Method of making shaped ceramic composites

Details Method of making shaped ceramic composites Method of making shaped ceramic composites

1988-06-13

1989-04-25

Cintins, Ivars

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

By mechanically introducing gas into material

264 60, 264 82, C04B 3332, C04B 3560

Patent

active

048246220

ABSTRACT:
The present invention provides a method for producing a self-supporting ceramic composite by the oxidation of a parent metal to form a polycrystalline ceramic material consisting essentially of the oxidation reaction product of the parent metal with an oxidant, including a vapor-phase oxidant, and, optionally, one or more metallic constituents. A permeable filler material, such as a preform, with at least one surface bearing a permeable stratum, is contacted with a body of molten parent metal heated to a temperature above its melting point but below the melting point of the oxidation reaction product. At least a portion of the oxidation reaction product is maintained in contact with and between the molten metal and oxidant to transport the molten metal through the oxidation reaction product toward the permeable stratum and into contact with the oxidant so that the oxidation reaction product continues to form at the interface between the oxidant and previously formed oxidation reaction product that has infiltrated the filler material. The reaction is continued to infiltrate at least a portion of the stratum with the oxidation reaction product and to produce an intermediate ceramic body having an adjacent ceramic composite overlaid with a ceramic stratum. The ceramic stratum is removed from the underlying ceramic composite to produce a self-supporting ceramic composite having the surface established by the permeable stratum.

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