Method for in situ tailoring the metallic component of ceramic articles

Claim 1

A method for producing a ceramic body comprising an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) heating a source of precursor metal in the presence of a vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (b) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein a primary constituent of said at least one second metal comprises at least one material selected from the group consisting of titanium, iron, nickel, copper, zirconium, hafnium, cobalt, manganese, silver, gold and platinum and wherein said second metal is present in an amount greater than about 2.0% by weight of said parent metal when the formation of said oxidation reaction product is begun; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product, said maintaining being continued for a time sufficient to deplete said precursor metal in said flux relative to said at least one second metal to result in formation or enrichment of at least one metallic phase comprising at least said second metal; and (d) continuing step (c) at said temperature for a time sufficient to form said ceramic body comprising (a) said oxidation reaction product; and (b) a metallic component comprising said at least one metallic phase; and (e) recovering said formed ceramic body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic body is effected by said at least one metallic phase.

Claim 2

A method for producing a ceramic body comprising an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) heating a source of precursor metal in the presence of a vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (b) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein a primary constituent of said at least one second metal comprises at least one material selected from the group consisting of titanium, iron, nickel, copper, zirconium, hafnium, cobalt, manganese, silver, gold and platinum and wherein said second metal is present in an amount greater than about 2.0% by weight of said parent metal when the formation of said oxidation reaction product is begun; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product, said maintaining being continued for a time sufficient to deplete said precursor metal in said flux relative to said at least one second metal to result in formation or enrichment of at least one metallic phase comprising at least said second metal; and (d) continuing step (c) at said temperature for a time sufficient to form said ceramic body comprising (a) said oxidation reaction product; and (b) a metallic component comprising said at least one metallic phase; and (e) recovering said formed ceramic body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic body is effected by said at least one metallic phase.

Claim 3

A method for producing a ceramic composite body comprising infiltrating a porous body with an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) forming at least one porous body to be infiltrated, said at least one porous body comprising a body selected from the group consisting of a permeable mass of filter material an a permeable preform; (b) orienting said at least one porous body and a source of precursor metal relative to each other so that formation of said oxidation reaction product of said precursor metal will occur into said at least one porous body and towards said vapor-phase oxidant; (c) heating said source of precursor metal and said at least one porous body in the presence of said vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (d) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein a primary constituent of said at least one second metal comprises at least one material selected from the group consisting of titanium, iron, nickel, copper, zirconium, hafnium, cobalt, manganese, silver, gold and platinum and wherein said second metal is present in an amount greater than about 2.0% by weight of said parent metal when the formation of oxidation reaction product is begun; (e) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product that has unfiltrated said at least one body; (f) continuing step (e) at said temperature for a time sufficient to infiltrate at least a portion of said at least one porous body with said polycrystalline material, thereby forming said ceramic composite body comprising (a) said oxidation reaction product; (b) said at least one porous body; and (c) a metallic component comprising at least one metallic phase; and (g) recovering said formed ceramic composite body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic composite body is effected by said at least one metallic phase.

Claim 4

A method for producing a ceramic composite body comprising infiltrating a porous body with an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) forming at least one porous body to be infiltrated, said at least one porous body comprising a body selected from the group consisting of a permeable mass of filter material an a permeable preform; (b) orienting said at least one porous body and a source of precursor metal relative to each other so that formation of said oxidation reaction product of said precursor metal will occur into said at least one porous body and towards said vapor-phase oxidant; (c) heating said source of precursor metal and said at least one porous body in the presence of said vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (d) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein a primary constituent of said at least one second metal comprises at least one material selected from the group consisting of titanium, iron, nickel, copper, zirconium, hafnium, cobalt, manganese, silver, gold and platinum and wherein said second metal is present in an amount greater than about 2.0% by weight of said parent metal when the formation of oxidation reaction product is begun; (e) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product that has unfiltrated said at least one body; (f) continuing step (e) at said temperature for a time sufficient to infiltrate at least a portion of said at least one porous body with said polycrystalline material, thereby forming said ceramic composite body comprising (a) said oxidation reaction product; (b) said at least one porous body; and (c) a metallic component comprising at least one metallic phase; and (g) recovering said formed ceramic composite body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic composite body is effected by said at least one metallic phase.

Claim 5

A method for producing a ceramic body comprising an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) heating a source of precursor metal in the presence of a vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (b) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein said at least one second metal is present in a quantity greater than about 10% by weight of said parent metal when the formation of said oxidation reaction product is begun; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product, said maintaining being continued for a time sufficient to deplete said precursor metal in said flux relative to said at least one second metal to result in formation or enrichment of at least one metallic phase comprising at least said second metal; (d) continuing step (c) at said temperature for a time sufficient to form said ceramic body comprising (i) said oxidation reaction product; and (ii) a metallic component comprising said at least one metallic phase; and (e) recovering said formed ceramic body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic body is effected by said at least one metallic phase.

Claim 6

A method for producing a ceramic body comprising an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) heating a source of precursor metal in the presence of a vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (b) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein said at least one second metal is present in a quantity greater than about 10% by weight of said parent metal when the formation of said oxidation reaction product is begun; (c) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product, said maintaining being continued for a time sufficient to deplete said precursor metal in said flux relative to said at least one second metal to result in formation or enrichment of at least one metallic phase comprising at least said second metal; (d) continuing step (c) at said temperature for a time sufficient to form said ceramic body comprising (i) said oxidation reaction product; and (ii) a metallic component comprising said at least one metallic phase; and (e) recovering said formed ceramic body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic body is effected by said at least one metallic phase.

Claim 7

A method for producing a ceramic composite body comprising infiltrating a porous body with an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) forming at least one porous body to be infiltrated, said at least one porous body comprising a body selected from the group consisting of a permeable mass of filler material and a permeable preform; (b) orienting said at least one porous body and a source of precursor metal relative to each other so that formation of said oxidation reaction product of said precursor metal will occur into said at least one porous body and towards said vapor-phase oxidant; (c) heating said source of precursor metal and said at least one porous body in the presence of said vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (d) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein said at least one second metal is present in a quantity greater than about 10% by weight of said parent metal when the formation of said oxidation reaction product is begun; (e) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product that has infiltrated said at least one body; (f) continuing step (e) at said temperature for a time sufficient to infiltrate at least a portion of said at least one porous body with said polycrystalline material, thereby forming said ceramic composite body comprising (i) said oxidation reaction product; (ii) said at least one porous body; and (iii) a metallic component comprising at least one metallic phase; and (g) recovering said formed ceramic composite body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic composite body is effected by said at least one metallic phase.

Claim 8

A method for producing a ceramic composite body comprising infiltrating a porous body with an oxidation reaction product obtained by oxidation of a precursor metal to form a polycrystalline material comprising (i) an oxidation reaction product of said precursor metal with a vapor-phase oxidant, and (ii) a metallic component, said method comprising the steps of: (a) forming at least one porous body to be infiltrated, said at least one porous body comprising a body selected from the group consisting of a permeable mass of filler material and a permeable preform; (b) orienting said at least one porous body and a source of precursor metal relative to each other so that formation of said oxidation reaction product of said precursor metal will occur into said at least one porous body and towards said vapor-phase oxidant; (c) heating said source of precursor metal and said at least one porous body in the presence of said vapor-phase oxidant to a temperature above the melting point of said precursor metal but below the melting point of its oxidation reaction product to form a body of molten precursor metal; (d) reacting said body of molten precursor metal with said vapor-phase oxidant at said temperature to permit said oxidation reaction product to form; and inducing a flux of molten metal within said oxidation reaction product, said flux comprising said molten precursor metal and at least one second metal, wherein said at least one second metal is present in a quantity greater than about 10% by weight of said parent metal when the formation of said oxidation reaction product is begun; (e) maintaining at least a portion of said oxidation reaction product in contact with and between said molten precursor metal and said vapor-phase oxidant at said temperature to progressively draw molten precursor metal through said oxidation reaction product towards said vapor-phase oxidant to permit fresh oxidation reaction product to continue to form at an interface between said vapor-phase oxidant and previously formed oxidation reaction product that has infiltrated said at least one body; (f) continuing step (e) at said temperature for a time sufficient to infiltrate at least a portion of said at least one porous body with said polycrystalline material, thereby forming said ceramic composite body comprising (i) said oxidation reaction product; (ii) said at least one porous body; and (iii) a metallic component comprising at least one metallic phase; and (g) recovering said formed ceramic composite body, whereby said at least one metallic phase is present in a significant quantity such that at least one property of the formed ceramic composite body is effected by said at least one metallic phase.