Compositions: ceramic – Ceramic compositions – Carbide or oxycarbide containing
Patent
1995-02-21
1997-05-27
Group, Karl
Compositions: ceramic
Ceramic compositions
Carbide or oxycarbide containing
501 961, 264 82, 264332, C04B 3565
Patent
active
056332130
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to a novel method for producing self-supporting ceramic and ceramic composite bodies, formed by the oxidation reaction of a precursor metal and a vapor-phase oxidant, and having a metallic component including a second metal introduced during formation of the body and/or the formation of reaction product, each of which may impart certain desirable properties to the formed body. The invention also relates to ceramic and ceramic composite bodies produced by the novel method.
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 other. 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 to the same owner as this application (hereinafter referred to as Commonly Owned Patent Applications), overcome these limitations or difficulties and provide novel methods for reliably producing ceramic materials, including composites. The method is disclosed generically in Commonly Owned U.S. Pat. No. 4,713,360, issued on Dec. 15, 1987 and entitled "Novel Ceramic Materials and Methods for Making Same". 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 and Copending U.S. Pat. No. 4,853,352, which issued on Aug. 1, 1989, which is a continuation of U.S. patent application Ser. No. 06/822,999, filed Jan. 27, 1986, which is a continuation-in-part of Ser. No. 06/776,965, filed Sep. 17, 1985, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 06/747,788, filed Jun. 25, 1985, now abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 06/632,636, filed Jul. 20, 1984, now abandoned, all in the names of Marc S. Newkirk et al., and entitled "Methods of Making Self-Supporting Ceramic Materials".
This oxidation phenomenon was utilized in producing ceramic composite bodies as described in Commonly Owned U.S. Pat. No. 4,851,375, which issued on Jul. 25, 1989, from U.S. patent application Ser. No. 06/819,397, filed Jan. 17, 1986, which is a continuation-in-part of U.S. pat
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Aghajanian Michael K.
Johnson William B.
Kantner Robert C.
Kennedy Christopher R.
Newkirk Marc S.
Boland Kevin J.
Group Karl
Lanxide Technology Company, LP
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