics and ceramic composites have been utilized as refractory materials in a number of different applications. It has been found that ceramic and ceramic composite refractories can be used as many different components for applications which require, among other things, good resistance to thermal shock, good corrosion, abrasion and erosion resistance, etc. For example, ceramic and ceramic composite materials have been utilized as liners in molten glass furnaces and molten metal furnaces, as well as in apparatus associated with such furnaces (e.g., apparatus which direct or constrict the flow of molten fluids from one point to another).
Exemplary uses for ceramic materials in molten metal furnace and molten metal transfer systems include furnace linings, slide gates, sub-entry nozzles, ladle shrouds, tundishes, etc. Many metal manufacturing processes (including steel manufacturing processes) have recently been changed from traditional batch processes to some type of continuous process for reasons of economy and productivity. However, these continuous processing methods place extreme requirements upon the materials which are in contact with the static or flowing molten materials. For example, in the steel industry, slide gate systems, which are used for controlling the flow of molten metal from a large chamber (e.g., a furnace) into a smaller chamber (e.g., a mold), have been known for many years. However, only recently certain materials have been manufactured to meet the necessary mechanical/physical requirements imposed by such systems. Generally, slide gate systems include some type of rotor design which consists of, for example, a fixed nozzle attached to and within a moveable plate. The flow of molten metal from a ladle is controlled by moving the moveable plate to fully or partially aligned openings. When filling the ladle, and during shut off, the openings are misaligned. The advantage which stems from the use of a slide gate in continuous metal casting is that the conventional stopper rod system is eliminated. Specifically, in conventional stopper rod systems difficulties were encountered in stopping and/or modulating molten metal flow through an opening. Often the conventional stopper rod systems were not completely successful in terminating the flow of molten metal therethrough. However, even though slide gate systems have been achieving great successes in improving continuous casting of molten metals, the stringent requirements placed upon the materials for use as slide gates have resulted in many problems for the material design engineer. Accordingly, the need for new and better materials continues.
To date, common materials for use in slide gate systems include tar-impregnated alumina materials, fired-magnesia materials, etc. However, these materials suffer from many material deficiencies such as, for example, certain metals may corrode the bonding media or matrix which is utilized to hold together the refractory. Additionally, conventional materials may not possess the desired combination of thermal shock resistance, corrosion resistance, erosion resistance, abrasion resistance, and/or strength which permit the materials to function for a sufficient amount of time to achieve the economies and efficiencies needed in modern manufacturing operations. Accordingly, a need exists to develop a material which exhibits corrosion resistance, erosion resistance, thermal shock resistance, abrasion resistanc
REFERENCES:
patent: 2741822 (1956-04-01), Udy
patent: 3255027 (1966-06-01), Talsma
patent: 3262763 (1966-07-01), Bechtold
patent: 3296002 (1967-01-01), Hare
patent: 3298842 (1967-01-01), Seufert
patent: 3419404 (1968-12-01), Mao
patent: 3421863 (1969-01-01), Bawa et al.
patent: 3437468 (1969-04-01), Seufert
patent: 3473938 (1969-10-01), Oberlin
patent: 3473987 (1969-10-01), Sowards
patent: 3551101 (1970-12-01), Matsuo et al.
patent: 3789096 (1974-01-01), Church
patent: 3864154 (1975-02-01), Gazza et al.
patent: 3949804 (1976-04-01), Kaneko et al.
patent: 3973977 (1976-08-01), Wilson
patent: 4033400 (1977-07-01), Gurwell et al.
patent: 4573616 (1986-03-01), Shapland
patent: 4597514 (1986-07-01), Thrower
patent: 4828008 (1989-05-01), White et al.
patent: 4918034 (1990-04-01), Weinstein et al.
patent: 4923832 (1990-05-01), Newirk et al.
patent: 4996176 (1991-02-01), Newkirk et al.
patent: 5328878 (1994-07-01), Kuszyk et al.
patent: 5516734 (1996-05-01), Kuszyk et al.
"Oxidation of Molten Aluminum Alloys, Reaction with Refractories" -M. Drouzy and M. Richard -Mar. 1974 Founderie, France No. 332 pp. 121-128.
"Refractories for Aluminum Alloy Melting Furnaces" -B. Clavaud and V. Jost -Sep., 1980 -Lillian Brassinga (from French) Jan. 1985.
E. Luhrsen, M. Oberbach, and H. G. Stallmann, "Refractories for Continuous Casting of Steel-Requirements, Current State, and Developments", presented at Continuous Casting Symposium 1985, May 22-24, 1985, London, United Kingdom.
Jo Isenberg-O'Loughlin, "Getting More Out of Gates and Valves", Metal Producing, May 1986, pp. 31-35.
K. Sugita, M. Ikeda, S. Tamura "Microstructural Improvements in Slide Gate Plates for Steel Pouring", presented at 83rd Annual Meeting of the American Ceramic Society, Cincinnati, OH, May 4, 1982.
K. M. Taylor and Camilie Lenie, "Some Properties of Aluminum Nitride", Journal of the Electrochemical Society, Apr. 1960, pp. 308-314.
George Long and L. M. Foster, "Aluminum Nitride, A Refractory for Aluminum to 2000.degree. C", Journal of the American Ceramic Society, Feb. 1959, Vo. 42, No. 2 pp. 53-59.
Marija Trontelj and Drago Kolar "Wetting of Aluminum Nitride by Nickel Alloys", Journal of the American Ceramic Society -vol. 61, No. 5-6, pp. 204 and 207 (no date).
G. H. Schiroky et al., "Structural Ceramics You Can Count On", Machine Design, pp. 48-51, Jan. 10, 1991.
Biel, Jr. John P.
Kuszyk Jack A.
Group Karl
Lanxide Technology Company, LP
Ramberg Jeffrey R.
LandOfFree
Aluminum nitride refractory materials and methods for using the does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Aluminum nitride refractory materials and methods for using the , we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Aluminum nitride refractory materials and methods for using the will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-764451