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Methods of producing ceramic and ceramic composite bodies
| Details |
Inventors: Lesher, Harold D.; Dwivedi, Ratnesh K.; Goldberg, Perry B.;
Assignee: Lanxide Technology Company, LP (Newark, DE)
Primary Examiner: Beck; Shrive
Assistant Examiner: Dang; Vi D.
Attorney, Agent or Firm: Mortenson; Mark G., McShane; William E.
There is disclosed methods for producing self-supporting ceramic matrix and ceramic matrix composite bodies by batch, semi-continuous, and continuous processes utilzing the directed oxidation of a molten parent metal with an oxidant to form an oxidation reaction product which may embed filler material. |
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DETAILED DESCRIPTION The present invention relates to techniques whereby ceramic matrix and ceramic matrix composite bodies may be produced in a continuous or semi-continuous manner.
Generally, these techniques involve the growth of an oxidation reaction product formed by the reaction of a molten parent metal with an oxidant.
In a preferred embodiment of the invention, the formed body comprises a ceramic matrix composite body which is manufactured by growing an oxidation reaction product into a body of filler material, the body of filler material being configured in either an unbonded mass or as a preform.
The oxidation reaction product comprises the product of an oxidation reaction of a molten parent metal (e.
g.
, aluminum) with an oxidant.
Specifically, the body of filler material is positioned adjacent to a source of parent metal such that formation of an oxidation reaction product of the parent metal will occur in a direction towards an oxidant (e.
g.
, a solid, liquid and/or a vapor oxidant) and into the body of filler material.
Moreover, a barrier means can be used in combination with the body of filler material, the barrier means being capable of locally inhibiting, poisoning, stopping, interfering with, preventing or the like, continued growth of the oxidation reaction product.
Typically, the parent metal is heated to a temperature above its melting point, but below the melting point of its oxidation reaction product, to form a body of molten metal.
At this temperature, or within this temperature range, the molten metal reacts with the oxidant to form the oxidation reaction product.
At least a portion of the oxidation reaction product is maintained in contact with and between the molten metal and the oxidant to draw molten metal through the oxidation reaction product towards and into contact with the oxidant such that fresh oxidation reaction product continues to form at an interface between the oxidant and previously formed oxidation reaction product, thus allowing the growth of oxidation reaction product to infiltrate the adjacent body of filler material
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