Matrix Powder System and Composite Materials and Articles Made Therefrom

The present invention includes a matrix powder system comprising one or more polycrystalline carbides, binderless carbides, or a combination thereof, a composite comprising the matrix powder system and a metal bond phase, a matrix bit body for a drill bit for oil and gas drilling made of this composite material, and a drill bit for oil and gas drilling comprising the matrix bit body and at least one cutter. The polycrystalline and/or binderless carbides may comprise carbides of W, Ti, V, Cr, Nb, Mo, Ta, Hf, Zr, or a combination thereof. The binderless carbides have less than 3 wt. % binder and the binderless and/or polycrystalline carbides may have a grain size of ≦15 μm and a hardness of ≧1900 HV (0.5 kgf). Additional ceramic components and/or metals may also be present in the matrix powder system. Alternatively, the composite material may be present on only a portion of the matrix bit body surface.

Method of consolidating ultrafine metal carbide and metal boride particles and products made therefrom

Ultrafine metal carbide or metal boride particles are consolidated by a method including sintering at intermediate pressures. A green body comprising the ultrafine metal carbide or metal boride particles may be preheated under vacuum and then pressurized to the intermediate sintering pressure. After sintering, the article may be densified at an intermediate temperature below the sintering temperature, and at an elevated pressure above the intermediate sintering temperature. The resultant consolidated metal carbide or metal boride article may then be cooled and used for such applications as armor panels, abrasion resistant nozzles, and the like.

Polycrystalline diamond compacts including at least one transition layer and methods for stress management in polycrsystalline diamond compacts

Embodiments relate to polycrystalline diamond compacts (“PDCs”) that are less susceptible to liquid metal embrittlement damage due to the use of at least one transition layer between a polycrystalline diamond (“PCD”) layer and a substrate. In an embodiment, a PDC includes a PCD layer, a cemented carbide substrate, and at least one transition layer bonded to the substrate and the PCD layer. The at least one transition layer is formulated with a coefficient of thermal expansion (“CTE”) that is less than a CTE of the substrate and greater than a CTE of the PCD layer. At least a portion of the PCD layer includes diamond grains defining interstitial regions and a metal-solvent catalyst occupying at least a portion of the interstitial regions. The diamond grains and the catalyst collectively exhibit a coercivity of about 115 Oersteds or more and a specific magnetic saturation of about 15 Gauss·cm 3 /grams or less.

Device and method for producing a tubular refractory metal compound structure

The disclosure provides a device and method used to produce a tubular structure made of a refractory metal compound. In particular, the disclosure provides a device and method used to produce a tubular structure made of a refractory metal compound by reacting a green tubular structure made of a refractory metal with at least one reactive gas.

Polycrystalline compacts including grains of hard material, earth-boring tools including such compacts, and methods of forming such compacts and tools

Polycrystalline compacts include a polycrystalline superabrasive material comprising a first plurality of grains of superabrasive material having a first average grain size and a second plurality of grains of superabrasive material having a second average grain size smaller than the first average grain size. The first plurality of grains is dispersed within a substantially continuous matrix of the second plurality of grains. Earth-boring tools may include a body and at least one polycrystalline compact attached thereto. Methods of forming polycrystalline compacts may include coating relatively larger grains of superabrasive material with relatively smaller grains of superabrasive material, forming a green structure comprising the coated grains, and sintering the green structure. Other methods include mixing diamond grains with a catalyst and subjecting the mixture to a pressure greater than about five gigapascals (5.0 GPa) and a temperature greater than about 1,300° C. to form a polycrystalline diamond compact.

Refractory metal ceramics and methods of making thereof

A composition having nanoparticles of a refractory-metal carbide or refractory-metal nitride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles with an organic compound having a char yield of at least 60% by weight to form a precursor mixture.

Nano-structured refractory metals, metal carbides, and coatings and parts fabricated therefrom

Refractory metal and refractory metal carbide nanoparticle mixtures and methods for making the same are provided. The nanoparticle mixtures can be painted onto a surface to be coated and heated at low temperatures to form a gas-tight coating. The low temperature formation of refractory metal and refractory metal carbide coatings allows these coatings to be provided on surfaces that would otherwise be uncoatable or very difficult to coat, whether because they are carbon-based materials (e.g., graphite, carbon/carbon composites) or temperature sensitive materials (e.g., materials that would melt, oxidize, or otherwise not withstand temperatures above 800° C.), or because the high aspect ratio of the surface would prevent other coating methods from being effective (e.g., the inner surfaces of tubes and nozzles). The nanoparticle mixtures can also be disposed in a mold and sintered to form fully dense components.

Consumable core for manufacture of composite articles and related method

Systems, methods and devices adapted to ease manufacture of composite articles (e.g., ceramic composite articles), particularly composite articles which include a hollow feature are disclosed. In one embodiment, a system includes: a consumable core formed to be disposed within an inner portion of a composite precursor, the consumable core adapted to convert into an infiltrant during a manufacturing process and infiltrate the composite precursor.

PRESSED AND SELF SINTERED POLYMER DERIVED SiC MATERIALS, APPLICATIONS AND DEVICES

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC. 127-. (canceled)28. A filled silicon carbide composition comprising:a. polymer derived SiC particles;b. wherein the particles consist essentially of a ceramic having a filler bound into the ceramic;c. wherein the filler is selected to provide a predetermined property to a silicon carbide wafer; and,d. wherein the particles have less than 0.001% impurities.29. The silicon carbide composition of claim 28 , wherein the filler comprises a dopant.30. The silicon carbide composition of claim 28 , wherein the filler is a dopant.31. The silicon carbide composition of claim 29 , wherein the predetermined property is a band gap.32. The silicon carbide composition of claim 29 , wherein the predetermined property is a band gap.33. The silicon carbide composition of claim 29 , wherein the predetermined property is a p-n junction.34. The silicon carbide composition of claim 29 , wherein the predetermined property is a semiconductor feature.35. The silicon carbide composition of claim 29 , wherein the predetermined property is a p-type feature.36. The silicon carbide composition of claim 29 , wherein the predetermined property is a n-type feature.37. A filled polysilocarb composition comprising:a. polymer derived SiOC particles;b. wherein the particles consist essentially of a ceramic having a filler bound into the ceramic;c. wherein the filler is selected to provide a predetermined property to a silicon carbide wafer; and,d. wherein the particles have less than 0.001% impurities.38. The polysilocarb composition of claim 37 , wherein the filler comprises a dopant.39. The polysilocarb composition of ; wherein the filler is a dopant.40. The polysilocarb composition of ; wherein the predetermined property ...

Composite Ceramics and Ceramic Particles and Method for Producing Ceramic Particles and Bulk Ceramic Particles

Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 μm to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

High Purity SiOC and SiC, Methods Compositions and Applications

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC. 136-. (canceled)37. A method of making an article comprising ultra pure silicon carbide , the method comprising:a. combining a first liquid comprising silicon, carbon and oxygen with a second liquid comprising carbon;b. curing the combination of the first and second liquids to provide a cured SiOC solid material, consisting essentially of silicon, carbon and oxygen;c. heating the SiOC solid material in an inert atmosphere and at a temperature sufficient to convert SiOC to SiC, thereby converting the SiOC solid material to an ultra pure polymer derived SiC having a purity of at least 99.999%; and,d. forming a single crystal SiC structure, comprising a polytype selected from the group consisting of 4H SiC, 6H SiC and 3C SiC, by vapor deposition of the ultra pure polymer derived SiC; wherein the vapor deposed structure is defect free and has a purity of at least 99.9999%.38. The method of claim 37 , wherein the single crystal SiC structure consists essentially of 4H SiC.39. The method of claim 37 , wherein the single crystal SiC structure consists essentially of 6H SiC.40. The method of claim 37 , wherein the single crystal SiC structure consists of 4H SiC.41. The method of claim 37 , wherein the single crystal SiC structure consists of 6H SiC.42. The method of claim 37 , wherein the combination of the first and the second liquids is a polysilocarb precursor formulation having a molar ratio of about 30% to 85% carbon claim 37 , about 5% to 40% oxygen claim 37 , and about 5% to 35% silicon.43. The method of claim 37 , wherein the single crystal SiC structure is a boule.44. The method of claim 37 , wherein the single crystal SiC is a layer.45. The method of claim 37 , wherein the single ...

Pressed and Self Sintered Polymer Derived SiC Materials, Applications and Devices

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC. 118-. (canceled)19. A sinterable silicon carbide composition comprising:a. a plurality of silicon carbide particles, the plurality of particles having a total weight of greater than at least about 10 grams;b. the particles having a mean particle size of about 0.5 μm or smaller;{'sub': '4', 'c. the composition consisting essentially of silicon and carbon in an SiCconfiguration, wherein the particles have less than 0.5% excess carbon, and are at least 99.99999% pure;'}d. wherein the particles are capable of being sintered into a solid SiC article without the need for a sintering aid, the sintered SiC article having at least one strength properties at least 90% as strong as elemental SiC.20. A silicon carbide composition comprising:a. polymer derived silicon carbide particles;b. the particles having a mean particle size of about 0.5 μm or smaller, each particle having a surface, wherein the surfaces are free from an oxide layer;c. the particles consisting essentially of silicon and carbon, wherein the particles have less than 0.5% excess carbon, and are at least 99.99999% pure.2127-. (canceled) This application: (i) claims under 35 U.S.C. § 119(e)(1) the benefit of the filing date of Sep. 25, 2014 of U.S. provisional application Ser. No. 62/055,397; (ii) claims under 35 U.S.C. § 119(e)(1) the benefit of the filing date of Sep. 25, 2014 of U.S. provisional application Ser. No. 62/055,461; (iii) claims under 35 U.S.C. § 119(e)(1) the benefit of the filing date of Sep. 25, 2014 of U.S. provisional application Ser. No. 62/055,497; (iv) claims under 35 U.S.C. § 119(e)(1) the benefit of the filing date of Feb. 4, 2015 of U.S. provisional application Ser. No. 62/112,025; (v) is a continuation in ...

SILICON OXYCARBIDE ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix of barium-magnesium alumino-silicate or SiO, a dispersion of silicon oxycarbide particles in the matrix, and a dispersion of particles, of the other of barium-magnesium alumino-silicate or SiO, in the matrix. 1. (canceled)2. (canceled)3. (canceled)4. (canceled)5. A composite material comprising:{'sub': '2', 'a matrix of barium-magnesium alumino-silicate or SiO;'}a dispersion of silicon oxycarbide particles in the matrix, the silicon oxycarbide particles having Si, O, and C in a covalently bonded network; and{'sub': '2', 'a dispersion of particles, of the other of barium-magnesium alumino-silicate or SiO, in the matrix.'}6. The composite material as recited in claim 5 , including claim 5 , by volume claim 5 , 1-30% of the barium-magnesium alumino-silicate particles claim 5 , 5-40% of the matrix of SiO claim 5 , and a balance of the silicon oxycarbide particles.7. The composite material as recited in claim 6 , including claim 6 , by volume claim 6 , 1-5% of the barium-magnesium alumino-silicate particles.8. The composite material as recited in claim 5 , wherein the matrix of SiOis continuous.9. The composite material as recited in claim 5 , including claim 5 , by volume claim 5 , 30-94% of the silicone oxycarbide particles claim 5 , 5-40% of the matrix of SiO claim 5 , and 1-5% of the barium-magnesium alumino-silicate particles.10. The material of claim 5 , wherein the silicon oxycarbide particles have a composition SiOMC claim 5 , where M is at least one metal claim 5 , x<2 claim 5 , y>0 claim 5 , z<1 claim 5 , and x and z are non-zero.11. The material of claim 5 , wherein the material forms a layer having a first side and a second side claim 5 , and wherein barium-magnesium alumino-silicate particles are concentrated near the first side claim 5 , thereby forming a sealing layer.12. The material of claim 11 , wherein the second side of ...

DECORATIVE CERAMIC ITEM

A decorative item is made of a ceramic material, where ceramic material includes a carbide phase and an oxide phase, the carbide phase being present in a percentage by volume comprised between 50 and 95% and the oxide phase being present in a percentage by volume comprised between 5 and 50%. The decorative item is manufactured by a method of powder metallurgy. 1. A decorative item made of comprising a ceramic material , said ceramic material including a carbide phase and a phase of aluminium oxide , the carbide phase being in a major proportion and having a percentage by volume comprised between 70 and 85% , wherein the oxide phase is in a minor proportion and present in a percentage by volume comprised between 15 and 30% , andwherein the carbide phase includes molybdenum carbide in a major proportion.2. (canceled)3. The item according to claim 1 , wherein said carbide phase is present in a percentage by volume comprised between 55 and 90% claim 1 , the oxide phase being present in a percentage by volume comprised between 10 and 45%.4. The item according to claim 1 , wherein said carbide phase includes niobium carbide or tungsten carbide in a minor proportion.5. The item according to claim 1 , wherein said carbide phase including molybdenum carbide in a major proportion is present in a percentage by volume comprised between 50 and 75% claim 1 , the oxide phase being present in a percentage by volume comprised between 25 and 50%.6. The item according to claim 1 , further comprising chromium oxide in a minor proportion.7. The item according to claim 3 , wherein said carbide phase is present in a percentage by volume comprised between 65 and 85 claim 3 , and said aluminium oxide phase is present in a percentage by volume comprised between 15 and 35%.8. The item according to claim 3 , further comprising chromium oxide.9. The item according to claim 8 , wherein said carbide phase is present in a percentage by volume comprised between 55 and 75% claim 8 , and said oxide ...

FABRICATION OF CARBON NANOTUBE-NONOXIDE STRUCTURAL CERAMIC NANOCOMPOSITES THROUGH LASER SINTERING

Methods for making a carbon nanotube (CNT)-nonoxide structural ceramic nanocomposite as well as for enhancing at least one mechanical property or characteristic of a nonoxide structural ceramic material are provided. A mixture of CNT and nonoxide structural ceramic powder can be laser sintered to form desired carbon nanotube-nonoxide structural ceramic nanocomposites. 1. A method for making a carbon nanotube (CNT)-nonoxide structural ceramic nanocomposite , the method comprising:laser sintering a mixture of CNT and nonoxide structural ceramic powder to form a carbon nanotube-nonoxide structural ceramic nanocomposite.2. The method of wherein the nonoxide structural ceramic powder comprises at least one of chromium carbide (CrC) claim 1 , boron carbide (BC) and molybdenum carbide (MoC).3. The method of wherein the nonoxide structural ceramic powder comprises chromium carbide (CrC).4. The method of wherein the carbon nanotube-nonoxide structural ceramic powder mixture comprises at least 0.2 wt. % CNT.5. The method of wherein the carbon nanotube-nonoxide structural ceramic powder mixture comprises 0.3 to 0.5 wt. % CNT.6. The method of wherein the mixture is in an inert atmosphere during said laser sintering to avoid reaction of the mixture with the ambient atmosphere.7. The method of wherein during said laser sintering the mixture being sintered is within a chamber containing the inert atmosphere.8. The method of wherein the chamber is equipped with at least one of a flow system and a filtration system to permit at least one of periodic gas medium flow claim 7 , continuous gas medium flow claim 7 , periodic gas medium filtration and continuous gas medium filtration to avoid either or both the ambient atmosphere reacting with the mixture and undesirably adsorbing or scattering laser beam energy.9. The method of wherein during said laser sintering the mixture is contained within the chamber.10. The method of wherein the chamber at least in part comprises a gas application ...

Composite Ceramics and Ceramic Particles and Method for Producing Ceramic Particles and Bulk Ceramic Particles

Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 μm to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. Nano-sized ceramic particles are formed from the green body produced by methods for making bulk, dense composite ceramics. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process. 1. A polymer derived ceramic (PDC) particle , wherein the particle material is derived from at least one of a binary PDC system , a ternary PDC system or a quaternary PDC system formed in a spraying process for producing bulk ceramic components from an agglomeration of partially cured polymer ceramic precursor resin material , comprising:a plurality of partially-cured globules of polymer ceramic precursor material co-sprayed with a plurality of powder particles that are functional material fillers in the structure of the partially-cured globules of polymer ceramic precursor material that is subsequently fully cured, chemically bonded together, then fired to produce a uniform, fully-dense, single continuous ceramic part having a particle size of approximately 1.2 mm to approximately 300 mm in diameter.2. The polymer derived ceramic (PDC) particle of claim 1 , wherein the binary PDC system is at least one of boron nitride (BN) or silicon carbide (SiC).3. The polymer ...

SYSTEM AND METHOD FOR FOUR-DIMENSIONAL PRINTING OF CERAMIC ORIGAMI STRUCTURES

A system and method of constructing a 4D-printed ceramic object includes extruding inks including particles and polymeric ceramic precursors through a nozzle to deposit the inks on a heating plate, whereby a 3D-printed elastomeric object is formed on the heating plate, folding the 3D-printed elastomeric object into a complex structure to form a 4D-printed pre-strained elastomeric object, and converting the 4D-printed elastomeric object into the 4D-printed ceramic object. 1. A method of constructing a 4D-printed ceramic object , the method comprising:extruding inks including particles and polymeric ceramic precursors through a nozzle to deposit the inks on a heating plate, whereby a 3D-printed elastomeric object is formed on the heating plate, folding the 3D-printed elastomeric object into a complex structure to form a 4D-printed pre-strained elastomeric object, and converting the 4D-printed elastomeric object into the 4D-printed ceramic object.2. The method of claim 1 , wherein the particles are zirconium dioxide nanoparticles.3. The method of claim 1 , wherein the polymeric ceramic precursors are poly(dimethylsiloxane).4. The method of claim 1 , wherein the temperature of the heating plate is in the range of from about 30° C. to about 400° C.5. The method of claim 1 , wherein the folding of elastomeric object is achieved by metal wires.6. The method of claim 1 , wherein the polymer-to-ceramic transformation occurs via pyrolysis in a vacuum or under an inert atmosphere.7. The method of claim 1 , wherein the 4D-printed ceramic object has a Gaussian curvature.8. The method of claim 1 , wherein the 4D-printed ceramic object has a dimension of 100 μm or more.9. The method of claim 1 , wherein the inks are formed from a homogenous distribution of the particles in the polymeric ceramic precursors and wherein the weight percentage of the particles in the inks is in the range of from about 1% to about 90% and the weight percentage of the polymeric ceramic precursors in the ...

AQUEOUS SUSPENSION CONTAINING METAL CARBIDE PARTICLES

The present invention relates to aqueous suspensions containing 30 to 95 wt.-% metal carbide particles and a dispersant, and to a process for coating substrates using said aqueous suspensions. The invention also relates to the coated substrates that can be produced by the process according to the invention and to the uses thereof. 115-. (canceled)16. An aqueous suspension comprising at least one metal carbide particle and at least one dispersant , wherein the proportion of the at least one metal carbide particle is in the range from 30% to 95% by weight based on the total weight of the suspension.17. The aqueous suspension of claim 16 , wherein:the at least one metal carbide particle is selected from the group consisting of carbides of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, silicon, and mixtures thereof;the at least one metal carbide particle has an average particle size in the range from 0.05 to 25 μm;the at least one metal carbide particle has a content of individual elemental impurity of <300 ppm; and/orthe dispersant is selected from the group consisting of polyacrylic acid, tetrabutylammonium hydroxide, and mixtures thereof.18. The aqueous suspension of claim 16 , which comprises at least one additive selected from the group consisting of a base claim 16 , a defoamer claim 16 , a sintering aid claim 16 , and mixtures thereof.19. The aqueous suspension of claim 18 , wherein the base is sodium hydroxide solution claim 18 , the defoamer is a fatty alcohol polyalkylene glycol ether claim 18 , and/or the sintering aid is cobalt claim 18 , silicon claim 18 , or a mixture thereof.20. The aqueous suspension of claim 16 , wherein:the proportion of metal carbide particles is in the range from 40% to 90% by weight based on the total weight of the suspension; and/orthe proportion of the dispersant is in the range from 0.05% to 5% by weight based on the total weight of the suspension; and/orthe proportion of the at least ...

Vapor Deposition Apparatus and Techniques Using High Purity Polymer Derived Silicon Carbide

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Vapor deposition processes and articles formed by those processes utilizing such high purity SiOC and SiC. 110-. (canceled)11. A method of making boule for the production of a 4H N-Type silicon carbide wafer , having a diameter of from about 6 inches to about 10 inches , the wafer characterized with properties comprising:type/dopant:N/nitrogen;orientation:<0001>4.0°±0.5°;thickness: about 300 to about 800 μm; and,{'sup': '−2', 'micropipe density of <1 cm; and,'}the method comprising the steps of: forming a vapor of a polymer derived ceramic SiC starting material, wherein the polymer derived ceramic SiC starting material has a purity of at least about 6 nines, and is oxide layer free; depositing the vapor on a seed crystal to form a boule; and providing the boule to a wafer manufacturing process.121. The method of claim , wherein the wafer is further characterized with a property comprising RT 0.02-0.2 Ω·cm.131. The method of claim , wherein the wafer is further characterized with a property comprising RT 0.01-0.1 Ω·cm141. The method of claim , wherein the wafer is further characterized with a property comprising RT: 0.1-40 Ω·cm15. The methods of , , or , wherein the seed comprises a polymer derived ceramic SiC.16. The method of wherein the wafer manufacturing process produces a wafer having improved features claim 11 , when compared to a wafer made from a non-polymer derived SiC material.17. The method of wherein the wafer manufacturing process produces a wafer having improved features claim 12 , when compared to a wafer made from a non-polymer derived SiC material.18. The method of wherein the wafer manufacturing process produces a wafer having improved features claim 13 , when compared to a wafer made from a non-polymer derived SiC material.19. The ...

NANOCOMPOSITE SILICON OXYGEN CARBON MATERIALS AND USES

Nanocomposite silicon and carbon compositions. These compositions can be made from polymer derived ceramics, and in particular, polysilocarb precursors. The nanocomposite can have non-voids or be nano-void free and can form larger macro-structures and macro-composite structures. The nanocomposite can contain free carbon domains in an amorphous SiOC matrix. 142-. (canceled)43. A nanocomposite material comprising: a first composition comprising a free carbon domain and a second composition comprising a plurality of silicon based moieties; and wherein the first and second compositions are different compositions.44. The nanocomposite material of claim 43 , wherein the free carbon domain is selected from the group consisting of spcarbon claim 43 , aromatic structures having 6 or more carbons claim 43 , bent ring aromatic structures claim 43 , conjugated aliphatic carbons claim 43 , conjugated aliphatic carbons having from 3 to 10 carbons claim 43 , conjugated aliphatic carbons having from 10 to 20 carbons claim 43 , and alkanes.45. The nanocomposite material of claim 43 , wherein the free carbon domain is selected from the group consisting of turbostratic claim 43 , amorphous claim 43 , graphenic claim 43 , and graphitic.46. The nanocomposite material of claim 43 , wherein at least one of the moieties is selected from the group consisting of Si(CH)O claim 43 , SiCO claim 43 , SiC claim 43 , Si(CH)O claim 43 , SiCO claim 43 , Si(CH)(OH)O claim 43 , SiCOSiO claim 43 , esters claim 43 , ketones claim 43 , C—O—C claim 43 , C—O—Si claim 43 , Si(CH)O claim 43 , Si—C—C—Si claim 43 , Si(CH)O claim 43 , and Si(CH)O.47. The nanocomposite material of claim 44 , wherein at least one of the moieties is selected from the group consisting of Si(CH)O claim 44 , SiCO claim 44 , SiC claim 44 , Si(CH)O claim 44 , SiCO claim 44 , Si(CH) (OH)O claim 44 , SiCOSiO claim 44 , esters claim 44 , ketones claim 44 , C—O—C claim 44 , C—O—Si claim 44 , Si(CH)O claim 44 , Si—C—C—Si claim 44 , Si(CH)O ...

METHOD FOR PRODUCING A COMPOSITE MATERIAL WITH A CARBIDE MATRIX

A method of densifying a porous substrate with a matrix, includes subdividing the pores present in the porous substrate so as to form in the substrate a network of micropores, the subdividing being performed with a filler composition comprising at least one carbon-containing phase or carbide-containing phase that is accessible via the network of micropores; and infiltrating the network of micropores formed by the filler material by reactive chemical vapor infiltration, the infiltration being performed with a reactive gas composition that does not contain carbon and that includes at least one element suitable for reacting with the carbon of the filler composition in order to form a carbide. 1. A method of densifying a porous substrate with a matrix , said method comprising:subdividing the pores present in the porous substrate so as to form in said substrate a network of micropores, said subdividing being performed with a filler composition comprising at least one carbon-containing phase or carbide-containing phase that is accessible via the network of micropores; andinfiltrating the network of micropores formed by the filler material by reactive chemical vapor infiltration, the infiltration being performed with a reactive gas composition that does not contain carbon and that includes at least one element suitable for reacting with the carbon of the filler composition in order to form a carbide.2. A method according to claim 1 , further comprising making a fiber structure corresponding to the porous substrate that is to be densified.3. A method according to claim 2 , wherein the fiber structure is made from carbon 25 fibers or from silicon carbide fibers.4. A method according to claim 1 , wherein the subdividing of the pores comprises introducing a powder into the porous substrate claim 1 , the powder being constituted by micrometer or submicrometer particles of carbon-containing or carbide-containing material claim 1 , or including at least a surface layer of carbon- ...

SILICON OXYCARBIDE ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix of barium-magnesium alumino-silicate or SiO, a dispersion of silicon oxycarbide particles in the matrix, and a dispersion of particles, of the other of barium-magnesium alumino-silicate or SiO, in the matrix. 1. (canceled)2. (canceled)3. (canceled)4. (canceled)5. (canceled)6. (canceled)7. (canceled)8. (canceled)9. (canceled)10. (canceled)11. (canceled)12. (canceled)13. (canceled)14. (canceled)15. An article , comprising:a ceramic-based substrate; anda barrier layer on the ceramic-based substrate having a first, outward facing, side and a second side adjacent the ceramic-based substrate, the barrier layer including barium-magnesium alumino-silicate particles and silicon oxycarbide particles in a matrix, wherein an average maximum dimension of the barium-magnesium alumino-silicate particles is less than an average maximum dimension of the silicon oxycarbide particles.16. The article as recited in claim 15 , wherein the matrix is selected from the group of silicon dioxide and silica.17. The article as recited in claim 16 , wherein the matrix is silicon dioxide and is continuous.18. The article as recited in claim 17 , including claim 17 , by volume claim 17 , 30-94% of the silicone oxycarbide particles claim 17 , 5-40% of the matrix of silicon dioxide claim 17 , and 1-5% of the barium-magnesium alumino-silicate particles.19. The article as recited in claim 15 , wherein the barium-magnesium alumino-silicate particles are concentrated near the first side of the barrier layer.20. The article as recited in claim 15 , wherein the silicon oxycarbide particles have a composition SiOMC claim 15 , where M is at least one metal claim 15 , x<2 claim 15 , y>0 claim 15 , z<1 claim 15 , and x and z are non-zero.21. The article as recited in claim 15 , wherein a cationic metal species from the barium-magnesium alumino-silicate particles is diffused ...

A method of generating a mold and using it for printing a three-dimensional object

This invention relates to three-dimensional printing. This invention in particular relates to a method of generating mold and printing a three-dimensional object. The mold thickness is controlled and holes are generated in the mold surface for releasing moisture easily. The mold surface having holes is designed initially digitally and then combined with the three-dimensional model before printing the three-dimensional object. In case the thickness of the mold surface is more then it reduces the overall quality of the three-dimensional object. When the model is enclosed inside the mold, there will be some residue moisture in the model even if the drying apparatus can improve this by drying layer by layer. This affects the final quality of the part. A solution of these problems is provided in the present invention. The thickness of the mold layer is between 0.5 to 1 mm and holes having 0.1 to 0.4 mm diameter. The holes are evenly distributed on the mold. The mold having the holes is prepared from which moisture can easily escape. A method of digitally generated a mold having thin layer and holes is used for fabricating three dimensional objects with high precision and quality.

RESIN FORMULATIONS FOR POLYMER-DERIVED CERAMIC MATERIALS

This disclosure enables direct 3D printing of preceramic polymers, which can be converted to fully dense ceramics. Some variations provide a preceramic resin formulation comprising a molecule with two or more C═X double bonds or C≡X triple bonds, wherein X is selected from C, S, N, or O, and wherein the molecule further comprises at least one non-carbon atom selected from Si, B, Al, Ti, Zn, P, Ge, S, N, or O; a photoinitiator; a free-radical inhibitor; and a 3D-printing resolution agent. The disclosed preceramic resin formulations can be 3D-printed using stereolithography into objects with complex shape. The polymeric objects may be directly converted to fully dense ceramics with properties that approach the theoretical maximum strength of the base materials. Low-cost structures are obtained that are lightweight, strong, and stiff, but stable in the presence of a high-temperature oxidizing environment. 1. A preceramic resin formulation comprising:(a) first molecules comprising two or more C═X double bonds, two or more C≡X triple bonds, or at least one C═X double bond and at least one C≡X triple bond, wherein X is selected from the group consisting of C, S, N, O, and combinations thereof, and wherein said first molecules further comprise at least one non-carbon atom selected from the group consisting of Si, B, Al, Ti, Zn, P, Ge, S, N, O, and combinations thereof;(b) second molecules comprising R—Y—H,wherein R is an organic group or an inorganic group,wherein for at least one of said second molecules, R includes an inorganic group containing an element selected from the group consisting of B, Al, Ti, Zn, P, Ge, S, N, O, and combinations thereof, andwherein Y is selected from the group consisting of S, N, O, and combinations thereof;(c) a photoinitiator;(d) a free-radical inhibitor; and(e) a 3D-printing resolution agent.2. The preceramic resin formulation of claim 1 , wherein said first molecules are present from about 3 wt % to about 97 wt % of said formulation.3. The ...

REFRACTORY FOR CASTING, NOZZLE FOR CASTING AND SLIDING NOZZLE PLATE USING SAME

A refractory to be used repeatedly or for a long period of time, such as a refractory for casting, especially a nozzle for casting and an SN plate, has improved tolerance. The refractory for casting contains AlOC in the range of 15 to 60% by mass, both inclusive, an Al component as a metal in the range of 1.2 to 10.0% by mass, both inclusive, and a balance including AlO, a free C, and other refractory component; a sum of AlOC, AlO, and the Al component as a metal is 85% or more by mass; and a content of AlOC (AlOC), a content of the Al component as a metal (Al), and a content of the free carbon (C). The contact of the free carbon satisfies the following Equation 1 and Equation 2: 1. A refractory for casting , wherein the refractory for casting contains AlOC in the range of 15 to 60% by mass , both inclusive , an Al component as a metal in the range of 1.2 to 10.0% by mass , both inclusive , and a balance comprising AlO , a free C , and other refractory component; a sum of AlOC , AlO , and the Al component as a metal is 85% or more by mass; and a content of AlOC (AlOC) , a content of the Al component as a metal (Al) , and a content of the free C (C) satisfy following Equation 1 and Equation 2:{'br': None, 'sub': 4', '4, '1.0≦C/(AlOC×0.038+Al×0.33)\u2003\u2003Equation 1'}{'br': None, 'sub': 4', '4, '1.0≧C/(AlOC×0.13+Al×0.67)\u2003\u2003Equation 2'}2. The refractory for casting according to claim 1 , wherein the AlOC is derived from an AlOC-containing raw material particle produced by an electromelting method.3. The refractory for casting according to claim 2 , wherein a size of an AlOC crystal in the AlOC-containing raw material particle is 20 μm or more as an average diameter when a cross section of the AlOC crystal is converted to a circle.4. The refractory for casting according to claim 1 , wherein the other refractory component in the balance is one or more of the following materials: MgO claim 1 , SiO claim 1 , a tetragonal or a monoclinic ZrO claim 1 , SiC claim ...

METHOD FOR PYROLYZING PRECERAMIC POLYMER MATERIAL USING ELECTROMAGNETIC RADIATION

Disclosed is a method for fabricating a ceramic material from a preceramic polymer material. The method includes providing a preceramic polymer material that has a preceramic polymer and an electromagnetic radiation-responsive component. The electromagnetic radiation-responsive component is selected from cobalt, titanium, zirconium, hafnium, tantalum, tungsten, rhenium, and combinations thereof. An electromagnetic radiation is applied to the preceramic polymer material. The electromagnetic radiation interacts with the electromagnetic radiation-responsive component to generate heat that converts the preceramic polymer to a ceramic material 1. A method for fabricating a ceramic material from a preceramic polymer material , the method comprising:providing a preform that includes a fiber structure and preceramic polymer material within the fiber structure, the preceramic polymer material includes a preceramic polymer and an electromagnetic radiation-responsive component, the electromagnetic radiation-responsive component is a metal selected from the group consisting of cobalt, titanium, zirconium, hafnium, tantalum, tungsten, rhenium, and combinations thereof; andapplying electromagnetic radiation to the preform, the electromagnetic radiation interacting with the electromagnetic radiation-responsive component to generate heat that converts the preceramic polymer to a ceramic phase.2. The method as recited in claim 1 , wherein the metal is selected from the group consisting of cobalt claim 1 , zirconium claim 1 , hafnium claim 1 , tantalum claim 1 , rhenium claim 1 , and combinations thereof.3. The method as recited in claim 1 , wherein the metal is selected from the group consisting of cobalt claim 1 , hafnium claim 1 , tantalum claim 1 , rhenium claim 1 , and combinations thereof.4. The method as recited in claim 1 , wherein the electromagnetic radiation-responsive component is the cobalt.5. The method as recited in claim 1 , wherein the preceramic polymer includes ...

Ceramic matrix composite reinforced material

A CMC article may include a CMC substrate defining a major surface and a plurality of CMC reinforcing pins at least partially embedded in the CMC substrate. Each CMC reinforcing pin of the plurality of CMC reinforcing pins defines a respective long axis. The respective long axes may be oriented at an angle substantially perpendicular to the major surface of the CMC substrate. A method may include inserting a plurality of CMC reinforcing pins into a major surface of a ceramic fiber preform. Each CMC reinforcing pin of the plurality of CMC reinforcing pins defines a respective long axis. As the plurality of CMC reinforcing pins are inserted into the major surface, the respective long axes may be oriented at an angle substantially perpendicular to the major surface. The method also includes forming a matrix of material within pores of the ceramic fiber preform to form a CMC article.

REFRACTORY METAL CERAMICS AND METHODS OF MAKING THEREOF

A composition having nanoparticles of a refractory-metal carbide or refractory-metal nitride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles with an organic compound having a char yield of at least 60% by weight to form a precursor mixture. 1. A composition comprising:a refractory-metal hydride; andan organic compound having a char yield of at least 60% by weight.23-. (canceled)4. The composition of claim 1 , wherein the refractory-metal hydride is titanium hydride claim 1 , zirconium hydride claim 1 , hafnium hydride claim 1 , tungsten hydride claim 1 , niobium hydride claim 1 , molybdenum hydride claim 1 , chromium hydride claim 1 , tantalum hydride claim 1 , or vanadium hydride.5. The composition of claim 1 , wherein the organic compound:contains only carbon and hydrogen;contains aromatic and acetylene groups;contains only carbon, hydrogen, and nitrogen or oxygen;contains no oxygen; orcontains a heteroatom other than oxygen.6. The composition of claim 1 , wherein the organic compound is 1 claim 1 ,2 claim 1 ,4 claim 1 ,5-tetrakis(phenylethynyl)benzene or a prepolymer thereof claim 1 , N claim 1 ,N′-(1 claim 1 ,4-phenylenedimethylidyne)-bis-(3-ethynylaniline) claim 1 , dianilphthalonitrile claim 1 , or resorcinol phthalonitrile.7. (canceled)8. The composition of claim 1 , wherein the composition comprises a material selected from the group consisting of fibers claim 1 , carbon fibers claim 1 , ceramic fibers claim 1 , and ...

METHOD OF TREATING A PRECERAMIC MATERIAL

A method of treating a preceramic material includes providing a preceramic polycarbosilane or polycarbosiloxane material that includes a moiety Si—O—M, where Si is silicon, O is oxygen and M is at least one metal, and thermally converting the preceramic polycarbosilane or polycarbosiloxane that includes the moiety Si—O—M material into a ceramic material. 1. A method of treating a preceramic material , the method comprising:providing a preceramic polycarbosilane or polycarbosiloxane material that includes a moiety Si—O—M, where Si is silicon, O is oxygen and M is at least one metal; andthermally converting the preceramic polycarbosilane or polycarbosiloxane that includes the moiety Si—O—M material into a ceramic material.2. The method as recited in claim 1 , wherein thermally converting the preceramic polycarbosilane or polycarbosiloxane material produces a ceramic material having a composition SiOMC claim 1 , wherein x<2 claim 1 , y>0 and z<1 and x and z are non-zero.3. The method as recited in claim 1 , wherein the at least one metal is selected from the group consisting of aluminum claim 1 , boron claim 1 , alkaline earth metals claim 1 , transition metals claim 1 , refractory metals claim 1 , rare earth metals and combinations thereof.4. The method as recited in claim 1 , wherein the at least one metal is selected from the group consisting of aluminum claim 1 , boron and combinations thereof.5. The method as recited in claim 1 , wherein the at least one metal is a transition metal selected from the group consisting of titanium claim 1 , zirconium claim 1 , hafnium claim 1 , vanadium claim 1 , chromium and combinations thereof.6. The method as recited in claim 1 , wherein the at least one metal is a refractory metal selected from the group consisting of niobium claim 1 , tantalum claim 1 , molybdenum claim 1 , tungsten claim 1 , rhenium and combinations thereof.7. The method as recited in claim 1 , wherein the at least one metal is a rare earth metal selected from ...

Formulations with active functional additives for 3d printing of preceramic polymers, and methods of 3d-printing the formulations

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

METHODS OF SINTERING DENSE ZETA-PHASE TANTALUM CARBIDE

A method of forming a sintered ζ-phase tantalum carbide can include assembling a particulate mixture including a tantalum hydride powder and a carbon source powder. The particulate mixture can be sintered to form a tantalum carbide having at least 70 wt. % of a ζ-phase with at least about 90% densification. After sintering, the tantalum carbide can be cooled to substantially retain the ζ-phase. 1. A method of forming a sintered ζ-phase tantalum carbide , comprising:assembling a particulate mixture including a tantalum hydride powder and a carbon source powder;sintering the particulate mixture to form a tantalum carbide having at least 70 wt. % of a ζ-phase with at least about 90% densification, wherein the sintering is performed at a pressure of from about 0.01 atm to about 10 atm; andcooling the tantalum carbide to substantially retain the ζ-phase.2. The method of claim 1 , wherein the carbon source powder is γ-TaC powder.3. The method of claim 1 , wherein the tantalum hydride powder is prepared by hydrogenation of a tantalum metal powder.4. The method of claim 1 , wherein the tantalum hydride powder has an average particle size of 2-20 μm.5. The method of claim 1 , wherein the tantalum hydride powder has an average particle aspect ratio from about 1 to about 1.3.6. The method of claim 1 , wherein the particulate mixture is prepared by planetary milling.7. The method of claim 1 , wherein the particulate mixture has a C/Ta mole ratio of about 0.64 to about 0.68.8. The method of claim 1 , wherein the particulate mixture has a C/Ta mole ratio of about 0.66.9. The method of claim 1 , further comprising annealing the particulate mixture at a temperature from 900° C. to 1300° C. before sintering.10. The method of claim 1 , wherein the sintering is performed at a pressure of from about 0.9 atm to 1.5 atm.11. The method of claim 1 , wherein the sintering is performed at a pressure of from about 0.01 atm to about 3 atm.12. The method of claim 1 , wherein the sintering is ...

Physical Forms of MXene Materials Exhibiting Novel Electrical And Optical Characteristics

The present invention(s) is directed to novel conductive MX(T) compositions exhibiting high volumetric capacitances, and methods of making the same. The present invention(s) is also directed to novel conductive MX(T) compositions, methods of preparing transparent conductors using these materials, and products derived from these methods. 1. An article , comprising:a substrate,{'sub': n+1', 'n', 's, 'the substrate having disposed thereon a coating that comprises a MX(T) composition having multiple layers, each layer having a first and second surface,'}each layer comprisinga substantially two-dimensional array of crystal cells,{'sub': n+1', 'n, 'each crystal cell having an empirical formula of MX, such that each X is positioned within an octahedral array of M,'}wherein M is at least one Group 3, 4, 5, 6, or 7 metal,wherein each X is C, N, or a combination thereof andn=1, 2, or 3;{'sub': 's', 'wherein at least one of said surfaces of the layers has surface terminations, T, independently comprising alkoxide, alkyl, carboxylate, halide, hydroxide, hydride, oxide, sub-oxide, nitride, sub-nitride, sulfide, sulfonate, thiol, or a combination thereof,'}said coating being electrically conductive and exhibiting:(i) a resistivity in a range of from about 0.01 to about 1000 micro-ohm-meters, preferably 1-10 micro-ohm-meters;(ii) an ability to transmit at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% of incident light of at least one wavelength in a range of from about 300 nm to about 2000 nm(iii) a ratio of DC conductivity, measured in Siemens/meter, to light absorbance, (including visible light absorbance), measured as a decadic absorbance per meter, of at least 0.1 Siemens measured at at least one wavelength in the range of 300 to 2500 nm;(iv) a value of the real dielectric permittivity less than negative one for wavelengths ...

SYSTEMS AND METHODS FOR SILICON OXYCARBIDE CERAMIC MATERIALS COMPRISING SILICON METAL

Disclosed herein are systems and methods for synthesis of polymer derived ceramic materials, including silicon oxycarbide comprising silicon metal. In some embodiments, the silicon metal is formed by carbothermal reduction during thermal processing. In some embodiments, the thermal processing comprises microwave plasma processing. In some embodiments, the silicon metal forms nanodomains within a structure of the silicon oxycarbide ceramic material. 1. A silicon oxycarbide (SiOC) ceramic material comprising:silicon metal, wherein the silicon metal is formed by carbothermal reduction of a preceramic polymer during thermal processing of the preceramic polymer, wherein the thermal processing is used to form the SiOC ceramic material.2. The silicon oxycarbide ceramic material of claim 1 , wherein the SiOC ceramic material comprises an amorphous microstructure.3. The silicon oxycarbide ceramic material of claim 1 , wherein the SIOC ceramic material comprises a cell structure of SiOC claim 1 , wherein the silicon metal is integrated with the cell structure.4. The silicon oxycarbide ceramic material of claim 3 , wherein the cell structure comprises an open-cell crystal structure.5. The silicon oxycarbide ceramic material of claim 3 , wherein the cell structure comprises a closed-cell crystal structure.6. The silicon oxycarbide ceramic material of claim 1 , wherein phases of SiOC and the silicon metal are continuous within a microstructure SiOC ceramic material.7. The silicon oxycarbide ceramic material of claim 1 , wherein the SiOC ceramic material comprises a plurality of nanodomains of silicon metal.8. The silicon oxycarbide ceramic material of claim 7 , wherein each of the plurality of nanodomains of silicon metal comprise a diameter of 50 nm or less.9. The silicon oxycarbide ceramic material of claim 1 , wherein the thermal processing comprises microwave plasma processing.10. A method for manufacturing a polymer derived ceramic claim 1 , the method comprising: ...

HIGH PURITY POLYSILOCARB MATERIALS, APPLICATIONS AND PROCESSES

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC. 1. A high purity SiOC composition consisting essentially of: silicon , carbon and oxygen; and wherein the composition is substantially free from impurities , whereby the composition is at last 99.99% pure.2. The composition of claim 1 , having a molar ratio of about 30% to 85% carbon claim 1 , about 5% to 40% oxygen claim 1 , and about 5% to 35% silicon.3. The composition of claim 1 , having a molar ratio of about 50% to 65% carbon claim 1 , about 20% to 30% oxygen claim 1 , and about 15% to 20% silicon.4. The composition of claim 1 , wherein the composition is a solid5. The composition of claim 1 , wherein the composition is a ceramic.6. The composition of claim 1 , having impurities of less than about 1 claim 1 ,000 ppm total of the elements selected from the group consisting of Al claim 1 , Fe claim 1 , B claim 1 , P claim 1 , Pt claim 1 , Ca claim 1 , Mg claim 1 , Li claim 1 , Na claim 1 , Ni claim 1 , V claim 1 , Ce claim 1 , Cr claim 1 , S and As.7. The composition of claim 1 , having impurities of less than about 500 ppm total of the elements selected from the group consisting of Al claim 1 , Fe claim 1 , B claim 1 , P claim 1 , Pt claim 1 , Ca claim 1 , Mg claim 1 , Li claim 1 , Na claim 1 , Ni claim 1 , V claim 1 , Ce claim 1 , Cr claim 1 , S and As.8. The composition of claim 1 , having impurities of less than about 100 ppm total of the elements selected from the group consisting of Al claim 1 , Fe claim 1 , B claim 1 , P claim 1 , Pt claim 1 , Ca claim 1 , Mg claim 1 , Li claim 1 , Na claim 1 , Ni claim 1 , V claim 1 , Ce claim 1 , Cr claim 1 , S and As.9. The composition of claim 1 , having impurities of less than about 50 ppm total of the elements selected from the group ...

MODIFIED PRECERAMIC POLYMERS, METHOD OF MAKING AND CERAMIC MATRIX COMPOSITE FORMED THEREFROM

Disclosed is a modified preceramic polymer having a polymer backbone consisting of silicon or a combination of silicon and carbon; and a pendant modifier bonded to the backbone wherein the modifier includes silicon, boron, aluminum, a transition metal, a refractory metal, or a combination thereof. The modified preceramic polymer can be used to form a ceramic matrix composite. 1. A modified preceramic polymer comprising a polymer backbone consisting of silicon or a combination of silicon and carbon; and pendant modifier bonded to the backbone wherein the pendant modifier includes silicon , boron , aluminum , a transition metal , a refractory metal , or a combination thereof.2. The modified preceramic polymer of claim 1 , wherein the pendant modifier includes silicon claim 1 , boron claim 1 , aluminum claim 1 , or a combination thereof.3. The modified preceramic polymer of claim 1 , wherein the pendant modifier includes titanium claim 1 , zirconium claim 1 , hafnium claim 1 , vanadium claim 1 , chromium claim 1 , or a combination thereof.4. The modified preceramic polymer of claim 1 , wherein the pendant modifier includes niobium claim 1 , tantalum claim 1 , molybdenum claim 1 , tungsten claim 1 , rhenium claim 1 , or a combination thereof.5. The modified preceramic polymer of claim 1 , wherein the metal atom to backbone silicon ratio is 4:1 to 0.05:1.6. The modified preceramic polymer of claim 1 , wherein the metal atom to carbon ratio is 4:1 to 0.05:1.7. The modified preceramic polymer of claim 1 , wherein the polymer backbone consists of silicon.8. The modified preceramic polymer of claim 1 , wherein the polymer backbone consists of silicon and carbon.9. A method of making a modified preceramic polymer comprising reacting a preceramic polymer with a modifier source selected from the group consisting of silicon compounds having a reactive group claim 1 , boron compounds having a reactive group claim 1 , organometallic compounds having a reactive group claim 1 , ...

FORMULATIONS AND METHODS FOR 3D PRINTING OF CERAMIC MATRIX COMPOSITES

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment. 1. A 3D-printing composition comprising:(a) from about 10 vol % to about 99.9 vol % of one or more preceramic, UV-curable, silicon-containing monomers in a liquid phase; and{'sub': 3', '4', '2', '2', '3', '2', '2', '3', '5', '12', '4, '(b) from about 1 vol % to about 70 vol % of solid-phase fillers, wherein said solid-phase fillers are selected from the group consisting of SiOC, SiCN, SiC, SiCBN, SiOCN, SiAlON, SiN, SiO, silicate glasses, AlO, ZrO, TiO, carbon, TiC, ZrC, HfC, YAlO, BC, BN, TiN, ZrN, AlN, and combinations thereof.'}2. The composition of claim 1 , wherein said preceramic claim 1 , UV-curable claim 1 , silicon-containing monomers are selected from the group consisting of silazanes claim 1 , siloxanes claim 1 , silanes claim 1 , carbosilanes claim 1 , and combinations claim 1 , analogues claim 1 , or derivatives thereof.3. The composition of claim 1 , wherein said solid-phase fillers are in the form of fibers claim 1 , whiskers claim 1 , nanotubes claim 1 , ...

Monomer formulations and methods for 3d printing of preceramic polymers

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

FORMULATIONS WITH ACTIVE FUNCTIONAL ADDITIVES FOR 3D PRINTING OF PRECERAMIC POLYMERS, AND METHODS OF 3D-PRINTING THE FORMULATIONS

This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment. 1. A 3D-printing composition comprising:(a) from about 10 vol % to about 99 vol % of one or more preceramic, UV-curable monomers; and(b) from about 1 vol % to about 70 vol % of solid-phase functional additives, wherein said functional additives have at least one average dimension from about 5 nanometers to about 50 microns, and wherein said functional additives are characterized in that when heated, said functional additives are reactive to cause an increase in volume of said composition.2. The composition of claim 1 , wherein said preceramic claim 1 , UV-curable monomers are selected from unsaturated ethers claim 1 , vinyls claim 1 , acrylates claim 1 , methacrylates claim 1 , cyclic ethers (epoxies or oxetanes) claim 1 , thiols claim 1 , or a combination thereof.3. The composition of claim 1 , wherein said preceramic claim 1 , UV-curable monomers are selected from silazanes claim 1 , siloxanes claim 1 , silanes claim 1 , carbosilanes claim 1 , or a combination thereof.4 ...

High temperature inks for electronic and aerospace applications

A printable material in ink form for forming electronic and structural components capable of high temperature performance may include a polymeric or oligomeric ceramic precursor. The material may also include a filler material and an optional liquid carrier. The ceramic precursor materials may be silicon carbide, silicon oxycarbide, silicon nitride, silicon carbonitride, silicon oxycarbonitride, gallium containing group 13 oligomeric compounds and mixtures thereof. The ceramic precursor may be deposited by a direct ink writing (DIW) process.

Functional composite particles

A complex proppant particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant.

METHODS OF FORMING CUTTING ELEMENTS, AND RELATED EARTH-BORING TOOLS

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, AXZ, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described. 1. An earth-boring tool , comprising: inter-bonded diamond particles; and', [{'br': None, 'sub': 3', '1-n, 'AXZ,'}, 'where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U;', 'X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P;', 'Z comprises C; and', 'n is greater than or equal to 0 and less than or equal to 0.75., 'a thermally stable material within interstitial spaces between the inter-bonded diamond particles, the thermally stable material comprising a carbide precipitate having the general chemical formula], 'a cutting table comprising, 'a cutting element comprising2. A method of forming a cutting element , comprising:providing a diamond-containing material comprising discrete diamond particles over a substrate;sintering the diamond-containing material in the presence of a liquid phase of a homogenized alloy comprising at least one first element selected ...

CUTTING ELEMENTS, AND RELATED EARTH-BORING TOOLS, SUPPORTING SUBSTRATES, AND METHODS

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, AXZ, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described. 1. A cutting element , comprising: inter-bonded diamond particles; and', {'br': None, 'sub': 3', '1-n, 'AXZ,'}, 'a thermally stable material within interstitial spaces between the inter-bonded diamond particles, the thermally stable material comprising a ternary κ-carbide precipitate having the general chemical formula], 'a cutting table comprising X comprises only one of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P;', 'Z comprises C; and', 'n is greater than or equal to 0 and less than or equal to 0.75., 'where A comprises only one of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U;'}2. The cutting element of claim 1 , wherein the ternary κ-carbide precipitate is selected from SmSnC claim 1 , SmBiC claim 1 , SmTeC claim 1 , SmPC claim 1 , SmSiC claim 1 , SmGaC claim 1 , ScSnC claim 1 , ScGeC claim 1 , ScSbC claim 1 , ScAsC claim 1 , SmBeC claim 1 , ScPC claim 1 , ScSiC claim 1 , YSnC claim 1 , ScBiC claim 1 ...

ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix of SiO2 and a dispersion of silicon oxycarbide particles in the matrix. The silicon oxycarbide particles have Si, O, and C in a covalently bonded network, and a dispersion of barium-magnesium alumino-silicate particles in the matrix. The barium-magnesium alumino-silicate particles have an average maximum dimension that is between about 10-40% of an average maximum dimension of the silicon oxycarbide particles. A composite material and a method of applying a barrier layer to a substrate are also disclosed. 1. An article comprising:a ceramic-based substrate; and{'sub': '2', 'a barrier layer on the ceramic-based substrate, the barrier layer including a matrix of SiO, a dispersion of silicon oxycarbide particles in the matrix, the silicon oxycarbide particles having Si, O, and C in a covalently bonded network, and a dispersion of barium-magnesium alumino-silicate particles in the matrix, the barium-magnesium alumino-silicate particles having an average maximum dimension that is between about 10-40% of an average maximum dimension of the silicon oxycarbide particles.'}2. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the barium-magnesium alumino-silicate particles.3. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 30-94% of the silicon oxycarbide particles.4. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 5-40% of the matrix of SiO.5. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the barium-magnesium alumino-silicate particles claim 1 , 5-40% of the matrix of SiO claim 1 , and a balance of the silicon oxycarbide particles.6. The article as recited in claim 5 , wherein the barrier layer includes claim 5 , by ...

HONEYCOMB STRUCTURE PRODUTION METHOD

A method for manufacturing a honeycomb structure includes a tubular circumferential wall and partition walls forming a honeycomb-shaped cross-section and defining a plurality of cells extending inside the circumferential wall in the axial direction of the circumferential wall. The method includes a molding process, a degreasing process, and an impregnation process. The molding process molds a mixture including ceramic particles, an organic binder, and a dispersion medium to obtain a molded body. The degreasing process removes the organic binder included in the molded body to obtain a degreased body. The impregnation process impregnates the inside of the circumferential wall and the partition walls of the degreased body with metal silicon. The impregnation process is performed under an inert gas atmosphere or a vacuum at a temperature between 1400° C. and 1900° C. 1. A method for manufacturing a honeycomb structure that includes a tubular circumferential wall and partition walls forming a honeycomb-shaped cross-section and defining a plurality of cells extending inside the circumferential wall in an axial direction of the circumferential wall , the method comprising:a molding process that molds a mixture including ceramic particles, an organic binder, and a dispersion medium to obtain a molded body;a degreasing process that removes the organic binder included in the molded body to obtain a degreased body; andan impregnation process that impregnates an inside of the circumferential wall and the partition walls of the degreased body with metal silicon, whereinthe impregnation process is performed under an inert gas atmosphere or a vacuum at a temperature between 1400° C. and 1900° C.2. The method according to claim 1 , wherein the ceramic particles are particles of silicon carbide.3. The method according to claim 1 , wherein the impregnation process is performed using metal silicon of an amount corresponding to a volume of 1.00 to 1.05 times a pore volume of the ...

Composites

Composites having the composition of at least one principal strengthening phase compound and one cemented phase of principal refractory metal are disclosed. The components of the strengthening phase compound can be a boride or a mixture of a boride and one or more than one carbide. In addition, the composites are obtained by smelting the principal strengthening phase compound and the cemented phase principal refractory metal in a non-equal molar ratio.

Physical Forms of MXene Materials Exhibiting Novel Electrical and Optical Characteristics

The present invention(s) is directed to novel conductive MX(T) compositions exhibiting high volumetric capacitances, and methods of making the same. The present invention(s) is also directed to novel conductive MX(T) compositions, methods of preparing transparent conductors using these materials, and products derived from these methods. 1. A method comprising ,(a) applying a MXene dispersion onto a substrate surface, said MXene dispersion comprising at least one type of MXene platelets dispersed in a solvent; and(b) removing at least a portion of solvent so as to provide a coated film of at least one layer of MXene platelets oriented to be essentially coplanar with the substrate surface,{'sub': n+1', 'n', 's, 'said MXene platelets comprising a MX(T) composition having at least one layer, each layer having a first and second surface, each layer comprising'}a substantially two-dimensional array of crystal cells.{'sub': n+1', 'n, 'each crystal cell having an empirical formula of MXsuch that each X is positioned within an octahedral array of M,'}wherein M is at least one Group 3, 4, 5, 6, or 7,wherein each X is C, N, or a combination thereof andn=1, 2, or 3;{'sub': 's', 'wherein at least one of said surfaces of the layers has surface terminations, T, independently comprising alkoxide, alkyl, carboxylate, halide, hydroxide, hydride, oxide, sub-oxide, nitride, sub-nitride, sulfide, sulfonate, thiol, or a combination thereof;'} (i) a resistivity in a range of from about 0.01 to about 1000 micro-ohm-meters, preferably 1-10 micro-ohm-meters;', '(ii) an ability to transmit at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% of incident light of at least one wavelength in a range of from about 300 nm to about 2000 nm', '(iii) a ratio of DC conductivity, measured in Siemens/meter, to light absorbance, (including visible light ...

Ceramic Composite Structures and Processing Technologies

Methods, systems, and processes are used to prepare novel ceramic composite structures that are strong, durable, light-weight, high performance and suitable for a myriad of industrial applications, including, but not limited to, ceramic plates of material suitable for use as ballistic armor. The low manufacturing costs of the processes disclosed provide cheaper, faster ways of producing ceramic matrix composites at lower temperatures and allow for the existence of composite materials and structures which currently are not available.

Applications, Methods And Systems For Additive Manufacturing With SiOC Build Materials

Optical additive manufacturing, including laser additive manufacturing systems, apparatus and methods using polymer derived ceramic build materials. Additive manufacturing build materials are made of polymer derived ceramic including SiOC, precures, cured materials, hard cured materials, and pyrolized materials. Polymer derived ceramic build materials are mixed with and used in conjunction with other build materials. 1. A laser additive manufacturing apparatus (LAM) comprising:a polymer derived ceramic build material.2. The LAM of claim 1 , wherein the polymer derived ceramic build material comprises SiOC.3. The LAM of claim 2 , wherein the polymer derived ceramic build material comprises a liquid.4. The LAM of claim 2 , wherein the polymer derived ceramic build material comprises a solid.5. The LAM of claim 2 , wherein the polymer derived ceramic build material comprises a hard cured material.6. The LAM of claim 2 , wherein the polymer derived ceramic build material comprises a cured material.7. The LAM of claim 2 , wherein the polymer derived ceramic build material comprises a ceramic material.8. A method of additive manufacturing comprising:providing a build material selected from the group consisting of one or more of the materials, precursors, particles, pigments, cured materials, hard cured materials and pyrolized materials that are disclosed in in U.S. Pat. Nos. 9,815,952, 9,815,943, 10,167,366, 9,499,677, and in US Patent Publication Nos. 2017/0368668, 2019/0315969, and 2018/0065995, the entire disclosure of which is incorporated herein by reference.directing light in a predetermined illumination pattern at the build material, wherein the build material is formed into an article having a predetermined shape that is based upon the predetermined illumination pattern.9. The method of claim 8 , wherein the directed light is a laser beam.10. The method of claim 9 , wherein the directed light has a wavelength in the IR range.11. The method of claim 8 , wherein the ...

METHODS OF PROVIDING HIGH PURITY SiOC AND SiC MATERIALS

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

MIXER, METHOD OF MIXING RAW MATERIAL FOR POWDER METALLURGY BINDER FOR INJECTION MOULDING COMPOSITION

Mixer for ceramic feedstock pellets with a tank, a mixing means, and heat exchange means including cooling means for the cooling of the content of this tank. 1. A mixer for the manufacture of ceramic type pellets known as feedstock from a mixture including , on the one hand , at least one inorganic powder of at least one oxide or cermet or metal or nitride type element or of at least one compound including at least one of said elements , and on the other hand , at least one organic binder , said mixer including at least one tank in which at least one mixing means is moveable , and including a heat exchange means , wherein said heat exchange means includes a heating means arranged for heating said tank and/or the content thereof , and in that said heating means exchange energy , in a first connection , with a first heat exchange and mixing temperature maintenance circuit , external to said tank , and wherein the thermal inertia of said first circuit is higher than that of said tank fully loaded with said mixture.2. The mixer according to claim 1 , wherein the thermal inertia of said first circuit is higher than that of said tank fully loaded with said mixture by a first factor higher than 2.3. The mixer according to claim 1 , wherein the heat exchange means include cooling means which exchange energy claim 1 , in a second connection claim 1 , with a second circuit at ambient temperature claim 1 , external to said tank claim 1 , and distinct from said first circuit claim 1 , and whose thermal inertia is far higher than that of said tank fully loaded with said mixture.4. The mixer according to claim 3 , wherein the thermal inertia of said second circuit is far higher than that of said tank fully loaded with said mixture by a second factor higher than 2.5. The mixer according to claim 1 , wherein said mixer includes control means connected to means for measuring and means for storing temperature parameters according to the type of material to be manufactured claim 1 , ...

Pressed and Self Sintered Polymer Derived SiC Materials, Applications and Devices

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC. 111-. (canceled)12. A silicon carbide composition comprising:a. polymer derived silicon carbide particles;b. the particles having a mean particle size of about 0.5 μm or smaller;{'sub': '4', 'c. the particles consisting essentially of silicon and carbon in an SiCconfiguration, wherein the particles have less than 0.5% excess carbon, and are at least 99.99999% pure.'}13. The composition of claim 12 , wherein the mean particle size is about 0.2 μm or smaller.14. The composition of claim 12 , wherein the mean particle size is about 0.1 μm or smaller.15. A self sinterable silicon carbide composition comprising:a. polymer derived silicon carbide particles;b. the particles having a mean particle size of about 0.5 μm or smaller;{'sub': '4', 'c. the particles consisting essentially of silicon and carbon in an SiCconfiguration, wherein the particles have less than 0.1% excess carbon, and are at least 99.99999% pure;'}d. wherein the particles are capable of being formed into a solid SiC volumetric shape without the need for a sintering aid.16. The composition of claim 15 , wherein the volumetric shape is a layer.17. The composition of claim 15 , wherein the volumetric shape claim 15 , is selected from the group of shapes consisting of a window claim 15 , a lens claim 15 , and a fiber.18. The composition of claim 15 , wherein the volumetric shape is an article selected from the group consisting of armor claim 15 , ballistic materials claim 15 , blast shields claim 15 , penetration resistant materials claim 15 , windows claim 15 , lenses claim 15 , fibers claim 15 , internal reflection optics claim 15 , and optics.19. (canceled)20. (canceled)21. A silicon carbide composition comprising:a. polymer ...

COMPOSITES WITH ONE OR MULTIPLE PRINCIPAL STRENGTHENING COMPOUNDS AND AT LEAST ONE PRINCIPAL CEMENTED REFRACTORY METAL

A composite composed of one or a plurality of principal strengthening compounds and at least one principal cemented refractory metal that is prepared by combining a suitable binary to senary borides and/or carbides with a unitary to binary principal refractory metal is disclosed. As compared with the conventional sintered cemented carbides, the composite of the disclosure not only possess high hardness and high toughness but also has various ratios of principal components since it is not prepared with equal mole during the process. 1. A composite having one or a plurality of principal strengthening compounds and at least one principal cemented refractory metal , wherein the composition of the composite is two or three principal strengthening compounds and a principal cemented refractory metal , and the principal strengthening compounds is selected from borides or carbides , wherein the mole fraction of the principal strengthening phase compounds and the mole fraction of the principal cemented refractory metal are different.2. The composite composed of one or a plurality of principal strengthening compounds and at least one principal cemented refractory metal according to claim 1 , wherein the principal cemented refractory metal is selected from Nb claim 1 , Ta claim 1 , Mo and W.3. The composite composed of one or a plurality of principal strengthening compounds and at least one principal cemented refractory metal according to claim 1 , wherein the boride is selected from TiBand ZrB.4. The composite composed of one or a plurality of principal strengthening compounds and at least one principal cemented refractory metal according to claim 1 , wherein the carbide is selected from TiC claim 1 , VC claim 1 , ZrC claim 1 , HfC claim 1 , WC claim 1 , NbC and TaC.5. A composite composed of one or a plurality of principal strengthening compounds and at least one principal cemented refractory metal claim 1 , wherein the composition of the composite is two to six principal ...

RESIN FORMULATIONS FOR POLYMER-DERIVED CERAMIC MATERIALS

This disclosure enables direct 3D printing of preceramic polymers, which can be converted to fully dense ceramics. Some variations provide a preceramic resin formulation comprising a molecule with two or more C═X double bonds or C≡X triple bonds, wherein X is selected from C, S, N, or O, and wherein the molecule further comprises at least one non-carbon atom selected from Si, B, Al, Ti, Zn, P, Ge, S, N, or O; a photoinitiator; a free-radical inhibitor; and a 3D-printing resolution agent. The disclosed preceramic resin formulations can be 3D-printed using stereolithography into objects with complex shape. The polymeric objects may be directly converted to fully dense ceramics with properties that approach the theoretical maximum strength of the base materials. Low-cost structures are obtained that are lightweight, strong, and stiff, but stable in the presence of a high-temperature oxidizing environment. 1. A preceramic resin formulation comprising:(a) first molecules comprising two or more C═X double bonds, two or more C≡X triple bonds, or at least one C═X double bond and at least one C≡X triple bond, wherein X is selected from the group consisting of C, S, N, O, and combinations thereof, and wherein said first molecule further comprises at least one non-carbon atom selected from the group consisting of Si, B, Al, Ti, Zn, P, Ge, S, N, O, and combinations thereof;(b) second molecules comprising R—Y—H;wherein R is an organic group or an inorganic group; wherein, for at least one of said second molecules, R comprises a group having at least one Si atom; and wherein Y is selected from the group consisting of S, N, O, and combinations thereof;(c) a photoinitiator;(d) a free-radical inhibitor; and(e) a 3D-printing resolution agent.2. The preceramic resin formulation of claim 1 , wherein said first molecules comprise one or more functional groups selected from the group consisting of vinyl claim 1 , ethynyl claim 1 , vinyl ether claim 1 , vinyl ester claim 1 , vinyl amide ...

High Strength Low Density Synthetic Proppants for Hydraulically Fracturing and Recovering Hydrocarbons

There is provided synthetic proppants, and in particular polysilocarb derived ceramic proppants. There is further provided hydraulic fracturing treatments utilizing these proppants, and methods of enhance hydrocarbon recovery.

Nano-crystalline refractory metal carbides, borides or nitrides with homogeneously dispersed inclusions

Disclosed are compositions containing nanoparticles of a metal nitride, boride, silicide, or carbide, a filler material, and a carbonaceous matrix. The precursor to this material contains nanoparticles or particles of boron, silicon, iron, a refractory metal, or a refractory metal hydride, an organic compound having carbon and hydrogen, and a filler material. Multilayered materials are also disclosed.

Methods and apparatus for conducting heat exchanger based reactions

Methods, apparatus and systems using heat exchanger reactors to form polymer derived ceramic materials, including methods for making polysilocarb (SiOC) precursors.

SINTERED MATERIAL, TOOL INCLUDING SINTERED MATERIAL, AND SINTERED MATERIAL PRODUCTION METHOD

To provide a sintered material having excellent oxidation resistance, as well as excellent abrasion resistance and chipping resistance. A sintered material containing a first compound formed of Ti, Al, Si, O, and N is provided. 1. A sintered material comprising a first compound formed of Ti , Al , Si , O , and N.2. The sintered material according to claim 1 , wherein{'sub': (1-a-b)', 'a', 'b', 'x', 'y, 'said first compound contains TiAlSiON, and'}{'sub': (1-a-b)', 'a', 'b', 'x', 'y, 'a, b, x and y in said TiAlSiONrespectively satisfy 0.01≦a≦0.70, 0.01≦b≦0.55, 0.06≦a+b≦0.88, 0.005≦x≦0.6, 0.4≦y≦0.995, and 0.5 Подробнее

Ceramic coating for foundry core

A process for coating a refractory alloy part is provided and includes coating an area of a refractory alloy part by means of a treatment composition including a type of preceramic polymer and a solvent, and heat treating the part coated with the treatment composition. The heat treating partially converts the preceramic polymer and forms a ceramic coating obtained by conversion, the ceramic coating protecting the refractory alloy from oxidation. The treatment composition also includes active fillers to form an alloy coating on a surface of the part by solid diffusion in addition to the ceramic coating obtained by conversion, and the alloy coating generates a protective oxide layer when subjected to oxidizing conditions.

APPARATUS AND METHOD FOR JOINING OF CARBIDE CERAMICS

A bonding tape for joining carbide ceramic structures, wherein the bonding tape comprises: a mixture comprising carbide ceramic particles, preceramic polymer liquid, fine carbon particles and metal nanoparticles that form a eutectic liquid at temperatures below 1400° C. 1. A bonding tape for joining carbide ceramic structures , wherein the bonding tape comprises:a mixture comprising carbide ceramic particles, preceramic polymer liquid, fine carbon particles and metal nanoparticles that form a eutectic liquid at temperatures below 1400° C.2. The bonding tape of wherein the carbide ceramic particles comprise one or more porous preforms and wherein the preceramic polymer liquid claim 1 , fine carbon particles and metal nanoparticles that form a eutectic liquid at temperatures below 1400° C. infiltrate pores in the one or more porous preforms. The present application is a CONTINUATION of copending U.S. patent application Ser. No. 15/651,839 (the “'839 Application”) entitled “Apparatus and Method for Joining of Carbide Ceramics” and filed Jul. 17, 2017, now U.S. Pat. No. 10,906,203, the entirety of which is incorporated herein by reference for all purposes. The '839 Application claims priority to U.S. Provisional Application Ser. No. 62/362,973 filed Jul. 15, 2016, which is incorporated by reference herein for all purposes.This invention was made with government support under grant #NRC-HQ-12-G-38-0011 awarded by the US Nuclear Regulatory Commission (NRC). The government has certain rights in the invention.There is a need for better processing methods of carbide ceramics for additive manufacturing and carbide-carbide joining. Currently, joining or sintering of carbide ceramics such as silicon carbide (SiC) and tungsten carbide (WC) occurs through applying high temperature and/or high pressure and/or electric field and/or high energy light through processes such as hot isostatic pressing, polymer infiltration and pyrolysis (PIP) technique, reaction bonding and spark ...

METHODS OF FORMING POLYCRYSTALLINE COMPACTS

Polycrystalline compacts include a polycrystalline superabrasive material comprising a first plurality of grains of superabrasive material having a first average grain size and a second plurality of grains of superabrasive material having a second average grain size smaller than the first average grain size. The first plurality of grains is dispersed within a substantially continuous matrix of the second plurality of grains. Earth-boring tools may include a body and at least one polycrystalline compact attached thereto. Methods of forming polycrystalline compacts may include coating relatively larger grains of superabrasive material with relatively smaller grains of superabrasive material, forming a green structure comprising the coated grains, and sintering the green structure. Other methods include mixing diamond grains with a catalyst and subjecting the mixture to a pressure greater than about five gigapascals (5.0 GPa) and a temperature greater than about 1,300° C. to form a polycrystalline diamond compact. 1. A method of forming a polycrystalline compact , comprising:coating relatively larger grains of superabrasive material with relatively smaller grains of superabrasive material, the relatively larger grains having a first average grain size between about five microns (5 μm) and about forty microns (40 μm), the relatively smaller grains having a second average grain size between about five nanometers (5 nm) and about two microns (2 μm);forming a green structure comprising the relatively larger grains coated with the relatively smaller grains; andsintering the green structure to form in-situ nucleated grains of hard material, a continuous matrix of the relatively smaller grains, and inter-granular bonds between the relatively larger grains and the relatively smaller grains, wherein the relatively larger grains are dispersed within the continuous matrix, and wherein at least some of the relatively larger grains are non-contiguous.2. The method of claim 1 , ...

N-H FREE AND SI-RICH PER-HYDRIDOPOLYSILZANE COMPOSITIONS, THEIR SYNTHESIS, AND APPLICATIONS

Solid or liquid N—H free, C-free, and Si-rich perhydropolysilazane compositions comprising units having the following formula [—N(SiH)(SiH—)], wherein x=0, 1, or 2 and y=0, 1, or 2 when x+y=2; and x=0, 1 or 2 and y=1, 2, or 3 when x+y=3 are disclosed. Also disclosed are synthesis methods and applications for the same. 1. A method of forming a Si-containing film on a substrate , the method comprising forming a solution comprising a N—H free , C-free , and Si-rich perhydropolysilazane composition and contacting the solution with the substrate via a spin coating , spray coating , dip coating , or slit coating technique to form the Si-containing film , the N—H free , C-free , and Si-rich perhydropolysilazane composition comprising N—H free repeating units having the formula [—N(SiH)(SiH—)] , wherein x=0 , 1 , or 2 and y=0 , 1 , or 2 with x+y=2; or x=0 , 1 or 2 and y=1 , 2 , or 3 with x+y=3.2. The method of claim 1 , further comprising curing the Si-containing film.3. The method of claim 1 , the Si-containing film being SiON.4. The method of claim 1 , wherein the N—H free claim 1 , C-free claim 1 , and Si-rich perhydropolysilazane composition comprises between approximately 0 wt % and approximately 1 wt % of any N—H containing unit.5. The method of claim 1 , wherein the N—H free claim 1 , C-free claim 1 , and Si-rich perhydropolysilazane composition comprises between approximately 99 wt % to approximately 100 wt % of N—H free repeating units having a N atom bonded to 3 silicon atoms.6. The method of claim 5 , wherein the N—H free claim 5 , C-free claim 5 , and Si-rich perhydropolysilazane composition has a molecular weight ranging from approximately 332 dalton to approximately 100 claim 5 ,000 dalton.7. The method of claim 5 , wherein the N—H free claim 5 , C-free claim 5 , and Si-rich perhydropolysilazane composition has a Si:N ratio ranging from approximately 1.5:1 to approximately 2.5:1.8. The method of claim 5 , wherein the N—H free claim 5 , C-free claim 5 , and Si- ...

FUNCTIONALLY GRADED CARBIDES

A functionally graded carbide body () can include a group 5 metal carbide substrate having a bulk composition region () that contains at least 70 wt % of a rhombohedral ζ-phase carbide. A γ-phase-rich region () having a γ-phase-rich composition can be at a surface () of the substrate, and a phase composition gradient region () can transition from the γ-phase-rich composition region at the surface to the bulk composition region at a gradient depth () below the surface. 1. A functionally graded carbide body of a group 5 metal carbide , comprising:a bulk composition region comprising at least 70 wt % of a rhombohedral ζ-phase carbide of the group 5 metal carbide;a γ-phase-rich region having a γ-phase-rich composition at a surface of the carbide body; anda phase composition gradient region transitioning from the γ-phase-rich composition region to the bulk composition region at a gradient depth below the surface.2. The functionally graded carbide body of claim 1 , wherein the γ-phase-rich composition region is from 70 wt % to 100 wt % γ-phase.3. The functionally graded carbide body of claim 1 , wherein the phase composition gradient region transitions substantially continuously from the γ-phase-rich composition region to the bulk composition region.4. The functionally graded carbide body of claim 1 , wherein the γ-phase-rich composition region has a substantially uniform carbon to group 5 metal atomic ratio to a first depth from the surface claim 1 , and then transitions continuously to the bulk composition region at the gradient depth.5. The functionally graded carbide body of claim 4 , wherein the first depth is from 2 micrometers to 30 micrometers.6. The functionally graded carbide body of claim 1 , wherein the gradient depth is from 5 micrometers to 50 micrometers.7. The functionally graded carbide body of claim 1 , wherein the carbide body is a substantially pure carbide.8. The functionally graded carbide body of claim 1 , wherein the carbide body has a surface ...

SINTERED MATERIAL, TOOL INCLUDING SINTERED MATERIAL, AND SINTERED MATERIAL PRODUCTION METHOD

To provide a sintered material having excellent oxidation resistance, as well as excellent abrasion resistance and chipping resistance. A sintered material containing a first compound formed of Ti, Al, Si, O, and N is provided. 15.-. (canceled)6. A method for producing a sintered material , comprising the steps of:preparing first grains containing elements Ti, Al, and Si;treating said first grains to make second grains formed of elements Ti, Al, Si, O, and N; andsintering said second grains to make a sintered material containing a first compound formed of Ti, Al, Si, O, and N, whereinthe step of making said second grains includes a step of heating said first grains, and a step of rapidly cooling said first grains after heating.7. The method for producing a sintered material according to claim 6 , further comprising a step of:mixing said second grains with third grains before the step of making said sintered material, whereinsaid third grains are grains formed of at least one selected from the group consisting of a fifth compound, a sixth compound, a seventh compound and a second metal,said fifth compound is cubic boron nitride,said sixth compound is a compound of at least one element selected from Al and Si, and at least one element selected from the group consisting of B, C, N, and O,said seventh compound is a compound of at least one element selected from the group consisting of elements in Group 4, elements in Group 5, and elements in Group 6 of the periodic table, and at least one element selected from the group consisting of B, C, N, and O, andsaid second metal is a metal formed of at least one selected from the group consisting of Ti, V, Cr, Mn, Co, Ni, Cu, Al, Sn, Si, Zr, Nb, Mo, Ag, Hf, Ta, W, and Pb.8. The method for producing a sintered material according to claim 7 , wherein said mixing step is executed in such a manner that a content of said third grains in mixed grains of said second grains and said third grains is less than or equal to 90% by volume. ...

DRILLING TOOLS HAVING MATRICES WITH CARBIDE-FORMING ALLOYS, AND METHODS OF MAKING AND USING SAME

Drilling tools, such as drill bits, having a shank, a crown, and a plurality of abrasive cutting elements. In the case of impregnated drilling tools, the abrasive cutting elements are dispersed throughout at least a portion of the crown. In the case of surface-set drilling tools, the abrasive cutting media is secured to and projects from a cutting face of the crown. The matrix of the crown of the drilling tools includes a carbide-forming alloy that forms a direct carbide bond with at least one cutting element of the plurality of abrasive cutting elements. 1. A drilling tool , comprising:a shank having a first end and an opposing second end, the first end being adapted to be secured to a drill string component;a crown extending from the second end of the shank, the crown comprising a matrix of hard particulate material and a carbide-forming alloy, a binder, a cutting face, and a crown body between the cutting face and the shank, wherein the hard particulate material is a powdered material that comprises one or more of carbide, tungsten, iron, cobalt, and/or molybdenum and carbides, borides, or alloys thereof, and wherein the carbide-forming alloy is provided as a powder; anda plurality of abrasive cutting elements secured at least partially within the matrix of the crown, wherein the plurality of abrasive cutting elements comprise a plurality of uncoated diamond cutting elements,wherein the carbide-forming alloy of the matrix forms an intermediate metallic layer that directly bonds with the binder and the hard particulate material of the matrix, and wherein the carbide-forming alloy of the matrix forms a direct carbide bond with at least one uncoated diamond cutting element of the plurality of uncoated diamond cutting elements, wherein the drilling tool does not include oxide layers between said at least one uncoated diamond cutting element and the carbide-forming alloy of the matrix,wherein the carbide-forming alloy of the matrix is configured to convert portions of ...

FUNCTIONAL COMPOSITE PARTICLES

A complex ceramic particle and ceramic composite material may be made of a pretreated coal dust and a polymer derived ceramic that is mixed together and pyrolyzed in a nonoxidizing atmosphere. Constituent portions of the particle mixture chemically react causing particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for a plurality of uses including composite articles and proppants. 1. A composite particle comprises a pyrolyzed ceramic composite core comprised of a first material , wherein the first material is a composite made of a mixture of coal dust preheated in a substantially non-oxidizing atmosphere at a temperature less than 400 degrees centigrade to produce a coal dust additive comprising carbon and organic compounds and a polymer derived ceramic material , the coal dust additive and the polymer derived ceramic material being selected and mixed together such that , when the first material is pyrolyzed in a substantially non-oxidizing atmosphere , the coal dust additive and the polymer derived ceramic material react when pyrolyzed and transform into a ceramic matrix composite.2. The composite particle of claim 1 , further comprising a coating substantially enclosing the pyrolyzed ceramic composite core within the coating.3. The composite particle of claim 2 , wherein the coating is comprised of a polymer derived ceramic material.4. The composite particle of claim 3 , wherein the polymer derived ceramic material of the pyrolyzed ceramic composite core is a silicon-oxy-carbide polymer derived ceramic material.5. The composite particle of claim 4 , wherein the polymer derived ceramic material of the coating is different than the polymer derived ceramic material used in the pyrolyzed ceramic composite core.6. The composite particle of claim 2 , wherein the polymer derived ceramic material of the coating is pyrolyzed in a substantially non-oxidizing atmosphere such that a hard shell substantially encloses the ...

BINDER FOR INJECTION MOULDING COMPOSITIONS

A binder for an injection moulding composition includes: from 35 to 54% by volume of a polymeric base, from 40 to 55% by volume of a mixture of waxes, and approximately 10% by volume of a surfactant, wherein the polymeric base contains copolymers of ethylene and methacrylic or acrylic acid, or copolymers of ethylene and vinyl acetate, or copolymers of ethylene including maleic anhydride or a mixture of these copolymers, as well as polyethylene, polypropylene and acrylic resin. 1. A binder for injection moulding composition including:from 35 to 54% by volume of a polymeric base,from 40 to 55% by volume of a mixture of waxes or a mixture of wax and palm oil,and approximately 10% by volume of a surfactant,wherein the polymeric base contains an ethylene and methacrylic or acrylic acid copolymer, or an ethylene copolymers comprising a maleic anhydride, or a mixture of these copolymers, in addition to polyethylene, polypropylene and an acrylic resin, the respective quantities of the binder components being such that added together, they do not exceed 100%.2. The binder according to claim 1 , including 2 to 7% by volume of one of said copolymers or their mixtures claim 1 , around 25% by volume of polyethylene claim 1 , 2 to 15% by volume of polypropylene and 6 to 15% by volume of acrylic resin.3. A binder for injection moulding composition including:from 35 to 54% by volume of a polymeric base,from 40 to 55% by volume of a mixture of waxes or a wax and palm oil mixture,and approximately 10% by volume of a surfactant,wherein the polymeric base contains 2 to 7% by volume of an ethylene vinyl acetate copolymer, approximately 25% by volume of polyethylene, from 2 to 15% by volume of polypropylene and 6 to 15% by volume of acrylic resin, the respective quantities of the binder components being such that added together, they do not exceed 100%.4. The binder according to claim 1 , wherein the ethylene and methacrylic or acrylic acid copolymer contains 3 to 10% by weight of a ...

SILICON OXYCARBIDE ENVIRONMENTAL BARRIER COATING

An article includes a ceramic-based substrate and a barrier layer on the ceramic-based substrate. The barrier layer includes a matrix of barium-magnesium alumino-silicate or SiO, a dispersion of silicon oxycarbide particles in the matrix, and a dispersion of particles, of the other of barium-magnesium alumino-silicate or SiO, in the matrix. 1. An article comprising:a ceramic-based substrate; and{'sub': 2', '2, 'a barrier layer on the ceramic-based substrate, the barrier layer including a matrix of barium-magnesium alumino-silicate or SiO, a dispersion of silicon oxycarbide particles in the matrix, the silicon oxycarbide particles having Si, O, and C in a covalently bonded network, and a dispersion of particles, of the other of barium-magnesium alumino-silicate or SiO, in the matrix.'}2. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the barium-magnesium alumino-silicate particles.3. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 30-94% of the silicon oxycarbide particles.4. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 5-40% of the matrix of SiO.5. The article as recited in claim 1 , wherein the barrier layer includes claim 1 , by volume claim 1 , 1-30% of the barium-magnesium alumino-silicate particles claim 1 , 5-40% of the matrix of SiO claim 1 , and a balance of the silicon oxycarbide particles.6. The article as recited in claim 5 , wherein the barrier layer includes claim 5 , by volume claim 5 , 1-5% of the barium-magnesium alumino-silicate particles.7. The article as recited in claim 1 , further comprising a distinct intermediate layer between the barrier layer and the ceramic-based substrate claim 1 , the distinct intermediate layer including an intermediate layer matrix of SiOand a dispersion of intermediate layer silicon oxycarbide particles in the intermediate layer matrix.81221. The ...

EROSION RESISTANT HARD COMPOSITE MATERIALS

A hard composite composition may comprise a binder and a polymodal blend of matrix powder. The polymodal blend of matrix powder may have at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm that has a value that is less than the first local maxima. 1. A hard composite composition comprising:a binder; anda polymodal blend of matrix powder, wherein the polymodal blend of matrix powder has at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm that has a value that is less than the first local maxima.2. The composition of wherein the first local maxima is at a particle size of about 0.5 nm to about 1 μm.3. The composition of wherein the first local maxima is at a particle size of about 1 μm to about 10 μm.4. The composition of wherein the polymodal blend of matrix powder comprises at least one material selected from the group consisting of: a carbide claim 1 , a nitride claim 1 , a natural diamond claim 1 , a synthetic diamond claim 1 , predominantly carbon structures claim 1 , iron oxides claim 1 , steels claim 1 , stainless steels claim 1 , austenitic steels claim 1 , ferritic steels claim 1 , martensitic steels claim 1 , precipitation-hardening steels claim 1 , duplex stainless steels claim 1 , iron alloys claim 1 , nickel alloys claim 1 , chromium alloys claim 1 , and any combination thereof.5. The composition of wherein the polymodal blend of matrix powder comprises at least one particle selected from the group consisting of: a whisker claim 1 , a rod claim 1 , a nanorod claim 1 , a wire claim 1 , a nanowire claim 1 , a lobal particle claim 1 , a nanostar claim 1 , a ...

CONTIGUOUSLY BLENDED NANO-SCALED MULTI-PHASE FIBERS

A multi-component or ‘composite’ inorganic fiber comprising a nano-scale contiguous collection of a plurality of packed unique phases of material randomly interspersed throughout the fiber body, without unwanted impurities, and a method for producing same. Said phases include three or more foundational chemical elements from the Periodic Table mixed together during fiber production, producing distinct material phases interspersed throughout the fiber volume. 1. A multi-component or ‘composite’ inorganic fiber comprising a nano-scale contiguous collection of a plurality of packed unique phases of material randomly interspersed throughout the fiber , said phases comprising three or more elements from the Periodic Table mixed together during fiber production using Laser Induced Chemical Vapor Deposition , producing said unique phases interspersed throughout the fiber.2. The fiber of claim 1 , wherein the three elements include silicon claim 1 , carbon and boron claim 1 , the unique phases including silicon carbide claim 1 , boron carbide claim 1 , silicon carbonitride claim 1 , and boron silicide.3. The fiber of claim 1 , wherein the three elements include silicon claim 1 , carbon and boron claim 1 , the phases including silicon carbide claim 1 , boron carbide claim 1 , silicon carbonitride claim 1 , and free silicon.4. The fiber of claim 1 , wherein the three elements include silicon claim 1 , carbon and boron claim 1 , the phases including silicon carbide claim 1 , boron carbide claim 1 , and free boron.5. The fiber of claim 1 , wherein the three elements include silicon claim 1 , carbon and boron claim 1 , the phases including silicon carbide claim 1 , boron carbide claim 1 , free boron and free silicon.6. The fiber of claim 1 , wherein the three elements include silicon claim 1 , carbon and nitrogen claim 1 , the phases including silicon carbide claim 1 , silicon nitride claim 1 , and silicon carbonitride.7. The fiber of claim 1 , wherein the three elements include ...

Erosion resistant hard composite materials

A hard composite composition may comprise a binder and a polymodal blend of matrix powder. The polymodal blend of matrix powder may have at least one first local maxima at a particle size of about 0.5 nm to about 30 μm, at least one second local maxima at a particle size of about 200 μm to about 10 mm, and at least one local minima between a particle size of about 30 μm to about 200 μm that has a value that is less than the first local maxima.

COMPLEX COMPOSITE PARTICLES AND METHODS

A complex composite particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant or in a composite structure. 1. A complex composite particle comprises a core comprised of a first material , wherein the first material is a composite made of a coal dust and a polymer derived ceramic material , the coal dust and the polymer derived ceramic material being pyrolyzed in a substantially non-oxidizing atmosphere and transforming into a ceramic matrix composite , wherein the coal dust of the core is preheated prior to being pyrolyzed in a substantially non-oxidizing atmosphere at a temperature no greater than 400 degrees centigrade to produce an in situ additive comprising carbon and organic compounds that vaporize and react when pyrolyzed in the presence of the polymer derived ceramic material.2. (canceled)3. The complex composite particle of claim 1 , further comprising a coating substantially enclosing the core within the coating.4. The complex composite particle of claim 3 , wherein the coating is comprised of a polymer derived ceramic material claim 3 , whereby the coating may be comprised of the same polymer derived ceramic material as the polymer derived ceramic material of the core or a different polymer derived ceramic material than the polymer derived ceramic material of the core.5. The complex composite particle of claim 4 , wherein the polymer derived ceramic material of the core is a silicon-oxy-carbide polymer derived ceramic material.6. The complex composite particle of claim 5 , wherein the polymer derived ceramic material of the coating is the same as the polymer derived ceramic material of the core.7. The complex composite particle of claim 3 , wherein the polymer derived ceramic material of the coating is pyrolyzed in a substantially non-oxydizing atmosphere ...

METHODS OF FORMING CERAMIC MATRIX COMPOSITES USING SACRIFICIAL FIBERS AND RELATED PRODUCTS

Methods for preparing ceramic matrix composites using melt infiltration and chemical vapor infiltration are provided as well as the resulting ceramic matrix composites. The methods and products include the incorporation of sacrificial fibers to provide improved infiltration of the fluid infiltrant. The sacrificial fibers are removed, such as decomposed during pyrolysis, resulting in the formation of regular and elongate channels throughout the ceramic matrix composite. Infiltration of the fluid infiltrant can then take place using the elongate channels resulting in improved density and an improved ceramic matrix composite product. 1. A ceramic matrix composite (CMC) product comprising:a ceramic matrix,a plurality of ceramic reinforcing fibers disposed throughout the ceramic matrix, andone or more infiltrant veins traversing the CMC product.2. The CMC product according to claim 1 , wherein the ceramic matrix comprises one or more of silicon carbide claim 1 , silicon nitride claim 1 , silicon oxycarbides claim 1 , silicon oxynitrides claim 1 , silicides claim 1 , aluminum oxide claim 1 , silicon dioxide claim 1 , yttrium aluminum garnet claim 1 , aluminosilicates claim 1 , zirconium carbide claim 1 , hafnium carbide claim 1 , carbon claim 1 , or boron carbide claim 1 , and wherein the ceramic reinforcing fibers comprise one or more of silicon carbide claim 1 , silicon nitride claim 1 , silicon oxycarbides claim 1 , silicon oxynitrides claim 1 , silicides claim 1 , aluminum oxide claim 1 , silicon dioxide claim 1 , yttrium aluminum garnet claim 1 , aluminosilicates claim 1 , zirconium carbide claim 1 , hafnium carbide claim 1 , carbon claim 1 , SiNC claim 1 , SiBNC claim 1 , or boron carbide.3. The CMC product according to claim 1 , wherein the CMC product comprises a plurality of infiltrant veins claim 1 , wherein the plurality of infiltrant veins are elongate bodies disposed in a grid pattern.4. The CMC product according to claim 1 , wherein the CMC product comprises ...

SPHERICAL SILICON OXYCARBIDE PARTICLE MATERIAL AND MANUFACTURING METHOD THEREOF

Provided are spherical silicon oxycarbide particle material and manufacturing method thereof, wherein the average particle size is in the range of 0.1-100 μm and having a sphericity of 0.95-1.0. 2. The manufacturing method of spherical silicon oxycarbide (SiOC) particle material according to claim 1 , wherein the forming of the hydrolysate is performed in the aqueous medium that the pH of which is adjusted to 3-6.3. The manufacturing method of spherical silicon oxycarbide (SiOC) particle material according to claim 1 , wherein the condensation reaction is performed while the pH is adjusted to 7-12.4. The manufacturing method of spherical silicon oxycarbide (SiOC) particle material according to claim 1 , wherein the spherical silicon oxycarbide precursor particles are spherical polysilsesquioxane having no melting point or softening point.5. The manufacturing method of spherical silicon oxycarbide (SiOC) particle material according to claim 1 , wherein the aqueous medium that is acidic is an acetic acid aqueous solution.6. The manufacturing method of spherical silicon oxycarbide (SiOC) particle material according to claim 1 , wherein the alkaline solution is aqueous ammonia.7. A spherical silicon oxycarbide (SiOC) particle material manufactured by the manufacturing method of spherical silicon oxycarbide (SiOC) particle material according to claim 1 , wherein the silicon claim 1 , the carbon and the oxygen content in total accounts for more than 98% of a composition of the spherical silicon oxycarbide (SiOC) particle material by elemental analysis claim 1 , wherein the silicon content is 20-50% claim 1 , the carbon content is 10-50% claim 1 , the oxygen content is 20-50% claim 1 , and the composition basically consist of Si claim 1 , O and C claim 1 , wherein if elements other than Si claim 1 , C and O are detected claim 1 , then hydrogen is the only other element detected claim 1 , the average particle size of the spherical silicon oxycarbide (SiOC) particle material ...

Polysilocarb Materials, Methods and Uses

Polysilocarb formulations, cured and pyrolized materials, was well as articles and use for this material. In particular pyrolized polysilocarb ceramic materials and articles contain these materials where, the ceramic has from about 30 weight % to about 60 weight % silicon, from about 5 weight % to about 40 weight % oxygen, and from about 3 weight % to about 35 weight % carbon, and wherein 20 weight % to 80 weight % of the carbon is silicon-bound-carbon and 80 weight % to about 20 weight % of the carbon is free carbon. 1. A polysilocarb derived reinforced composite grinding or cutting member; comprising: a bulk phase and a cutting material; wherein the bulk phase is derived from a polysilocarb formulation.2. The composite grinding or cutting member of claim 1 , wherein the polysilocarb formulation is a reaction type formulation.3. The composite grinding or cutting member of claim 1 , wherein the polysilocarb formulation is a reaction type formulation claim 1 , wherein the formulation comprises at least one precursor selected from the group consisting of Phenyltriethoxysilane claim 1 , Phenylmethyldiethoxysilane claim 1 , Methyldiethoxysilane claim 1 , Vinylmethyldiethoxysilane claim 1 , Trimethyethoxysilane Triethoxysilane claim 1 , and TES 40.4. The composite grinding or cutting member of claim 1 , wherein the polysilocarb formulation is a reaction type formulation claim 1 , whereby the formulation comprises at least two precursors selected from the group consisting of Phenyltriethoxysilane claim 1 , Phenylmethyldiethoxysilane claim 1 , Methyldiethoxysilane claim 1 , Vinylmethyldiethoxysilane claim 1 , Trimethyethoxysilane Triethoxysilane claim 1 , and TES 40.5. The composite grinding or cutting member of claim 1 , wherein the cutting material is selected from the group consisting of polycrystalline diamond compact claim 1 , SiC claim 1 , Aluminum oxide and diamond.6. The composite grinding or cutting member of claim 2 , wherein the cutting material is selected from ...

POLYSILOCARB BINDERS AND COATINGS

Silicon (Si) based high temperature coatings and base materials and methods of making those materials. More specifically, methods and materials having silicon, oxygen and carbon containing polymer derived ceramic liquids that form filled and unfiled coatings, including high temperature crack resistant coatings. 1. A liquid composition for forming high temperature crack resistant coatings , the liquid composition comprising:a. methyl hydrogen fluid;b. a polysilocarb having vinyl groups;c. a filler;d. a wetting agent for the filler; and,e. a catalysis;f. wherein the composition is capable of forming a coating on a substrate, whereby the coating will not have visible cracks under 25× magnification when heated to 300° C.2. The liquid composition of claim 1 , wherein the composition is essentially VOC free.3. The liquid composition of claim 1 , wherein the composition is essentially HAP free.4. The liquid composition of claim 1 , wherein the composition is essentially TAP free.5. The liquid composition of comprising at least about 50% by volume filler.6. The liquid composition of comprising at least about 30% by volume filler.7. The liquid composition of comprising at least about 20% by volume filler.8. The liquid composition of claim 1 , wherein the liquid composition is at least about 90 percent solids.9. The liquid composition of wherein the liquid composition is at least about 95 percent solids.10. The liquid composition of claim 1 , wherein the liquid composition is at least about 99 percent solids.11. The liquid composition of claim 1 , wherein the liquid composition is 100 percent solids.12. The liquid composition of claim 2 , comprising at least about 90 percent solids.13. The liquid composition of claim 3 , comprising at least about 95 percent solids.14. The liquid composition of claim 4 , comprising at least about 99 percent solids.15. The liquid compositions of claim 4 , claim 4 , claim 4 , claim 4 , claim 4 , and claim 4 , whereby the coating will not have ...

METHOD FOR PYROLYZING PRECERAMIC POLYMER MATERIAL USING ELECTROMAGNETIC RADIATION

Disclosed is a method for fabricating a ceramic material from a preceramic polymer material. The method includes providing a preceramic polymer material that has a preceramic polymer and an electromagnetic radiation-responsive component. The electromagnetic radiation-responsive component is selected from cobalt, titanium, zirconium, hafnium, tantalum, tungsten, rhenium, and combinations thereof. An electromagnetic radiation is applied to the preceramic polymer material. The electromagnetic radiation interacts with the electromagnetic radiation-responsive component to generate heat that converts the preceramic polymer to a ceramic material. 1. A method for fabricating a ceramic material from a preceramic polymer material , the method comprising:providing a preceramic polymer material that includes a preceramic polymer and an electromagnetic radiation-responsive component, the electromagnetic radiation-responsive component includes a metal selected from the group consisting of cobalt, titanium, zirconium, hafnium, tantalum, tungsten, rhenium, and combinations thereof; andapplying electromagnetic radiation to the preceramic polymer material, the electromagnetic radiation interacting with the electromagnetic radiation-responsive component to generate heat that converts the preceramic polymer to a ceramic phase.2. The method as recited in claim 1 , wherein the metal is the cobalt.3. The method as recited in claim 1 , wherein the electromagnetic radiation-responsive component further includes at least one of a boron-containing compound claim 1 , nitrides of aluminum claim 1 , nitrides of titanium claim 1 , nitrides of zirconium claim 1 , nitrides of hafnium claim 1 , nitrides of tantalum claim 1 , nitrides of tungsten claim 1 , nitrides of rhenium claim 1 , carbides of aluminum claim 1 , carbides of titanium claim 1 , carbides of zirconium claim 1 , carbides of hafnium claim 1 , carbides of tantalum claim 1 , carbides of tungsten claim 1 , carbides of rhenium and ...

Cutting elements, and related earth-boring tools, supporting substrates, and methods

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A 3 XZ n-1 , where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

Semiconductor device including a coupled dielectric layer and metal layer, method of fabrication thereof, and material for coupling a dielectric layer and a metal layer in a semiconductor device

A passivating coupling material for, on the one hand, passivating a dielectric layer in a semiconductor device, and on the other hand, for permitting or at least promoting liquid phase metal deposition thereon in a subsequent process step. In a particular example, the dielectric layer may be a porous material having a desirably decreased dielectric constant k, and the passivating coupling material provides steric shielding groups that substantially block the adsorption and uptake of ambient moisture into the porous dielectric layer. The passivating coupling materials also provides metal nucleation sides for promoting the deposition of a metal thereon in liquid phase, in comparison with metal deposition without the presence of the passivating coupling material. The use of a liquid phase metal deposition process facilitates the subsequent manufacture of the semiconductor device. In one example, the passivating coupling material has multiple Si atoms in its chemical composition, which desirably increases the thermal stability of the material.

Semiconductor device including a coupled dielectric layer and metal layer, method of fabrication thereor, and material for coupling a dielectric layer and a metal layer in a semiconductor device

A passivating coupling material for, on the one hand, passivating a dielectric layer in a semiconductor device, and on the other hand, for permitting or at least promoting liquid phase metal deposition thereon in a subsequent process step. In a particular example, the dielectric layer may be a porous material having a desirably decreased dielectric constant k, and the passivating coupling material provides steric shielding groups that substantially block the adsorption and uptake of ambient moisture into the porous dielectric layer. The passivating coupling materials also provides metal nucleation sides for promoting the deposition of a metal thereon in liquid phase, in comparison with metal deposition without the presence of the passivating coupling material. The use of a liquid phase metal deposition process facilitates the subsequent manufacture of the semiconductor device. In one example, the passivating coupling material has multiple Si atoms in its chemical composition, which desirably increases the thermal stability of the material.

실리콘-메틸 결합을 함유하는 절연층을 포함하는 다층 구조의 절연막 및 그 형성방법

Si-CH 3 결합을 함유하는 절연층의 접착 특성을 향상시킨 다층 구조의 절연막 및 그 형성 방법에 관하여 개시한다. 본 발명에 따른 다층 구조의 절연막은 도전 패턴 위에 형성되고, 그 내부에 Si-CH 3 결합을 함유하는 저유전막으로 이루어지는 제1 절연층을 포함한다. 상기 제1 절연층의 접착 특성을 향상시키기 위하여, 상기 제1 절연층을 플라즈마 처리하여 상기 제1 절연층 표면에 접착면을 형성하거나, 상기 제1 절연층 표면에 버퍼층을 형성함으로써, 절연층들 사이에 다이폴-다이폴 상호 작용 (dipole-dipole interaction)이 이루어질 수 있도록 한다.

Turbine solid nozzle element, method of its production, turbine nozzle with such multiple elements and gas turbine including such nozzle

FIELD: process engineering.SUBSTANCE: nozzle element is made of composite including fibrous reinforcement compacted by ceramic matrix. It comprises sections of inner and outer bases and at least one blade attached thereto. Base sections extend at every zone of their attachment to the blade. Fibrous reinforcement comprises fibrous structure woven by 3D or multiple ply weaving that features continuity in the entire volume of nozzle element and over the entire periphery of one or every blade. Solid fibrous blank is woven that contains in lengthwise direction, at least the following elements: one pattern including first segment that makes the blade preform blank, second segment extending the first one at its one lengthwise end to make two wings facing each other. Third element extends the first one at its opposite end to make two wings facing each other. This blank is turned to make wings of the second and third segments extend perpendicular to first segment. Blank shape is developed to make fibrous preform of nozzle element. Note here that blade part making the preform is produced by shaping the first segment. Parts that make the preforms of base sections are produced from wings. Then, preforms are compacted by matrix to make a solid nozzle element with fibrous reinforcement. Fibrous reinforcement comprises fibrous structure that features continuity in the entire volume of nozzle element and over the entire periphery of one or every blade. Other inventions of the set relate to turbine nozzle made as described above and to gas turbine with such nozzle.EFFECT: higher mechanical properties.15 cl, 30 dwg РОССИЙСКАЯ ФЕДЕРАЦИЯ (19) RU (11) (13) 2 539 910 C2 (51) МПК F01D 9/04 (2006.01) F01D 5/28 (2006.01) ФЕДЕРАЛЬНАЯ СЛУЖБА ПО ИНТЕЛЛЕКТУАЛЬНОЙ СОБСТВЕННОСТИ (12) ОПИСАНИЕ (21)(22) Заявка: ИЗОБРЕТЕНИЯ К ПАТЕНТУ 2012101635/06, 09.06.2010 (24) Дата начала отсчета срока действия патента: 09.06.2010 (72) Автор(ы): КУП Доминик (FR), РЕНОН Гийом Жан-Клод Робер (FR) 18.06.2009 FR ...

Mixer, method of mixing raw material for powder metallurgy binder for injection moulding composition

A mixer for ceramic feedstock pellets with a tank, a mixing shaft, and a heat exchanger including a cooler for the cooling of the content of this tank is provided. A controller controls the heat exchanger which includes a heater arranged to heat the content of this tank to a temperature comprised between a lower temperature (TINF) and a higher temperature (TSUP) stored in a memory for a specific mixture, and the heater exchanges energy with a heat exchange and mixing temperature maintenance circuit, external to this tank, and wherein the thermal inertia of this circuit is higher than that of this fully loaded tank. The invention also concerns a method for mixing raw material for powder metallurgy, implementing a specific injection molding composition and a specific binder.

복합재와 그의 제조방법

Substrate material for magnetic head

ガスバリアフィルム及びその製造方法、並びに該ガスバリアフィルムを用いた、有機ｅｌ素子用樹脂基材、有機ｅｌ素子

High purity SiOC and SiC, methods compositions and applications

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Pressed and self sintered polymer derived SiC materials, applications and devices

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

High purity polysilocarb materials, applications and processes

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Methods of providing high purity SiOC and SiC materials

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Polysilocarb based silicon carbide materials, applications and devices

Organosilicon chemistry, polymer derived ceramic materials, and methods. Such materials and methods for making polysilocarb (SiOC) and Silicon Carbide (SiC) materials having 3-nines, 4-nines, 6-nines and greater purity. Processes and articles utilizing such high purity SiOC and SiC.

Methods of hydraulically fracturing and recovering hydrocarbons

There is provided synthetic proppants, and in particular polysilocarb derived ceramic proppants. There is further provided hydraulic fracturing treatments utilizing these proppants, and methods of enhance hydrocarbon recovery.

Offshore methods of hydraulically fracturing and recovering hydrocarbons

There is provided synthetic proppants, and in particular polysilocarb derived ceramic proppants. There is further provided hydraulic fracturing treatments utilizing these proppants, and methods of enhance hydrocarbon recovery.

Detail containing metal-ceramic part and its manufacturing method

FIELD: metallurgy.SUBSTANCE: invention relates to the production of a soldering detail containing a metal-ceramic part including a solid phase based on niobium carbide and a nickel-based metal binder. The metal-ceramic part of the soldered detail is connected by silver-based solder with its other part made of metal-ceramic material, or sintered carbide, or steel. The metal-ceramic part contains at least 0.5 at. % of molybdenum as part of a metal binder phase.EFFECT: mentioned metal-ceramic part provides an edge wetting angle with molten solder, less than or equal to 45°, during the manufacture of the soldering detail.9 cl, 1 tbl, 8 dwg РОССИЙСКАЯ ФЕДЕРАЦИЯ (19) RU (11) (13) 2 762 282 C2 (51) МПК B22F 7/06 (2006.01) B23K 1/19 (2006.01) C22C 29/02 (2006.01) ФЕДЕРАЛЬНАЯ СЛУЖБА ПО ИНТЕЛЛЕКТУАЛЬНОЙ СОБСТВЕННОСТИ (12) ОПИСАНИЕ ИЗОБРЕТЕНИЯ К ПАТЕНТУ (52) СПК B22F 7/06 (2021.05); B23K 1/19 (2021.05); C22C 29/02 (2021.05) (21)(22) Заявка: 2019139036, 23.02.2018 (24) Дата начала отсчета срока действия патента: (73) Патентообладатель(и): ХИПЕРИОН МАТИРИАЛЗ ЭНД ТЕКНОЛОДЖИЗ (СВИДЕН) АБ (SE) Дата регистрации: 17.12.2021 05.05.2017 EP 17169649.5 (43) Дата публикации заявки: 07.06.2021 Бюл. № 16 (56) Список документов, цитированных в отчете о поиске: RU 2008113189 А, 20.10.2009. JPН 0598383 А, 20.04.1993. GB 2419618 A, 03.05.2006. RU 2536903 С2, 27.12.2014. (45) Опубликовано: 17.12.2021 Бюл. № 35 (85) Дата начала рассмотрения заявки PCT на национальной фазе: 05.12.2019 2 7 6 2 2 8 2 Приоритет(ы): (30) Конвенционный приоритет: R U 23.02.2018 (72) Автор(ы): МАРШАЛЛ, Джессика (GB), СВИТМЕН, Гэри (GB) EP 2018/054582 (23.02.2018) C 2 C 2 (86) Заявка PCT: (87) Публикация заявки PCT: R U 2 7 6 2 2 8 2 WO 2018/202339 (08.11.2018) Адрес для переписки: 129090, Москва, ул. Б. Спасская, 25, стр. 3, ООО "Юридическая фирма Городисский и Партнеры" (54) ДЕТАЛЬ, СОДЕРЖАЩАЯ МЕТАЛЛОКЕРАМИЧЕСКУЮ ЧАСТЬ, И СПОСОБ ЕЕ ИЗГОТОВЛЕНИЯ (57) Реферат: Изобретение относится к получению пайкой карбида, или стали. ...

Process for preparing metal carbide of high specific surface from activated carbon foams

내용없음. None.

Mixer, method of mixing raw material for powder metallurgy, binder for injection moulding composition

탱크 (2), 혼합 수단 (2), 및 이 탱크 (2) 의 내용물을 냉각시키는 냉각 수단 (42) 을 포함하는 열 교환 수단 (4) 을 구비한 세라믹 공급원료 펠릿들용 믹서 (1). 제어 수단 (5) 은 특정 혼합물을 위하여 메모리에 저장된 저온 (TINF) 와 고온 (TSUP) 사이에 포함된 온도로 이 탱크 (2) 의 내용물을 가열하도록 배열된 가열 수단 (41) 을 포함하는 열 교환 수단 (4) 을 제어하고, 이 가열 수단 (41) 은 탱크 (2) 외부에서 열 교환 및 혼합 온도 유지 회로 (8) 와 에너지 교환하고, 이 회로 (8) 의 열적 관성은 이 완전 충전된 탱크 (2) 의 열적 관성보다 더 높다. 또한, 본 발명은 분말 야금용 원료를 혼합하는 방법, 특정 사출 성형 조성물 및 특정 바인더를 구현하는 것에 관한 것이다. Mixer (1) for ceramic feedstock pellets comprising a tank (2), a mixing means (2) and a heat exchange means (4) comprising cooling means (42) for cooling the contents of the tank (2). The control means 5 comprises a heat exchanger comprising heating means 41 arranged to heat the contents of this tank 2 to a temperature comprised between a low temperature TINF and a high temperature TSUP stored in a memory for a particular mixture. The means 4 are controlled, and this heating means 41 exchanges energy with the heat exchange and mixing temperature holding circuit 8 outside the tank 2, and the thermal inertia of this circuit 8 is this fully charged tank. It is higher than the thermal inertia of (2). The present invention also relates to a method of mixing raw materials for powder metallurgy, to implementing particular injection molding compositions and specific binders.

Binder for injection moulding compositions

본 발명은 사출 성형 컴포지션용 바인더에 관한 것으로, - 40 ~ 55 부피% 의 폴리머 베이스, - 35 ~ 45 부피% 의 왁스 혼합물 또는 왁스 및 팜 오일 혼합물, 및 - 적어도 5 부피% 의 적어도 하나의 계면활성제를 포함하고, 폴리머 베이스는 에틸렌 및 메타크릴 또는 아크릴 산의 코폴리머, 에틸렌 및 프로필렌의 코폴리머 및/또는 말레산 무수물 그래프트된 폴리프로필렌, 및 이소프로필 알코올, 프로필 알코올 및/또는 테레빈을 포함하는 군으로부터 선택되고 또한 셀룰로오스 아세테이트 부티레이트, 폴리비닐 부티랄 및 코폴리아미드를 포함하는 군으로부터 선택되는 용매에서 용해성인 폴리머들로 형성되고, 바인더 컴포넌트들의 각 양은 그들의 합이 100 부피% 의 바인더와 동등하도록 되어 있다. The present invention relates to a binder for injection molded compositions, - 40 to 55% by volume of polymer base, - from 35 to 45% by volume of a wax mixture or a mixture of wax and palm oil, and - at least 5% by volume of at least one surfactant, The polymeric base is selected from the group comprising copolymers of ethylene and methacrylic or acrylic acid, copolymers of ethylene and propylene and/or maleic anhydride grafted polypropylene, and isopropyl alcohol, propyl alcohol and/or turpentine and also formed of polymers soluble in a solvent selected from the group comprising cellulose acetate butyrate, polyvinyl butyral and copolyamide, wherein each amount of the binder components is such that their sum equals 100% by volume of the binder.

Cast refractories, and casting nozzle and sliding nozzle plate using the same

Compression/injection molding of polymer-derived fiber reinforced ceramic matrix composite materials

Methods of making fiber reinforced ceramic matrix composite (FRCMC) parts by compression and injection molding. The compression molding method generally includes the initial steps of placing a quantity of bulk molding compound into a female die of a mold, and pressing a male die of the mold onto the female die so as to displace the bulk molding compound throughout a cavity formed between the female and male dies, so as to form the part. The injection molding method general includes an initial step of injecting a quantity of bulk molding compound into a cavity of a mold. In both methods, the bulk molding compound is a mixture which includes pre-ceramic resin, fibers, and, if desired, filler materials. Once the part has been formed by either method, the mold is heated at a temperature and for a time associated with the pre-ceramic resin which polymerizes the resin to form a fiber-reinforced polymer composite structure. The part is then removed from the mold, and heated a second time at a temperature and for a time associated with the polymerized resin which pyrolyzes it to form the finished FRCMC structure. These methods can also be modified to allow for the molding of heterogeneous FRCMC parts wherein different portions of the part contain different types of fiber and, if desired, different filler materials, so as to vary the characteristics exhibited by each portion thereof.

Combination continuous woven-fiber and discontinuous ceramic-fiber structure

A method of fabricating a ceramic structure as well as a pre-ceramic preimpregnated composite material incorporating a continuous woven fiber and a discontinuous fiber pre-ceramic matrix for subsequent curing and component construction. The method includes preparation of a mixture of discontinuous fibers, fillers, and a pre-ceramic precursor resin where the precursor resin is present in a quantity sufficient to substantially saturate subsequently adjacent woven fiber lengths, and thereafter introducing the mixture to a situs between an upper length of woven fiber and a lower length of woven fiber in alignment with each other while effectuating linear movement of these woven fiber lengths and moving the lengths toward each other for compression and retention in a sandwich configuration to thereby fabricate a pre-ceramic preimpregnated composite material. The material is cut to size in accord with the configuration of a part to be manufactured, formed into a green-state structure, and cured. Finished-product characteristics show a substantially uniform distribution of discontinuous fibers and fillers within the ceramic resin matrix to thereby provide a substantially internally stress-free end product component.

Method of fabricating ceramic matrix composites employing a vacuum mold procedure

A method of fabricating a discontinuous-fiber, ceramic matrix green-state composite component. The method includes preparation of a mixture of discontinuous fibers, in a quantity equal to about 100% of a desired end-product fiber quantity thereof, and a polymer-derived ceramic precursor resin in an excess quantity greater than about 150% of a desired end-product resin quantity thereof. The mixture so prepared then is introduced into a cavity of a molding tool and a vacuum is applied to the cavity through a vacuum aperture leading from the cavity. The mixture is drawn toward the vacuum aperture and consequently compacts a quantity of fibers within the cavity at the aperture site such that the fibers function as a filter to efficiently retain within the cavity fibers within the original mixture while removing under vacuum the excess resin that provided an effective vehicle for carrying and dispersing the discontinuous fibers. Finally, the molding tool is heated to a temperature and for a time sufficient to cure the resin/fiber mixture within the cavity and thereby fabricate the green-state composite component in a structurally sound manner.