Abstract: This invention relates to printable polymerizable material systems for making dental products such as artificial teeth, dentures, splints, veneers, inlays, onlays, copings, frame patterns, crowns and bridges and the like. A DLP or stereolithography printer is used to cure polymerizable material in a layer-by-layer manner to build-up the object. The resulting three-dimensional object has good dimensional stability.

Abstract: This invention relates to ink-jet printing systems for making dental products such as artificial teeth, dentures, splints, veneers, inlays, onlays, copings, frame patterns, crowns and bridges and the like. An ink-jet printer is used to discharge wax-like polymerizable material in a layer-by-layer manner to build-up the object. In other methods, a heated capillary or dropper can be used to apply the polymerizable material. The resulting three-dimensional object has good dimensional stability. Light irradiation can be used to cure and harden the material, thereby producing the final dental product.

Abstract: There is disclosed a method for producing a self-supporting ceramic body by oxidation of a molten precursor metal with a vapor-phase oxidant to form an oxidation reaction product and inducing a molten flux comprising said molten precursor metal through said oxidation reaction product. A second metal is incorporated into said molten flux during the oxidation reaction. The resulting ceramic body includes sufficient second metal such that one or more properties of said ceramic body are at least partially affected by the presence and properties of said second metal in the metallic constituent.

Abstract: The present invention relates to the formation of a metal matrix composite body by the spontaneous infiltration of a molten matrix metal into a three-dimensionally interconnected material. Moreover, the three-dimensionally interconnected material may contain filler material within at least a portion of its porosity. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material and/or a three-dimensionally interconnected material and/or a matrix metal at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the three-dimensionally interconnected material and any filler material contained within at least a portion of the porosity of the three-dimensionally interconnected material.

Abstract: The present invention relates to the formation of a macrocomposite body by spontaneously infiltrating a permeable mass of filler material or a preform with molten matrix metal and bonding the spontaneously infiltrated material to at least one second material such as a ceramic or ceramic containing body and/or a metal or metal containing body. Particularly, an infiltration enhancer and/or infiltration enhancer precursor and/or infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Moreover, prior to infiltration, the filler material or preform is placed into contact with at least a portion of a second material such that after infiltation of the filler material or preform, the infiltrated material is bonded to the second material, thereby forming a macrocomposite body.

Abstract: The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the composite body such that any undesirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. In a preferred embodiment of the present invention, the getterer material(s) form at least one compound (e.g., at least one glassy material) which acts as a crack sealant, thereby further enhancing the oxidation protection of the composite body. One or more ceramic filler materials which serve as reinforcements may have a plurality of superimposed coatings thereon, at least one of which coatings may function as a getterer.

Abstract: The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. In a preferred embodiment of the invention, a coated ceramic filler material adaptable for use as a reinforcing component in a ceramic matrix composite is provided with a plurality of superimposed coatings. The coating system includes a first coating in substantially continuous contact with the ceramic filler material and one or more additional or outer coatings superimposed over the underlying coating and in substantially continuous contact therewith. Zonal junctions are formed between the filler and the first coating, between superimposed coatings, and between the outer coating and the ceramic matrix. The coatings are selected so that the interfacial shear strength of at least one of these several zones is weak relative to the other zones.

Abstract: The present invention relates to the use of a gating means in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform is spontaneously infiltrated by molten matrix metal to form a metal matrix composite body. A gating means is provided which controls or limits the areal contact between molten matrix metal and the filler material or preform. The use of a gating means provides for control of the amount of matrix metal which can contact the preform or filler material, which may result in less machining of a formed metal matrix composite body compared with a similar metal matrix composite body made without a gating mean. Moreover, the use of a gating means ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.

Abstract: The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the matrix such that any desirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. Ceramic filler materials which serve as reinforcements may have a plurality of super-imposed coatings thereon, at least one of which coatings may function as a getterer. The coated materials may be useful as reinforcing materials in ceramic matrix composites to provide improved mechanical properties such as fracture toughness.

Abstract: The invention comprises a method of making self-supporting ceramic and ceramic composite structures by the oxidation reaction of a body of molten parent metal precursor with a vapor-phase oxidant to form an oxidation reaction product. This reaction or growth is continued to form a thick, self-supporting ceramic or ceramic composite body. The body is recovered and in a separate subsequent operation, at least a portion of a surface is coated with one or more materials in order to effect desired changes in the properties of the surface, e.g., hardness, corrosion resistance.

Abstract: There is provided a method for producing a self-supporting ceramic composite comprising (1) a ceramic matrix obtained by oxidation of an aluminum zinc alloy to form a polycrystalline oxidation reaction product of the metal with an oxidant, and (2) one or more fillers embedded by the matrix. The metal alloy and permeable mass of filler having at least one defined surface boundary are oriented relative to each other so that formation of the oxidation reaction product will occur into said mass of filler and in a direction towards said defined surface boundary. On heating the metal to a first temperature above its melting point but below the melting point of said oxidation reaction product to form a body of molten parent metal, the molten metal reacts with said oxidant to form said oxidation reaction product which infiltrates said mass of filler to said defined surface boundary.

Abstract: The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the matrix such that any desirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. Ceramic filler materials which serve as reinforcements may have a plurality of super-imposed coatings thereon, at least one of which coatings may function as a getterer. The coated materials may be useful as reinforcing materials in ceramic matrix composites to provide improved mechanical properties such as fracture toughness.

Abstract: The present invention generally relates to mechanisms for preventing undesirable oxidation (i.e., oxidation protection mechanisms) of reinforcement materials in composite bodies. The oxidation protection mechanisms include getterer materials which are added to the composite body which gather or scavenge undesirable oxidants which may enter the composite body. The getterer materials may be placed into at least a portion of the matrix such that any desirable oxidant approaching, for example, a fiber reinforcement, would be scavenged by (e.g., reacted with) the getterer. Ceramic filler materials which serve as reinforcements may have a plurality of super-imposed coatings thereon, at least one of which coatings may function as a getterer. The coated materials may be useful as reinforcing materials in ceramic matrix composites to provide improved mechanical properties such as fracture toughness.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel products produced by the method. Particularly, a permeable mass of filler material or a preform is provided which has included therein at least two different matrix metal powders. Moreover, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material or preform, at least at some point during the process, which permits molten matrix metal, upon contact with the filler material or preform, to spontaneously infiltrate the filler material or preform. The presence of powdered matrix metal in the preform or filler material reduces the relative volume fraction of filler material to matrix metal.

Abstract: There is disclosed a method for producing a self-supporting ceramic body by oxidation of a molten precursor metal with a vapor-phase oxidant to form an oxidation reaction product and inducing a molten flux comprising said molten precursor metal through said oxidation reaction product. A second metal is incorporated into said molten flux during the oxidation reaction. The resulting ceramic body includes sufficient second metal such that one or more properties of said ceramic body are at least partially affected by the presence and properties of said second metal in the metallic constituent.

Abstract: In a method for producing ceramic body by oxidation of a parent metal having a graded microstructure characterized by a plurality of zones differing from each other in one or more properties by altering the process conditions during formation of said ceramic body such that a zone of the oxidation reaction product formed posterior to said altering has one or more properties different from a zone of the oxidation reaction product formed anterior to said altering.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.

Abstract: The invention relates to a method for producing ceramic composites obtained by oxidation of a parent metal to form a polycrystalline ceramic material by providing a filler having a coating of a silicon source on at least a portion of the filler different in composition from the primary composition of the filler, said silicon source possessing intrinsic doping properties. A body of molten parent metal, adjacent a mass of the filter material, reacts with an oxidant to form an oxidation reaction product which infiltrates the adjacent mass of filler, thereby forming the ceramic composite.

Abstract: The present invention relates to the use of a gating means in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform is spontaneously infiltrated by molten matrix metal to form a metal matrix composite body. A gating means is provided which controls or limits the areal contact between molten matrix metal and the filler material or preform. The use of a gating means provides for control of the amount of matrix metal which can contact the preform or filler material, which may result in less machining of a formed metal matrix composite body compared with a similar metal matrix composite body made without a gating mean. Moreover, the use of a gating means ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.

Abstract: The present invention relates to forming a metal matrix composite between at least two bodies having a similar or a different chemical composition, the metal matrix composite functioning as a bonding means which bond to or fixes the bodies together. Particularly, a metal matrix composite is produced by a spontaneous infiltration technique by providing a filler material or preform with an infiltration enhancer and/or an infiltration enhancer precursor and/or and infiltrating atmosphere, which are in communication with the filler material or preform at least at some point during the process. Molten matrix metal then spontaneously infiltrates the filler material or preform, whereby the metal matrix composite serves to bond together two or more bodies.