Powder metallurgy processes – Powder metallurgy processes with heating or sintering – Sintering which includes a chemical reaction
Patent
1994-09-19
1996-05-28
Walsh, Donald P.
Powder metallurgy processes
Powder metallurgy processes with heating or sintering
Sintering which includes a chemical reaction
419 5, 419 10, 419 12, 419 13, 419 14, 419 35, B22F 700
Patent
active
055208800
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to a novel method for producing self-supporting composite bodies, formed by the oxidation reaction of a parent metal and a solid-phase oxidant to produce at least one oxidation reaction product comprising, in most cases, at least one intermetallic phase, and, optionally, having at least one metallic component introduced during formation of the body to impart certain properties to the formed body. The invention also relates to formation of, in some cases, ceramic phases in addition to the intermetallic phase(s).
BACKGROUND ART AND COMMONLY OWNED PATENTS AND PATENT APPLICATIONS
In recent years, there has been an increasing interest in the use of ceramics for structural applications historically served by metals. The impetus for this interest has been the superiority of ceramics with respect to certain properties, such as corrosion resistance, hardness, modulus of elasticity, and refractory capabilities, when compared with metals.
Current efforts at producing higher strength, more reliable, and tougher ceramic articles are largely focused upon (1) the development of improved processing methods for monolithic ceramics and (2) the development of new material compositions, notably ceramic matrix composites.
A composite structure is one which comprises a heterogeneous material, body or article made of two or more different materials which are intimately combined in order to attain desired properties of the composite. For example, two different materials may be intimately combined by embedding one in a matrix of the ether. A ceramic matrix composite structure typically comprises a ceramic matrix which incorporates one or more diverse types of filler materials such as particulates, fibers, rods, and the like.
There are several known limitations or difficulties in substituting ceramics for metals, such as scaling versatility, capability to produce complex shapes, satisfying the properties required for the end use application, and costs. Several copending patent applications assigned and issued Patents to the same owner as this application (hereinafter referred to as Commonly Owned Patent Applications and Patents), overcome these limitations or difficulties and provide novel methods for reliably producing ceramic materials, including ceramic composite materials. The method is disclosed generically in Commonly Owned U.S. Pat. No. 4,713,360, entitled "Novel Ceramic Materials and Methods for Making Same", which issued on Dec. 15, 1987, from U.S. patent application Ser. No. 06/818,943, filed Jan. 15, 1986, which was a continuation-in-part of application U.S. Ser. No. 06/776,964, filed Sep. 17, 1985, and now abandoned, which was a continuation-in-part of application Ser. No. 06/705,787, filed Feb. 26, 1985, and now abandoned, which was a continuation-in-part of application Ser. No. 06/591,392, filed Mar. 16, 1984, and now abandoned, all in the names of Marc S. Newkirk et al. This Patent discloses a method of producing self-supporting ceramic bodies grown as the oxidation reaction product of a molten parent precursor metal which is reacted with a vapor-phase oxidant to form an oxidation reaction product. Molten metal migrates through the formed oxidation reaction product to react with the oxidant, thereby continuously developing a ceramic polycrystalline body which can, if desired, include an interconnected metallic component. The process may be enhanced by the use of one or more dopants alloyed with the parent metal. For example, in the case of oxidizing aluminum in air, it is desirable to alloy magnesium and silicon with the aluminum to produce alpha-alumina ceramic structures. This method was improved upon by the application of dopant materials to the surface of the precursor metal, as described in Commonly Owned U.S. Pat. No. 4,853,352, entitled "Methods of Making Self-Supporting Ceramic Materials and Materials Made Thereby", which issued on Aug. 1, 1989, from U.S. patent application Ser. No. 07/220,935, which was a Rule 62 continuation of commonly owned U.S. patent applicatio
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Claar Terry D.
Johnson William B.
Park Eugene S.
Schiroky Gerhard H.
White Danny R.
Greaves John N.
Lanxide Technology Company, LP
Ramberg Jeffrey R.
Walsh Donald P.
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