US5434113A
Expired / Lapsed
US
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Ceramic composite and methods of making the same
Assignee: Lanxide Technology Co LP
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Filing: 1993-05-28
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Granted: 1995-07-18
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Expires: 2013-05-28
Abstract
Abstract There is provided a method for producing a self-supporting ceramic composite comprising (1) a ceramic matrix obtained by oxidation of an aluminum zinc alloy to form a polycrystalline oxidation reaction product of the metal with an oxidant, and (2) one or more fillers embedded by the matrix. The metal alloy and permeable mass of filler having at least one defined surface boundary are oriented relative to each other so that formation of the oxidation reaction product will occur into said mass of filler and in a direction towards said defined surface boundary. On heating the metal to a first temperature above its melting point but below the melting point of said oxidation reaction product to form a body of molten parent metal, the molten metal reacts with said oxidant to form said oxidation reaction product which infiltrates said mass of filler to said defined surface boundary. The resulting infiltrated mass is heated to a second temperature in order to remove or oxidize at least a substantial portion of one or more residual non-oxidized metallic constituents from or in said infiltrated mass without substantial formation of said oxidation reaction product beyond said defined surface boundary, thereby producing a self-supporting ceramic composite.
Inventors
- 👤 Jack A. Kuszyk
- 👤 Christopher R. Kennedy
- 👤 Ralph R. Ballario, Jr.
- 👤 Craig B. Shumaker
- 👤 Eric J. Van Voorhees
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 09:11
CPC Classifications
B; B22; B22D; B22D41/00; B22D41/14; B22D41/22; B22D41/28; B22D41/30; B22D41/32; C; C04; C04B; C04B35/00; C04B35/622; C04B35/64; C04B35/65; C04B35/652; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49988
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
53 words
A self-supporting ceramic composite body comprising at least one filler embedded by a ceramic matrix, said ceramic matrix comprising a three-dimensionally interconnected oxidation reaction product and one or more metallic constituents of a parent metal comprising aluminum, said metallic constituents totalling no more than about 0.5% by weight of said ceramic composite body.
Claim 2
Dependent Claim
53 words
A self-supporting ceramic composite body comprising at least one filler embedded by a ceramic matrix, said ceramic matrix comprising a three-dimensionally interconnected oxidation reaction product and one or more metallic constituents of a parent metal comprising aluminum, said metallic constituents totalling no more than about 0.5% by weight of said ceramic composite body.
Claim 3
Dependent Claim
15 words
The ceramic composite body of claim 1, wherein said oxidation reaction product comprises aluminum oxide.
Claim 4
Dependent Claim
16 words
The ceramic composite body of claim 1, further comprising between about 2% and about 25% porosity.
Claim 5
Dependent Claim
21 words
The ceramic composite body of claim 3, wherein said porosity is accessible to an exterior surface of said ceramic composite body.
Claim 6
Dependent Claim
15 words
The ceramic composite body of claim 3, wherein said porosity is at least partially interconnected.
Claim 7
Dependent Claim
44 words
The ceramic composite body of claim 1, wherein said filler comprises one or more metal oxides, borides, nitrides, or carbides of a metal selected from the group consisting of aluminum, cerium, hafnium, lanthanum, silicon, neodymium, praseodymium, samarium, scandium, thorium, uranium, titanium, yttrium, and zirconium.
Claim 8
Dependent Claim
27 words
The ceramic composite body of claim 1, wherein said filler comprises a material selected from the group consisting of granules, fibers, whiskers, pellets, tubes and mixtures thereof.
Claim 9
Dependent Claim
25 words
The ceramic composite body of claim 1, wherein said filler comprises at least one material selected from the group consisting of alumina and silicon carbide.
Claim 10
Dependent Claim
19 words
The ceramic composite body of claim 1, further comprising no more than about 5 percent by weight zinc aluminate.
Claim 11
Dependent Claim
38 words
The ceramic composite body of claim 1, wherein said three-dimensionally interconnected oxidation reaction product comprises crystallites, wherein further adjoining crystallites define a grain boundary therebetween, and wherein still further said grain boundaries are substantially devoid of silicious phases.
Claim 12
Dependent Claim
16 words
The ceramic composite body of claim 10, wherein said grain boundaries have no other phase present.
Claim 13
Independent Claim
446 words
A method for producing a self-supporting ceramic composite comprising (1) a ceramic matrix obtained by oxidation of a parent metal comprising an aluminum alloy to form a polycrystalline material comprising (a) an oxidation reaction product of the parent metal with at least one oxidant and (b) at least 0.5 percent by volume of an at least partially interconnected metal phase comprising residual non-oxidized metallic constituents of said parent metal; and (2) at least one filler embedded by the matrix, which method comprises: (a) positioning a parent metal comprising aluminum and at least one dopant adjacent to a permeable mass of filler having at least one defined surface boundary and orienting said parent metal and said filler relative to each other so that formation of an oxidation reaction product of the parent metal with an oxidant will occur into said mass of filler and in a direction towards said defined surface boundary; (b) heating said parent metal to a first temperature above its melting point but below the melting point of said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said at least one oxidant at said first temperature to form said oxidation reaction product, and at said first temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said at least one oxidant, to draw molten metal through the oxidation reaction product towards the at least one oxidant and towards and into the adjacent mass of filler so that oxidation reaction product continues to form within the mass of filler at the interface between the oxidant and previously formed oxidation reaction product, and continuing said reaction for a time sufficient to infiltrate said mass of filler to said defined surface boundary with a ceramic matrix, said ceramic matrix comprising said oxidation reaction product and said at least partially interconnected metal phase comprising at least two residual non-oxidized metallic constituents of said parent metal, said at least two metallic constituents including said at least one dopant and aluminum; and (c) heating the resulting infiltrated mass of step (b) in an environment selected from the group consisting of an inert atmosphere and a vacuum to a second temperature above the first temperature but below the melting point of the oxidation reaction product in order to remove at least a sufficient portion of substantially only said at least one dopant from said infiltrated mass, thereby preventing continued reaction of said residual parent metal constituent of said at least partially interconnected metal phase with at least said at least one oxidant at at least said first temperature.
Claim 14
Independent Claim
446 words
A method for producing a self-supporting ceramic composite comprising (1) a ceramic matrix obtained by oxidation of a parent metal comprising an aluminum alloy to form a polycrystalline material comprising (a) an oxidation reaction product of the parent metal with at least one oxidant and (b) at least 0.5 percent by volume of an at least partially interconnected metal phase comprising residual non-oxidized metallic constituents of said parent metal; and (2) at least one filler embedded by the matrix, which method comprises: (a) positioning a parent metal comprising aluminum and at least one dopant adjacent to a permeable mass of filler having at least one defined surface boundary and orienting said parent metal and said filler relative to each other so that formation of an oxidation reaction product of the parent metal with an oxidant will occur into said mass of filler and in a direction towards said defined surface boundary; (b) heating said parent metal to a first temperature above its melting point but below the melting point of said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said at least one oxidant at said first temperature to form said oxidation reaction product, and at said first temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said at least one oxidant, to draw molten metal through the oxidation reaction product towards the at least one oxidant and towards and into the adjacent mass of filler so that oxidation reaction product continues to form within the mass of filler at the interface between the oxidant and previously formed oxidation reaction product, and continuing said reaction for a time sufficient to infiltrate said mass of filler to said defined surface boundary with a ceramic matrix, said ceramic matrix comprising said oxidation reaction product and said at least partially interconnected metal phase comprising at least two residual non-oxidized metallic constituents of said parent metal, said at least two metallic constituents including said at least one dopant and aluminum; and (c) heating the resulting infiltrated mass of step (b) in an environment selected from the group consisting of an inert atmosphere and a vacuum to a second temperature above the first temperature but below the melting point of the oxidation reaction product in order to remove at least a sufficient portion of substantially only said at least one dopant from said infiltrated mass, thereby preventing continued reaction of said residual parent metal constituent of said at least partially interconnected metal phase with at least said at least one oxidant at at least said first temperature.
Claim 15
Dependent Claim
38 words
The method of claim 12, wherein said at least one dopant comprises at least one material selected from the group consisting of magnesium, zinc, silicon, germanium, tin, lead, boron, sodium, lithium, calcium, phosphorus, yttrium and rare earth metals.
Claim 16
Dependent Claim
25 words
The method of claim 12, wherein said at least one dopant comprises at least one material selected from the group consisting of magnesium and zinc.
Claim 17
Dependent Claim
16 words
The method of claim 12, wherein said environment comprises an inert atmosphere comprising a nitrogen-containing atmosphere.
Claim 18
Dependent Claim
15 words
The method of claim 12, wherein said at least a sufficient portion comprises substantially all.
Claim 19
Independent Claim
442 words
A method for producing a self-supporting ceramic composite comprising (1) a ceramic matrix obtained by oxidation of a parent metal comprising an aluminum alloy to form a polycrystalline material comprising (a) an oxidation reaction product of the parent metal with at least one oxidant and (b) at least 0.5 percent by volume of an at least partially interconnected metal phase comprising residual non-oxidized metallic constituents of said parent metal; and (2) at least one filler embedded by the matrix, which method comprises: (a) positioning a parent metal comprising aluminum and at least about 1 percent by weight zinc adjacent to a permeable mass of filler having at least one defined surface boundary and orienting said parent metal and said filler relative to each other so that formation of an oxidation reaction product of the parent metal with an oxidant will occur into said mass of filler and in a direction towards said defined surface boundary; (b) heating said parent metal to a first temperature above its melting point but below the melting point of said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said at least one oxidant at said first temperature to form said oxidation reaction product, and at said first temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said at least one oxidant, to draw molten metal through the oxidation reaction product towards the at least one oxidant and towards and into the adjacent mass of filler so that oxidation reaction product continues to form within the mass of filler at the interface between the at least one oxidant and previously formed oxidation reaction product, and continuing said reaction for a time sufficient to infiltrate said mass of filler to said defined surface boundary with a ceramic matrix, said ceramic matrix comprising said oxidation reaction product and said at least partially interconnected metal phase comprising at least two residual non-oxidized metallic constituents of said parent metal, said at least two metallic constituents including zinc and aluminum; and (c) heating the resulting infiltrated mass of step (b) in an environment selected from the group consisting of an inert atmosphere and a vacuum to a second temperature above the first temperature but below the melting point of the oxidation reaction product in order to remove at least a substantial portion of substantially only said residual zinc from said infiltrated mass, thereby preventing continued reaction of said parent metal of said at least partially interconnected metal phase with at least said oxidant at at least said first temperature.
Claim 20
Independent Claim
442 words
A method for producing a self-supporting ceramic composite comprising (1) a ceramic matrix obtained by oxidation of a parent metal comprising an aluminum alloy to form a polycrystalline material comprising (a) an oxidation reaction product of the parent metal with at least one oxidant and (b) at least 0.5 percent by volume of an at least partially interconnected metal phase comprising residual non-oxidized metallic constituents of said parent metal; and (2) at least one filler embedded by the matrix, which method comprises: (a) positioning a parent metal comprising aluminum and at least about 1 percent by weight zinc adjacent to a permeable mass of filler having at least one defined surface boundary and orienting said parent metal and said filler relative to each other so that formation of an oxidation reaction product of the parent metal with an oxidant will occur into said mass of filler and in a direction towards said defined surface boundary; (b) heating said parent metal to a first temperature above its melting point but below the melting point of said oxidation reaction product to form a body of molten parent metal and reacting the molten parent metal with said at least one oxidant at said first temperature to form said oxidation reaction product, and at said first temperature maintaining at least a portion of said oxidation reaction product in contact with and extending between said body of molten metal and said at least one oxidant, to draw molten metal through the oxidation reaction product towards the at least one oxidant and towards and into the adjacent mass of filler so that oxidation reaction product continues to form within the mass of filler at the interface between the at least one oxidant and previously formed oxidation reaction product, and continuing said reaction for a time sufficient to infiltrate said mass of filler to said defined surface boundary with a ceramic matrix, said ceramic matrix comprising said oxidation reaction product and said at least partially interconnected metal phase comprising at least two residual non-oxidized metallic constituents of said parent metal, said at least two metallic constituents including zinc and aluminum; and (c) heating the resulting infiltrated mass of step (b) in an environment selected from the group consisting of an inert atmosphere and a vacuum to a second temperature above the first temperature but below the melting point of the oxidation reaction product in order to remove at least a substantial portion of substantially only said residual zinc from said infiltrated mass, thereby preventing continued reaction of said parent metal of said at least partially interconnected metal phase with at least said oxidant at at least said first temperature.
Claim 21
Dependent Claim
21 words
The method of claim 17, wherein said parent metal comprises from about 4 percent to about 7 percent by weight zinc.
Claim 22
Dependent Claim
21 words
The method of claim 17, wherein said first temperature is about 940° C. and said second temperature is about 1000° C.
Claim 23
Dependent Claim
15 words
The method of claim 17, wherein said oxidant comprises air and said environment comprises nitrogen.
Claim 24
Dependent Claim
12 words
The method of claim 17, wherein said substantial portion comprises substantially all.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1998-07-17 | 1999-01-16 | 1999-07-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-07-17 | 2003-01-16 | 2003-07-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-07-17 | 2007-01-16 | 2007-07-18 | $7700.00 | Window Closed / Lapsed |