Method for producing composite ceramic structures

Claim 1

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first stage comprising: (a) heating a source of 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 a temperature above the melting point of said parent metal but below the melting point of an oxidation reaction product which forms from a reaction between said molten parent metal and said oxidant, which oxidation reaction product is in contact with, and extends between, said body of molten parent metal and said oxidant; (b) maintaining said temperature to progressively draw molten metal through said oxidation reaction product towards said oxidant so that fresh oxidation reaction product continues to form at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reaction for a time sufficient to produce a polycrystalline material comprising said oxidation reaction product; said second-stage comprising: (d) comminuting said polycrystalline material from said first-stage to a particulate size for use as filler, and forming a permeable mass of said particulate filler; (e) orienting a source of parent metal and said permeable mass of said particulate filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable mass of particulate filler; (f) heating said parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of particulate filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of particulate filler so that fresh oxidation reaction product continues to form within the permeable mass of particulate filler at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of particulate filler thereby forming said ceramic composite body.

Claim 2

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first stage comprising: (a) heating a source of 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 a temperature above the melting point of said parent metal but below the melting point of an oxidation reaction product which forms from a reaction between said molten parent metal and said oxidant, which oxidation reaction product is in contact with, and extends between, said body of molten parent metal and said oxidant; (b) maintaining said temperature to progressively draw molten metal through said oxidation reaction product towards said oxidant so that fresh oxidation reaction product continues to form at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reaction for a time sufficient to produce a polycrystalline material comprising said oxidation reaction product; said second-stage comprising: (d) comminuting said polycrystalline material from said first-stage to a particulate size for use as filler, and forming a permeable mass of said particulate filler; (e) orienting a source of parent metal and said permeable mass of said particulate filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable mass of particulate filler; (f) heating said parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of particulate filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of particulate filler so that fresh oxidation reaction product continues to form within the permeable mass of particulate filler at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of particulate filler thereby forming said ceramic composite body.

Claim 8

The method according to any of claims 1, 2, 5 or 6, wherein the composition of said oxidant used in said first-stage has the same composition as said oxidant used in said second-stage.

Claim 9

The method according to any of claims 1, 2, 5 or 6, wherein the composition of said oxidant used in said first-stage does not have the same composition as said oxidant used in said second-stage.

Claim 10

The method according to claims 1, 2, 5 or 6, wherein at least one additional filler is admixed with said permeable mass of particulate filler in said second-stage prior to step (e) of said second-stage.

Claim 11

The method according to any of claims 1, 2, 5 or 6, wherein said permeable mass of particulate filler in said second-stage comprises a permeable, shaped, self-supporting preform, and said oxidation reaction product infiltrates said preform to produce a self-supporting ceramic composite body having a configuration of said preform.

Claim 12

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first-stage comprising: (a) heating a first source of aluminum parent metal in the presence of air as a vapor-phase oxidant and in conjunction with at least one dopant material to form a body of molten parent metal and reacting said molten parent metal with said oxidant at a temperature of from about 850° C. to about 1450° C. to form alumina as an oxidation reaction product, which oxidation reaction product is in contact with, and extends between, said body of molten parent metal and said oxidant; (b) maintaining said temperature to progressively draw molten metal through said oxidation reaction product towards said oxidant so that fresh oxidation reaction product continues to form at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reaction for a time sufficient to produce a polycrystalline material comprising said oxidation reaction product; said second-stage comprising: (d) comminuting said polycrystalline material from said first-stage to a particulate size for use as filler, and forming a shaped, permeable, self-supporting preform of said particulate filler; (e) orienting a source of aluminum parent metal and said preform relative to each other so that formation of an oxidation reaction product from a reaction between said aluminum parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable preform; (f) heating said aluminum parent metal to a temperature above its melting point but below the melting point of either of said filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into said permeable preform so that fresh oxidation reaction product continues to form within said preform at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates said permeable preform thereby forming said ceramic composite body having a configuration of said preform.

Claim 13

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first-stage comprising: (a) heating a first source of aluminum parent metal in the presence of air as a vapor-phase oxidant and in conjunction with at least one dopant material to form a body of molten parent metal and reacting said molten parent metal with said oxidant at a temperature of from about 850° C. to about 1450° C. to form alumina as an oxidation reaction product, which oxidation reaction product is in contact with, and extends between, said body of molten parent metal and said oxidant; (b) maintaining said temperature to progressively draw molten metal through said oxidation reaction product towards said oxidant so that fresh oxidation reaction product continues to form at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reaction for a time sufficient to produce a polycrystalline material comprising said oxidation reaction product; said second-stage comprising: (d) comminuting said polycrystalline material from said first-stage to a particulate size for use as filler, and forming a shaped, permeable, self-supporting preform of said particulate filler; (e) orienting a source of aluminum parent metal and said preform relative to each other so that formation of an oxidation reaction product from a reaction between said aluminum parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable preform; (f) heating said aluminum parent metal to a temperature above its melting point but below the melting point of either of said filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into said permeable preform so that fresh oxidation reaction product continues to form within said preform at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates said permeable preform thereby forming said ceramic composite body having a configuration of said preform.

Claim 14

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first-stage comprising: (a) orienting a source of parent metal and a permeable bed of filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable mass of filler; (b) heating said parent metal to a temperature above its melting point but below the metling point of either of said permeable mass of filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of filler so that fresh oxidation reaction product continues to form within the permeable mass of filler at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of filler thereby forming a body of oxidation reaction product embedding filler; said second-stage comprising: (d) comminuting said body of oxidation reaction product embedding filler from said first-stage to a particulate size for use as filler, and forming a permeable mass of said particulate filler; (e) orienting a source of parent metal and said permeable mass of said particulate filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and vapor-phase oxidant will occur in a direction towards and into said permeable mass of particulate filler; (f) heating said parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of particulate filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of particulate filler so that fresh oxidation reaction product continues to form within the permeable mass of particulate filler at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of particulate filler thereby forming said ceramic composite body.

Claim 15

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first-stage comprising: (a) orienting a source of parent metal and a permeable bed of filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable mass of filler; (b) heating said parent metal to a temperature above its melting point but below the metling point of either of said permeable mass of filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of filler so that fresh oxidation reaction product continues to form within the permeable mass of filler at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of filler thereby forming a body of oxidation reaction product embedding filler; said second-stage comprising: (d) comminuting said body of oxidation reaction product embedding filler from said first-stage to a particulate size for use as filler, and forming a permeable mass of said particulate filler; (e) orienting a source of parent metal and said permeable mass of said particulate filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and vapor-phase oxidant will occur in a direction towards and into said permeable mass of particulate filler; (f) heating said parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of particulate filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of particulate filler so that fresh oxidation reaction product continues to form within the permeable mass of particulate filler at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of particulate filler thereby forming said ceramic composite body.

Claim 19

The method according to any of claims 12, 13, 14 or 15, wherein said vapor-phase oxidant in said first-stage and said second-stage comprises air.

Claim 20

The method according to any of claims 12, 13, 14 or 15, further comprising utilizing at least one dopant material in combination with said source of parent metal in at least one of said first-stage and said second-stage.

Claim 21

The method according to any of claims 12, 13, 14 or 15, whereins said source of parent metal in said first-stage and said source of parent metal in said second-stage have the same composition.

Claim 22

The method according to any of claims 12, 13, 14 or 15, wherein said source of parent metal in said first-stage and said source of parent metal in said second-stage do not have the same composition.

Claim 23

The method according to any of claims 12, 13, 14 or 15, wherein the composition of said oxidant used in said first-stage has the same composition as said oxidant used in said second-stage.

Claim 24

The method according to any of claims 12, 13, 14 or 15, wherein the composition of said oxidant used in said first-stage does not have the same composition as said oxidant used in said second-stage.

Claim 25

The method according to any of claims 12, 13, 14, or 15, wherein at least one additional filler is admixed with said permeable mass of particulate filler in said second-stage prior to step (e) of said second-stage.

Claim 26

The method according to any of claims 12, 13, 14 or 15, wherein said permeable mass of particulate filler in said second-stage comprises a permeable, shaped, self-supporting preform, and said oxidation reaction product infiltrates said preform to produce a self-supporting ceramic composite body having a configuration of said preform.

Claim 27

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first-stage comprising: (a) orienting a source of parent metal and a permeable mass of filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable mass of filler; (b) heating said parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of filler so that fresh oxidation reaction product continues to form within the permeable mass of filler at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of filler thereby forming a body of oxidation reaction product embedding filler; said second-stage comprising: (d) comminuting said body of oxidation reaction product embedding filler from said first-stage to a particulate size for use as filler, and forming a shaped, permeable, self-supporting preform of said particulate filler; (e) orienting a source of parent metal and said preform relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said preform; (f) heating said parent metal to a temperature above its melting point but below the melting point of either of said preform or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the preform so that fresh oxidation reaction product continues to form within the preform at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates said preform thereby forming said ceramic composite body having a configuration of said preform.

Claim 28

A method for producing a self-supporting ceramic composite body, said method comprising a first-stage and a second-stage, said first-stage comprising: (a) orienting a source of parent metal and a permeable mass of filler relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said permeable mass of filler; (b) heating said parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of filler so that fresh oxidation reaction product continues to form within the permeable mass of filler at an interface between the oxidant and previously formed oxidation reaction product; (c) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said permeable mass of filler thereby forming a body of oxidation reaction product embedding filler; said second-stage comprising: (d) comminuting said body of oxidation reaction product embedding filler from said first-stage to a particulate size for use as filler, and forming a shaped, permeable, self-supporting preform of said particulate filler; (e) orienting a source of parent metal and said preform relative to each other so that formation of an oxidation reaction product from a reaction between said parent metal and a vapor-phase oxidant will occur in a direction towards and into said preform; (f) heating said parent metal to a temperature above its melting point but below the melting point of either of said preform or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant, to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the preform so that fresh oxidation reaction product continues to form within the preform at an interface between the oxidant and previously formed oxidation reaction product; and (g) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates said preform thereby forming said ceramic composite body having a configuration of said preform.

Claim 29

The method according to either of claims 1 or 12, wherein said source of parent metal in said second-stage comprises a shaped body of parent metal, and further comprising: (1) placing said permeable mass of particulate filler in said second-stage in conforming engagement with said shaped body of parent metal in step (e) of said second-stage; (2) heating said shaped body of parent metal to a temperature above its melting point but below the melting point of either of said permeable mass of particulate filler or said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said oxidant at said temperature to form said oxidation reaction product, and at said temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said oxidant to draw molten metal through the oxidation reaction product towards the oxidant and towards and into the permeable mass of particulate filler so that fresh oxidation reaction product continues to form within the permeable mass of particulate filler at an interface between the oxidant and previously formed oxidation reaction product; and (3) continuing said reacting for a time sufficient so that said oxidation reaction product infiltrates and embeds at least a portion of said mass of particulate filler thereby forming a ceramic composite body having a configuration which inversely replicates that of said shaped body of parent metal, said ceramic composite body further comprising a cavity which resembles said shaped body of parent metal.