US4940679A
Expired / Lapsed
US
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Process for preparing self-supporting bodies and products made thereby
Assignee: Lanxide Technology Co LP
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Filing: 1987-12-23
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Granted: 1990-07-10
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Expires: 2007-12-23
Abstract
Abstract Self-supporting bodies are produced by reactive infiltration of a parent metal into boron carbide typically resulting in a composite comprising a boron-containing compound and metal. The mass to be infiltrated may contain one or more inert fillers admixed with the boron carbide, or at least one carbon donor material, to produce a composite by reactive infiltration, which composite comprises a matrix of metal and boron-containing compound embedding the filler. In one embodiment of the invention, a parent metal is reactively infiltrated into a mass comprising a boron carbide material mixed with a carbon-containing compound. In this embodiment, a self-supporting composite is formed typically comprising a boron-containing compound, a carbon-containing compound, and metal. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal and/or porosity. The mass to be infiltrated can be contained within a refractory vessel having a venting means included therein.
Inventors
- 👤 Terry D. Claar
- 👤 Steven M. Mason
- 👤 Kevin P. Pochopien
- 👤 Danny R. White
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 00:48
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/009; C04B35/00; C04B35/71; C04B35/74; C04B35/515; C04B35/56; C04B35/5607; C04B35/5611; C04B35/5622; C04B35/58; C04B35/5805; C04B35/58064; C04B35/58071; C04B35/58078; C04B35/622; C04B35/64; C04B35/65; C04B35/652; C04B35/653; C04B41/45; C04B41/50; C04B41/5053; C04B41/5062; C04B41/80; C04B41/81; C04B41/85; C04B41/87; C22; C22C; C22C29/00
Claims Analysis
Total Claims: 49
Claim 1
Independent Claim
166 words
A method for producing a self-supporting body, comprising: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal; contacting said body of molten parent metal with a permeable mass comprising boron carbide and a carbon donor material; maintaining said temperature for a time sufficient to permit infiltration of said molten parent metal into said permeable mass and to permit reaction of said molten parent metal with both said carbon donor material and said boron carbide to form at least one parent metal carbon-containing compound and at least one parent metal boron-containing compound; and continuing said infiltration and reaction for a time sufficient to react said boron carbide substantially completely to produce said self-supporting body comprising at least one parent metal carbon-containing compound and at least one parent metal boron-containing compound.
Claim 2
Independent Claim
166 words
A method for producing a self-supporting body, comprising: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal; contacting said body of molten parent metal with a permeable mass comprising boron carbide and a carbon donor material; maintaining said temperature for a time sufficient to permit infiltration of said molten parent metal into said permeable mass and to permit reaction of said molten parent metal with both said carbon donor material and said boron carbide to form at least one parent metal carbon-containing compound and at least one parent metal boron-containing compound; and continuing said infiltration and reaction for a time sufficient to react said boron carbide substantially completely to produce said self-supporting body comprising at least one parent metal carbon-containing compound and at least one parent metal boron-containing compound.
Claim 3
Dependent Claim
24 words
The method of claim 1, wherein said carbon donor material comprises a material selected from the group consisting of graphite powder and carbon black.
Claim 4
Dependent Claim
32 words
The method of claim 1, wherein said self-supporting body comprises a parent metal boride compound and a parent metal carbon compound, formed upon reaction of said boron carbide and said parent metal.
Claim 5
Independent Claim
137 words
A method for producing a self-supporting body comprising: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal, and contacting said body of molten parent metal with a mass comprising boron carbide and boron; maintaining said temperature for a time sufficient to permit infiltration of molten parent metal into said mass and to permit reaction of said molten parent metal with said boron carbide and boron to form parent metal boron-containing compounds; and continuing said infiltration and reaction for a time sufficient to react said boron carbide substantially completely to produce said self-supportng body comprising at least one parent metal boride.
Claim 6
Independent Claim
137 words
A method for producing a self-supporting body comprising: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal, and contacting said body of molten parent metal with a mass comprising boron carbide and boron; maintaining said temperature for a time sufficient to permit infiltration of molten parent metal into said mass and to permit reaction of said molten parent metal with said boron carbide and boron to form parent metal boron-containing compounds; and continuing said infiltration and reaction for a time sufficient to react said boron carbide substantially completely to produce said self-supportng body comprising at least one parent metal boride.
Claim 7
Dependent Claim
49 words
The method of claim 1, wherein said parent metal comprises zirconium, and said self-supporting body comprises a zirconium compound having at least one phase selected from the group of phases consisting of a boride of zirconium, and a mixture of a boride of zirconium and a carbide of zirconium.
Claim 8
Dependent Claim
22 words
The method of claim 1, wherein said carbon donor material comprises carbon black present in an amount of about 5-75 weight percent.
Claim 9
Dependent Claim
22 words
The method of claim 1, wherein said carbon donor material comprises carbon black present in an amount of about 5-50 weight percent.
Claim 10
Dependent Claim
22 words
The method of claim 1, wherein said carbon donor material comprises carbon black present in an amount of about 5 weight percent.
Claim 11
Dependent Claim
21 words
The method of claim 8, wherein said parent metal comprises zirconium, and a ratio of ZrB 2 /ZrC is about 1.
Claim 12
Independent Claim
154 words
A method for producing a self-supporting body, comprising: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal; contacting said body of molten parent metal with a mass comprising boron carbide; containing said mass of boron carbide and said body of molten parent metal within a graphite mold, said graphite mold including a venting means; maintaining said temperature for a time sufficient to permit infiltration of said molten parent metal into said mass and to permit substantially complete reaction of said molten parent metal with said boron carbide to form at least one boron-containing compound; and continuing said infiltration and reaction for a time sufficient to produce said self-supporting body comprising at least one parent metal boron-containing compound.
Claim 13
Independent Claim
154 words
A method for producing a self-supporting body, comprising: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal; contacting said body of molten parent metal with a mass comprising boron carbide; containing said mass of boron carbide and said body of molten parent metal within a graphite mold, said graphite mold including a venting means; maintaining said temperature for a time sufficient to permit infiltration of said molten parent metal into said mass and to permit substantially complete reaction of said molten parent metal with said boron carbide to form at least one boron-containing compound; and continuing said infiltration and reaction for a time sufficient to produce said self-supporting body comprising at least one parent metal boron-containing compound.
Claim 14
Dependent Claim
18 words
The method of claim 10, wherein said venting means comprises a plurality of through-holes in the graphite mold.
Claim 15
Dependent Claim
47 words
The method of claim 10, wherein said venting means comprises a plurality of through-holes in the graphite mold, said through-holes being located in the graphite mold at a position corresponding to the direction of said infiltration reaction of the parent metal into the mass of boron carbide.
Claim 16
Independent Claim
121 words
A method for producing a self-supporting body, which comprises: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal, and contacting said body of molten parent metal with a permeable mass comprising boron carbide; maintaining said temperature for a time sufficient to permit infiltration of molten parent metal into said mass and to permit reaction of molten parent metal with said boron carbide; and continuing said infiltration and reaction for a time sufficient to react said boron carbide substantially completely to produce said self-supporting body.
Claim 17
Independent Claim
121 words
A method for producing a self-supporting body, which comprises: selecting a parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, hafnium, vanadium, chromium and niobium; heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal, and contacting said body of molten parent metal with a permeable mass comprising boron carbide; maintaining said temperature for a time sufficient to permit infiltration of molten parent metal into said mass and to permit reaction of molten parent metal with said boron carbide; and continuing said infiltration and reaction for a time sufficient to react said boron carbide substantially completely to produce said self-supporting body.
Claim 18
Dependent Claim
40 words
The method according to claim 13, further comprising forming said mass by admixing said boron carbide with an inert filler, permitting said infiltration and reaction into said mass to embed said filler, and producing a composite as said self-supporting body.
Claim 19
Dependent Claim
16 words
The method according to claim 13 or claim 14, wherein said body comprises a metallic phase.
Claim 20
Dependent Claim
42 words
The method according to claim 13 or claim 14, wherein said self-supporting body comprises at least one parent metal boron-containing compound and at least one parent metal carbon-containing compound formed upon reaction of said mass comprising boron carbide and said parent metal.
Claim 21
Dependent Claim
33 words
The method according to claim 13 or claim 14, wherein said mass comprising boron carbide is present in at least a stoichiometric amount with respect to the parent metal infiltrated into said mass.
Claim 22
Dependent Claim
22 words
The method according to claim 13 or claim 14, wherein carbon is incorporated into said mass for reaction with said parent metal.
Claim 23
Dependent Claim
25 words
The method according to claim 16, wherein said parent metal comprising at least one metal selected from the group consisting of titanium, zirconium, and hafnium.
Claim 24
Dependent Claim
21 words
The method of claim 18, wherein said carbon comprises from about 5 to about 10 percent by weight of said mass.
Claim 25
Dependent Claim
46 words
The method according to claim 13 or claim 14, wherein said parent metal comprises zirconium, and said self-supporting body comprises a zirconium compound selected from the group consisting of a boride of zirconium or a mixture of a boride of zirconium and a carbide of zirconium.
Claim 26
Dependent Claim
13 words
The method according to claim 21, wherein said self-supporting body further comprises zirconium.
Claim 27
Dependent Claim
38 words
The method according to claim 13 or claim 14, wherein said mass comprises a preform of predetermined shape, and said infiltration and said reaction into said preform produce a self-supporting body having a configuration corresponding to said preform.
Claim 28
Dependent Claim
39 words
The method according to claim 14, wherein said filler comprises at least one filler selected from the group consisting of fibers, whiskers, particulates, powders, rods, wires, wire cloth, refractory cloth, reticulated foam, plates, platelets, solid spheres, and hollow spheres.
Claim 29
Dependent Claim
14 words
The method according to claim 23, wherein said filler further comprises a protective precoat.
Claim 30
Dependent Claim
30 words
The method according to claim 14 or claim 25, wherein said filler comprises at least one filler selected from the group consisting of alumina and carbon with a protective precoat.
Claim 31
Dependent Claim
46 words
The method according to claim 13 or claim 14, wherein said parent metal comprises titanium, and said self-supporting body comprises a titanium compound selected from the group consisting of a boride of titanium or a mixture of a boride of titanium and a carbide of titanium.
Claim 32
Dependent Claim
45 words
The method according to claim 13 or claim 14, wherein said parent metal comprises hafnium, and said self-supporting body comprises a hafnium compound selected from the group consisting of a boride of hafnium and a mixture of boride of hafnium and a carbide of hafnium.
Claim 33
Dependent Claim
13 words
The method according to claim 27, wherein said self-supporting body further comprises titanium.
Claim 34
Dependent Claim
13 words
The method according to claim 28, wherein said self-supporting body further comprises hafnium.
Claim 35
Dependent Claim
22 words
The method of claim 13 or claim 14, wherein at least one of said parent metal boron-containing compounds exhibits a platelet-like structure.
Claim 36
Dependent Claim
14 words
The method of claim 21, wherein said boride of zirconium exhibits a platelet-like structure.
Claim 37
Dependent Claim
14 words
The method of claim 27, wherein said boride of titanium exhibits a platelet-like structure.
Claim 38
Dependent Claim
14 words
The method of claim 28, wherein said boride of hafnium exhibits a platelet-like structure.
Claim 39
Dependent Claim
61 words
The method of claim 4, further comprising admixing an inert filler with said mass, permitting said infiltration and reaction into said mass to embed said filler, and producing a composite as said self-supporting body having a matrix embedding said filler, said matrix comprising a metallic phase of unreacted constituents of the parent metal and at least one parent metal boron-containing compound.
Claim 40
Dependent Claim
82 words
A self-supporting composite body comprising at least one metal phase selected from the group consisting of zirconium, titanium and hafnium, and a three-dimensionally interconnected ceramic phase extending to the boundaries of said composite body, said ceramic phase comprising at least one carbide selected from the group consisting of a carbide of zirconium, a carbide of titanium, and a carbide of hafnium, and said composite body further comprising a boride of the metal corresponding to said carbide, said boride having a platelet-like structure.
Claim 41
Dependent Claim
82 words
A self-supporting composite body comprising at least one metal phase selected from the group consisting of zirconium, titanium and hafnium, and a three-dimensionally interconnected ceramic phase extending to the boundaries of said composite body, said ceramic phase comprising at least one carbide selected from the group consisting of a carbide of zirconium, a carbide of titanium, and a carbide of hafnium, and said composite body further comprising a boride of the metal corresponding to said carbide, said boride having a platelet-like structure.
Claim 42
Dependent Claim
27 words
The composite body of claim 36, wherein said metal phase comprises zirconium, said carbide comprises a carbide of zirconium, and said boride comprises a boride of zirconium.
Claim 43
Dependent Claim
22 words
The composite body of claim 37, said composite body possessing a fracture toughness of at least about 12 MPa m 1/2 .
Claim 44
Dependent Claim
24 words
The method of claim 1, wherein said parent metal comprises at least one metal selected from the group consisting of titanium, zirconium, and hafnium.
Claim 45
Dependent Claim
11 words
The method of claim 1, wherein said parent metal comprises zirconium.
Claim 46
Dependent Claim
24 words
The method of claim 13, wherein said parent metal comprises at least one metal selected from the group consisting of titanium, zirconium, and hafnium.
Claim 47
Dependent Claim
11 words
The method of claim 13, wherein said parent metal comprises zirconium.
Claim 48
Dependent Claim
24 words
The method of claim 4, wherein said parent metal comprises at least one metal selected from the group consisting of titanium, zirconium, and hafnium.
Claim 49
Dependent Claim
11 words
The method of claim 4, wherein said parent metal comprises zirconium.
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