Method of forming a silicon carbide article - III

Claim 2

In a method of forming a silicon carbide article: (a) wherein 60-80% by weight of silicon carbide particles having an average particle size in the range from about 40 microns to less than 1 micron are mixed together with 40-20% by weight of a thermosetting binder which produces a flowable liquid phase when melted and which produces carbon upon nonoxidative pyrolysis; (b) wherein the mixture is heated to a temperature whereat the thermosetting binder is in a liquid phase; (c) wherein the mixture is injected molded by an injection molding technique to form an article, the injection molding technique operating on the basis that the flowable thermosetting binder forms a continuous phase about the silicon carbide particles supported therein; (d) wherein the thermosetting binder is stiffened to lend sufficient strength to the molded article so that it may be removed from its mold; (e) wherein the molded article is pyrolized in the absence of oxygen so that the thermosetting binder undergoes a volumetric reduction in breaking down to form a vitreous carbon phase which serves to bond silicon carbon particles together, this action also developing a pore structure throughout the article and producing excess carbon at the surface; and (f) wherein the article is silicided at an elevated temperature by permitting the penetration of the article through its pore structure with silicon whereby the silicon reacts with the available carbon to form silicon carbide; the improvement which comprises: treating the surface of the article after it has been pyrolized and prior to the siliciding thereof to remove said excess carbon on the surface thereof by heating the article to a treatment temperature in the range from 700° F to 850° F and thereafter exposing the article to an oxygen containing atmosphere for a period of time up to 5 minutes.

Claim 3

In a method of forming a silicon carbide article: (a) wherein 60-75% by weight of silicon carbide particles having an average particle size in the range from about 40 microns to less than 1 micron and 0 to 7% by weight of graphite having an average particle size in the range from about 10 to 0.1 microns are mixed together with 40-23% by weight of a thermosetting binder which produces a flowable liquid phase when melted and which produces carbon upon nonoxidative pyrolysis; (b) wherein the mixture is heated to a temperature whereat the thermosetting binder is in a liquid phase; (c) wherein the mixture is injection molded by an injection molding technique to form an article, the injection molding technique operating on the basis that the flowable thermosetting binder forms a continuous phase about the silicon carbide particles supported therein; (d) wherein the thermosetting binder is stiffened to lend sufficient strength to the molded article so that it may be removed from its mold; (e) wherein the molded article is pyrolized in the absence of oxygen so that the thermosetting binder undergoes a volumetric reduction in breaking down to form a vitreous carbon phase which serves to bond the silicon carbide particles together, this action also developing a pore structure throughout the article and producing excess carbon at the surface; and (f) wherein the article is silicided at an elevated temperature by permitting the penetration of the article through its pore structure with silicon whereby the silicon reacts with the available carbon to form silicon carbide; the improvement which comprises: treating the surface of the article after it has been pyrolized and prior to the siliciding thereof to remove said excess carbon on the surface thereof by treating the article to a treatment temperature in the range from 700° F to 850° F and thereafter exposing the article to an oxygen containing atmosphere for a period of time up to 5 minutes.

Claim 4

In a method of forming a silicon carbide article: (a) wherein 60-75% by weight of silicon carbide particles having an average particle size in the range from about 40 microns to less than 1 micron and 0 to 7% by weight of graphite having an average particle size in the range from about 10 to 0.1 microns are mixed together with 40-23% by weight of a thermosetting binder which produces a flowable liquid phase when melted and which produces carbon upon nonoxidative pyrolysis; (b) wherein the mixture is heated to a temperature whereat the thermosetting binder is in a liquid phase; (c) wherein the mixture is injection molded by an injection molding technique to form an article, the injection molding technique operating on the basis that the flowable thermosetting binder forms a continuous phase about the silicon carbide particles supported therein; (d) wherein the thermosetting binder is stiffened to lend sufficient strength to the molded article so that it may be removed from its mold; (e) wherein the molded article is pyrolized in the absence of oxygen so that the thermosetting binder undergoes a volumetric reduction in breaking down to form a vitreous carbon phase which serves to bond the silicon carbide particles together, this action also developing a pore structure throughout the article and producing excess carbon at the surface; and (f) wherein the article is silicided at an elevated temperature by permitting the penetration of the article through its pore structure with silicon whereby the silicon reacts with the available carbon to form silicon carbide; the improvement which comprises: treating the surface of the article after it has been pyrolized and prior to the siliciding thereof to remove said excess carbon on the surface thereof by treating the article to a treatment temperature in the range from 700° F to 850° F and thereafter exposing the article to an oxygen containing atmosphere for a period of time up to 5 minutes.