Ceramic composite articles obtained by inverse shape replication

Compositions: ceramic – Ceramic compositions – Refractory

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501 87, 501 89, 501 96, 501 98, C04B 3565

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051680815

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. The method 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 surrounding bed 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 of 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.

REFERENCES:
patent: 2741822 (1956-04-01), Udy
patent: 3255027 (1966-06-01), Talsma
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: 3789096 (1974-01-01), Church
patent: 3864154 (1975-02-01), Gazza et al.
patent: 3973977 (1976-08-01), Wilson
patent: 5051382 (1991-09-01), Newkirk et al.
"Oxidation of Molten Aluminum Alloys, Reaction with Refractories"-M. Drouzy and M. Richard-Mar., 1974 Fonderie, 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.

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