Low thermal expansion coefficient synthetic cordierite-containing ceramic bodies and method for producing same

Claim 2

A polycrystalline cordierite-containing ceramic body of magnesium aluminum silicate having the composition in weight percent within the range of 13 to 16 percent magnesium oxide, 30 to 36 percent aluminum oxide, and 49 to 54 percent silicon dioxide, the body consisting essentially of at least 90 percent by weight of crystalline phase, remainder glassy phase, the body characterized by a microstructure having microcracks at least 3 micrometers in length and a microcrack occurrence frequency of at least 0.02 per micrometer, and further characterized by a thermal expansion within the temperature range of 25° to 800°C of up to 1100 parts per million.

Claim 3

The body of claim 1 in which the microcracks range in size from 15 to 150 micrometers and the microcrack occurrence frequency is up to 0.25 per micrometer.

Claim 4

The body of claim 1 consisting essentially of from 95 to 98 percent by weight of crystalline phase, remainder glassy phase.

Claim 5

The body of claim 1 characterized by a thermal expansion of up to 800 parts per million.

Claim 6

A process for producing a polycrystalline cordierite containing magnesium aluminum silicate ceramic body, the body consisting essentially of at least 90% by weight of crystalline phase, remainder glassy phase, the body characterized by a microstructure having microcracks at least 3 micrometers in length and a microcrack occurrence frequency of at least 0.02 per micrometer, and further characterized by having a thermal expansion within the range of 25° to 800°C of up to 1100 parts per million, the process comprising: a. combining talc, ball clay and alumina containing starting materials in amounts to achieve a sintered ceramic body having the composition in weight percent 13 to 16 percent MgO, 30 to 36 percent Al 2 O 3 , and 49 to 54 percent SiO 2 , the starting materials containing less than about 600 parts per million total of the alkaline earths selected from the group consisting of calcium, strontium and barium, less than about 6,000 parts per million total of the alkali metals selected from the group consisting of lithium, sodium and potassium, less than about 0.5 weight percent iron and less than about 1 weight percent titanium, b. ball milling the combined starting materials, c. consolidating the milled starting materials into a green ceramic body of a desired shape, d. heating the green body at a rate of up to 350°C per hour to a temperature within the range of about 1350° to 1425°C, e. maintaining the temperature of the green body within the above range for from 1/2 hour to 1 hour at the higher temperature, and for at least 6 hours at the lower temperature, thereby to convert the green body to a sintered polycrystalline cordierite-containing ceramic body, and f. cooling the sintered body at a rate of up to 500°C per hour down to a temperature below 1,000°C.

Claim 7

A process for producing a polycrystalline cordierite containing magnesium aluminum silicate ceramic body, the body consisting essentially of at least 90% by weight of crystalline phase, remainder glassy phase, the body characterized by a microstructure having microcracks at least 3 micrometers in length and a microcrack occurrence frequency of at least 0.02 per micrometer, and further characterized by having a thermal expansion within the range of 25° to 800°C of up to 1100 parts per million, the process comprising: a. combining talc, ball clay and alumina containing starting materials in amounts to achieve a sintered ceramic body having the composition in weight percent 13 to 16 percent MgO, 30 to 36 percent Al 2 O 3 , and 49 to 54 percent SiO 2 , the starting materials containing less than about 600 parts per million total of the alkaline earths selected from the group consisting of calcium, strontium and barium, less than about 6,000 parts per million total of the alkali metals selected from the group consisting of lithium, sodium and potassium, less than about 0.5 weight percent iron and less than about 1 weight percent titanium, b. ball milling the combined starting materials, c. consolidating the milled starting materials into a green ceramic body of a desired shape, d. heating the green body at a rate of up to 350°C per hour to a temperature within the range of about 1350° to 1425°C, e. maintaining the temperature of the green body within the above range for from 1/2 hour to 1 hour at the higher temperature, and for at least 6 hours at the lower temperature, thereby to convert the green body to a sintered polycrystalline cordierite-containing ceramic body, and f. cooling the sintered body at a rate of up to 500°C per hour down to a temperature below 1,000°C.

Claim 8

The method of claim 5 wherein the impurity levels of the alkaline earths are kept below about 300 parts per million total, the alkali metals are kept below about 3,000 parts per million total and the titanium is kept below about 0.5 weight percent.

Claim 9

The method of claim 5 wherein the body is sintered for from 1/2 to 3/4 hour at the higher temperature, and for at least 10 hours at the lower temperature.

Claim 10

The method of claim 5 wherein the body is sintered at a temperature of from about 1375° to 1400°C for about 3 to 5 hours.

Claim 11

The method of claim 5 wherein cooling from the sintering temperature is carried out at the rate of from 30° to 150°C per hour to a temperature below 500°C.

Claim 12

The method of claim 5 wherein ball milling is carried out as dry ball milling in noncontaminating milling media, resulting in thermal expansions up to about 800 parts per million.