EP0262075A1
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Reservoir feed method of making ceramic composite structures and structures made thereby
Assignee: Lanxide Technology Co LP
•
Filing: 1987-09-03
•
Granted: —
•
Expires: 2007-09-03
Abstract
Abstract A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix embedding a filler (38) includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal with an oxidant and, optionally, one or more metallic constituents, and the filler (38) embedded by the matrix. The method includes heating the parent metal to provide a first source (36) of molten parent metal and a reservoir (34) of molten parent metal and contacting the first source (36) of molten parent metal with a permeable bedding of filler (38). The first source (36) of molten parent metal is reacted with the oxidant to form the oxidation reaction product and is replenished from the reservoir (34) as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired boundary and thereby embed at least a portion of the bedding of filler (38) within the oxidation reaction product to form the ceramic composite structure. The bedding of filler (38) may have any suitable shape, including that of a hollow body, the interior of which is contacted by the first source (36) of molten parent metal to grow the oxidation reaction product through the shaped, hollow body of filler.
Inventors
- 👤 Marc S. Newkirk
- 👤 Ratnesh K. Dwivedi
- 👤 H. Daniel Lesher
- 👤 Robert C. Kantner
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-02 21:22
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/71; B; B28; B28B; B28B7/00; B28B7/34; B28B7/344; B28B7/342; C04B35/622; C04B35/64; C04B35/65; C04B35/652
Claims Analysis
Total Claims: 34
Claim 1
Independent Claim
247 words
A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix obtained by oxidation reaction of a parent metal with an oxidant to form a polycrystalline material which comprises an oxidation reaction product and a filler infiltrated by said matrix, the method comprising: (a) orienting a body of said parent metal and a permeable mass of said filler relative to each other so that formation of said oxidation reaction product will occur in a direction towards and into said mass of filler; (b) providing from the parent metal (i) a first source of molten parent metal and (ii) a reservoir of molten parent metal communicating with said first source; (c) reacting said first source of molten parent metal with an oxidant to form said oxidation reaction product by maintaining at least a portion of said oxidation reaction product in contact with and extending between said first source of molten parent metal and said oxidant to progressively draw molten parent metal through the oxidation reaction product towards the oxidant and into said mass of filler so that the oxidation reaction product continues to form within said mass of filler at the interface between said oxidant and previously formed oxidation reaction product; and (d) replenishing said first source of molten parent metal from said reservoir as said reacting continues to form said oxidation reaction product to infiltrate at least a portion of said mass of filler with said oxidation reaction product to form said ceramic composite structure.
Claim 2
Independent Claim
247 words
A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix obtained by oxidation reaction of a parent metal with an oxidant to form a polycrystalline material which comprises an oxidation reaction product and a filler infiltrated by said matrix, the method comprising: (a) orienting a body of said parent metal and a permeable mass of said filler relative to each other so that formation of said oxidation reaction product will occur in a direction towards and into said mass of filler; (b) providing from the parent metal (i) a first source of molten parent metal and (ii) a reservoir of molten parent metal communicating with said first source; (c) reacting said first source of molten parent metal with an oxidant to form said oxidation reaction product by maintaining at least a portion of said oxidation reaction product in contact with and extending between said first source of molten parent metal and said oxidant to progressively draw molten parent metal through the oxidation reaction product towards the oxidant and into said mass of filler so that the oxidation reaction product continues to form within said mass of filler at the interface between said oxidant and previously formed oxidation reaction product; and (d) replenishing said first source of molten parent metal from said reservoir as said reacting continues to form said oxidation reaction product to infiltrate at least a portion of said mass of filler with said oxidation reaction product to form said ceramic composite structure.
Claim 3
Dependent Claim
73 words
The method of Claim 1 including providing said parent metal in the form of (1) a solid parent metal emplaced in contact with said mass of filler which provides said first source of molten parent metal on melting, and (2) a parent metal reservoir which provides said reservoir of molten parent metal, and flowing molten parent metal from said reservoir to said first source of molten parent metal to carry out said replenishing.
Claim 4
Dependent Claim
55 words
The method of Claim 1 or Claim 2 wherein said first source of parent metal is provided as a solid parent metal having a pattern formed thereon, and said mass of filler comprises a filler in conforming engagement with said pattern which is th ereby inversely replicated in the geometry of said ceramic composite structure.
Claim 5
Dependent Claim
17 words
The method of Claim 1 or Claim 2 wherein said mass of filler is a shaped preform.
Claim 6
Dependent Claim
22 words
The method of Claim 4 wherein at least a portion of the surface of said preform is defined by a barrier means.
Claim 7
Dependent Claim
56 words
The method of Claim 1 or Claim 2 wherein said mass of filler comprises a hollow body, and said orienting is done so as to contact said first source of molten parent metal with at least one wall of said hollow body whereby said infiltration of said oxidation reaction product proceeds from or along said wall.
Claim 8
Dependent Claim
31 words
The method of Claim 1 or Claim 2 including a plurality of masses of filler and flowing molten parent metal from a common reservoir to said plurality of masses of filler.
Claim 9
Dependent Claim
48 words
The method of Claim 1 or Claim 2 including maintaining molten parent metal in contact with said mass of filler and after said reacting is completed, permitting unreacted metal to solidify in contact with said ceramic composite structure so as to provide a metal substrate integrally formed therewith.
Claim 10
Dependent Claim
49 words
The method of Claim 8 wherein said mass of filler has one or more cavities formed therein and including maintaining said unreacted molten parent metal in contact within said one or more cavities to provide said metal substrate as an interior substrate having an outer surface of ceramic composite.
Claim 11
Dependent Claim
47 words
The method of Claim 8 including maintaining said unreacted molten parent metal in contact with at least part of an exterior surface of said mass of filler to provide a ceramic composite structure having a surface of solidified parent metal disposed exteriorly to said ceramic composite structure.
Claim 12
Dependent Claim
25 words
The method of Claim 8 including forming said ceramic composite structure to a volume greater than or less than the volume of said metal substrate.
Claim 13
Dependent Claim
83 words
The method of Claim 1 or Claim 2 wherein the volume of said first source of molten parent metal with which said oxidation reaction product is maintained in contact in step (c) is sufficiently less than the pore volume of said mass of filler to be infiltrated by said oxidation reaction product formed from said first source, that replenishing of said first source from said reservoir is used in forming said oxidation reaction product throughout the entire volume of said mass of filler.
Claim 14
Dependent Claim
17 words
The method of Claim 1 or Claim 2 wherein said parent metal is an aluminum parent metal.
Claim 15
Dependent Claim
27 words
The method of Claim 13 wherein said oxidant is air, said temperature regoin is from about 850°C to about 1450°C, and said oxidation reaction product comprises alumina.
Claim 16
Dependent Claim
31 words
The method of Claim 1 or Claim 2 including heating said parent metal to a temperature region above its melting point but below the melting point of said oxidation reaction product.
Claim 17
Dependent Claim
19 words
The method of Claim 15 including using at least one suitable dopant material in conjunction with said parent metal.
Claim 18
Dependent Claim
45 words
A self-supporting ceramic-surfaced metal structure comprising (a) a substrate comprising a precursor parent metal, (b) a filler superimposed on said substrate, and (c) a ceramic matrix formed integrally with said substrate and embedding said filler by oxidation reaciton of said precursor metal with an oxidant.
Claim 19
Dependent Claim
45 words
A self-supporting ceramic-surfaced metal structure comprising (a) a substrate comprising a precursor parent metal, (b) a filler superimposed on said substrate, and (c) a ceramic matrix formed integrally with said substrate and embedding said filler by oxidation reaciton of said precursor metal with an oxidant.
Claim 20
Dependent Claim
13 words
The ceramic-surfaced metal structure of Claim 17 wherein said filler comprises a preform.
Claim 21
Dependent Claim
25 words
The ceramic-surfaced metal structure of Claim 17 or Claim 18 wherein at least one surface boundary of said filler is defined by a barrier means.
Claim 22
Dependent Claim
17 words
The ceramic-surfaced metal structure of Claim 17 or Claim 18 wherein said ceramic matrix envelops said substrate.
Claim 23
Dependent Claim
29 words
The ceramic-surfaced lined metal structure of Claim 17 or Claim 18 wherein the volume of said substrate is insufficient to provide sufficient parent metal to form the ceramic matrix.
Claim 24
Dependent Claim
22 words
The ceramic-surfaced metal structure of Claim 17 or Claim 18 wherein comprising a ceramic matrix disposed exteriorly or interiorly to said substrate.
Claim 25
Dependent Claim
20 words
The ceramic-surfaced metal structure of Claim 17 or Claim 18 wherein said precursor parent metal comprises an aluminum parent metal.
Claim 26
Dependent Claim
13 words
The ceramic-surfaced metal structure of Claim 22 wherein said ceramic matrix comprises alumina.
Claim 27
Dependent Claim
29 words
Ther ceramic-surfaced metal structure of Claim 17 or Claim 18 wherein the volume of said ceramic matrix is greater than or less than the volume of said metal substrate.
Claim 28
Dependent Claim
25 words
The method of Claim 1 or Claim 2 wherein said parent metal is selected from the group consisting of titanium, silicon, zirconium, hafnium and tin.
Claim 29
Dependent Claim
16 words
The method of Claim 8 wherein said substrate is intimately bonded to said ceramic composite structure.
Claim 30
Dependent Claim
18 words
The product of Claim 17 or Claim 18 wherein said substrate is intimately bonded to said ceramic matrix.
Claim 31
Dependent Claim
23 words
The product of Claim 17 or Claim 18 wherein said ceramic matrix is an interior lining to a hollow cavity within said substrate.
Claim 32
Dependent Claim
27 words
The product of Claim 17 or Claim 18 wherein said ceramic matrix is in compression and said substrate is in tension at the interface between the two.
Claim 33
Dependent Claim
28 words
The product of Claim 17 or Claim 18 wherein said substrate comprises one or more metals selected from the group consisting of titanium, zirconium, hafnium, tin and silicon.
Claim 34
Dependent Claim
13 words
The product of Claim 17 or Claim 18 wherein said substrate comprises aluminum.
References Cited (Backward Citations)
EP0155831A2
Cited
EP0193292A2
Cited
USPTO Annuity & Maintenance Windows
Maintenance schedule is calculated for granted US utility patents.