EP0256963A2
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Ceramic articles with a modified metal-containing component and methods of making same
Assignee: Lanxide Technology Co LP
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Filing: 1987-07-28
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Granted: —
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Expires: 2007-07-28
Abstract
Abstract A method of producing self-supporting ceramic bodies (10) having a modified metal-containing component includes first providing a self-supporting ceramic body (10) comprising (i) a polycrystalline oxidation reaction product (12) formed upon oxidation of a molten parent metal precursor with an oxidant, and (ii) an interconnected metal-containing component (14) at least partially accessible from one or more surfaces (15) of said ceramic body (10). The surface or surfaces (15) of the ceramic body (10) is contacted with a quantity of foreign metal different from said interconnected metal-containing component (14) at a temperature and for a time sufficient to allow for interdiffusion, whereby at least a portion of said metal-containing component (14) is displaced by said foreign metal. The resulting ceramic body, having an altered metal-containing component, exhibits modified or improved properties.
Inventors
- 👤 Marc S. Newkirk
- 👤 Andrew W. Urquhart
- 👤 Harry R. Zwicker
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-31 22:51
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/009; C04B35/00; C04B35/622; C04B35/64; C04B35/65; C04B35/652; C04B41/45; C04B41/50; C04B41/51; C04B41/80; C04B41/81; C04B41/85; C04B41/88; C22; C22C; C22C29/00; C22C29/12; C22C47/00; C22C47/02; C22C47/06; C23; C23C; C23C10/00; C23C10/18; C23C10/20; C23C10/22; B; B22; B22F; B22F2999/00; Y; Y10; Y10S; Y10S264/00; Y10S264/36; Y10T; Y10T428/00; Y10T428/12; Y10T428/12007; Y10T428/12014; Y10T428/12028; Y10T428/12049; Y10T428/12056; Y10T428/12146; Y10T428/1216; Y10T428/12167; Y10T428/12493; Y10T428/12535; Y10T428/12583
Claims Analysis
Total Claims: 16
Claim 1
Independent Claim
124 words
A method of producing a self-supporting ceramic body with a modified metal-containing component comprising the steps of: (a) providing a self-supporting ceramic body comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal precursor with an oxidant, and (ii) an interconnected metal-containing component at least partially accessible from one or more surfaces of said ceramic body; (b) contacting said surface or surfaces of said ceramic body with a quantity of foreign metal different from said interconnected metal-containing component at a temperature and for a time sufficient to allow for interdiffusion, whereby at least a portion of said metal-containing component is at least partially displaced by said foreign metal; and (c) recovering the ceramic body having a modified metal-containing component.
Claim 2
Independent Claim
124 words
A method of producing a self-supporting ceramic body with a modified metal-containing component comprising the steps of: (a) providing a self-supporting ceramic body comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal precursor with an oxidant, and (ii) an interconnected metal-containing component at least partially accessible from one or more surfaces of said ceramic body; (b) contacting said surface or surfaces of said ceramic body with a quantity of foreign metal different from said interconnected metal-containing component at a temperature and for a time sufficient to allow for interdiffusion, whereby at least a portion of said metal-containing component is at least partially displaced by said foreign metal; and (c) recovering the ceramic body having a modified metal-containing component.
Claim 3
Dependent Claim
23 words
The invention of Claim 1 wherein the parent metal is selected from the group consisting of aluminum, silicon, titanium, tin, zirconium, and hafnium.
Claim 4
Dependent Claim
17 words
The invention of Claim 1 wherein the parent metal is aluminum and the metal-containing component includes aluminum.
Claim 5
Dependent Claim
59 words
The invention of any of Claims 1, 2 or 3 wherein the foreign metal comoprises at least one constituent which is selected from the gorup consisting of nickel, iron, silver, titanium, vanadium, copper, uranium, cobalt, chromium, molybedenum, silicon, tungsten, germanium, tin, magnesium, yttrium, zirconium, hafnium, niobium, manganese, platinum, palladium, gold, zinc, aluminum, lead, and alloys, intermetallics, and combinations thereof.
Claim 6
Dependent Claim
32 words
The invention of any of Claims 1, 2, 3 or 4 wherein the volume of foreign metal is at least five times greater than the volume of metal-containing component to be displaced.
Claim 7
Dependent Claim
39 words
The invention of any of Claims 1, 2, 3 or 4 wherein the interconnected metal-containing component constitutes between about 1 to 40 percent by volume of the ceramic body before the ceramic body is contacted with the foreign metal.
Claim 8
Dependent Claim
25 words
The invention of any of Claims 1, 2, 3 or 4 additionally including agitating said ceramic body and/or said foreign metal during said contacting step.
Claim 9
Dependent Claim
36 words
The invention of any of Claims 1, 2, 3, 4, 6 or 7 wherein said temperature during said contacting step is above the melting point of said foreign metal, or said metal-containing component, or their combination.
Claim 10
Dependent Claim
27 words
The invention of any of Claims 1, 2, 3 or 4 wherein the self-supporting ceramic body further comprises a filler infiltrated by said polycrystalline oxidation reaction product.
Claim 11
Dependent Claim
208 words
In the method of any of the foregoing claims for producing a self-supporting ceramic body by oxidation of a parent metal, which further includes the steps of: (a) heating said parent metal in the presence of a vapor-phase oxidant to form a body of molten parent metal and reacting said molten parent metal with said oxidant at said temperature to form an oxidation reaction product, which product is in contact with and extends between said body of molten metal and said oxidant, (b) maintaining the temperature to keep the metal molten and progressively drawing molten metal through the oxidation reaction product towards the oxidant so that the oxidation reaction product continues to form at the interface between the oxidant and previously formed oxidation reaction product, and (c) continuing said reaction for a time sufficient to produce said ceramic body comprising said oxidation reaction product and an interconnected, metal- containing component, which component is at least partially interconnected and at least partially accessible from an external surface of the ceramic body, contacting said external surface of said ceramic body with a foreign metal different from said parent metal, so as to create a concentration gradient between said two metals, and allowing sufficient time for interdiffusion of said two metals.
Claim 12
Dependent Claim
106 words
A self-supporting ceramic body which comprises (a) a polycrystalline oxidation reaction product formed upon oxidation of a molten metal precursor with an oxidant, and (b) an interconnected metal-containing component at least partially open to one or more surfaces of said ceramic body and at least a portion of which is derived from an extrinsic source by interdiffusion, occurring post-operatively to formation of said polycrystalline oxidation reaction product, between a first metal formed in situ during formation of said polycrystalline oxidation reaction product and a second metal from said extrinsic source, whereby said ceramic body has one or more properties modified from that formed upon said oxidation.
Claim 13
Dependent Claim
106 words
A self-supporting ceramic body which comprises (a) a polycrystalline oxidation reaction product formed upon oxidation of a molten metal precursor with an oxidant, and (b) an interconnected metal-containing component at least partially open to one or more surfaces of said ceramic body and at least a portion of which is derived from an extrinsic source by interdiffusion, occurring post-operatively to formation of said polycrystalline oxidation reaction product, between a first metal formed in situ during formation of said polycrystalline oxidation reaction product and a second metal from said extrinsic source, whereby said ceramic body has one or more properties modified from that formed upon said oxidation.
Claim 14
Dependent Claim
17 words
The ceramic body of Claim 11 wherein the volume percent of interconnected metal-containing component is about 1-40%.
Claim 15
Dependent Claim
112 words
A self-supporting ceramic body which comprises (a) α-alumina as the polycrystalline oxidation reaction product formed upon oxidation of molten aluminum metal precursor with a vapor-phase oxidant, and (b) about 1-40 volume percent interconnected metal-containing component at least partially open to one or more surfaces of said ceramic body and at least a portion of which is derived from an extrinsic source by interdiffusion, occurring post-operatively to formation of said polycrystalline oxidation reaction product, between a first metal formed in situ during formation of said polycrystalline oxidation reaction product and a second metal from said extrinsic source, whereby said ceramic body has one or more properties modified from that formed upon said oxidation.
Claim 16
Dependent Claim
112 words
A self-supporting ceramic body which comprises (a) α-alumina as the polycrystalline oxidation reaction product formed upon oxidation of molten aluminum metal precursor with a vapor-phase oxidant, and (b) about 1-40 volume percent interconnected metal-containing component at least partially open to one or more surfaces of said ceramic body and at least a portion of which is derived from an extrinsic source by interdiffusion, occurring post-operatively to formation of said polycrystalline oxidation reaction product, between a first metal formed in situ during formation of said polycrystalline oxidation reaction product and a second metal from said extrinsic source, whereby said ceramic body has one or more properties modified from that formed upon said oxidation.
References Cited (Backward Citations)
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