Patents by Inventor Marc S. Newkirk

Marc S. Newkirk has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 5015609
    Abstract: A method is provided of producing a self-supporting ceramic composite structure having one or more encasement members, such as an encasing steel sleeve, joined to it by growth of the ceramic material to engagement surface(s) of the encasement member(s). A parent metal is contacted with a body of filler which is encased by the encasement member(s). The resulting assembly is heated to melt and oxidize the parent metal, e.g., aluminum, to form a polycrystalline material comprising an oxidation reaction product which grows through the body of filler and stops at the engagement surface(s) of the encasement member(s) which thereby determines the surface geometry of the grown ceramic matrix. Upon cooling, the encasement member(s) is shrink-fitted about the ceramic composite body. The invention also provides the resultant articles, for example, a ceramic composite body having a stainless steel member affixed thereto.
    Type: Grant
    Filed: March 30, 1989
    Date of Patent: May 14, 1991
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, H. Daniel Lesher
  • Patent number: 5010044
    Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron donor material and a carbon donor material. The reactive infiltration typically results in a composite comprising a boron-containing compound, a carbon-containing compound and residual metal, if desired. The mass to be infiltrated may contain one or more inert fillers admixed with the boron donor material and carbon donor material. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal, ratios of one ceramic to another and porosity.
    Type: Grant
    Filed: December 5, 1989
    Date of Patent: April 23, 1991
    Assignee: Lanxide Technology Company, LP.
    Inventor: Marc S. Newkirk
  • Patent number: 5007476
    Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel metal matrix composite bodies produced thereby. Particularly, a polycrystalline oxidation reaction product of a parent metal and an oxidant is first formed. The polycrystalline oxidation reaction product is thereafter comminuted into an appropriately sized filler material which can be placed into a suitable container or formed into a preform. The filler material or preform of comminuted polycrystalline oxidation reaction product is thereafter placed into contact with a matrix metal alloy in the presence of an infiltration enhancer, and/or an infiltration enhancer precursor and/or an infiltrating atmosphere, at least at some point during the process, whereupon the matrix metal alloy spontaneously infiltrates the filler material or preform. As a result of utilizing comminuted or crushed polycrystalline oxidation reaction product, enhanced infiltration (e.g., enhanced rate or amount) is achieved.
    Type: Grant
    Filed: November 10, 1988
    Date of Patent: April 16, 1991
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Michael K. Aghajanian
  • Patent number: 5004035
    Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique and thereafter thermo-forming the produced metal matrix composite body. 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. After formation of the metal matrix composite body, the body is subjected to a thermo-forming technique such as rolling, extruding, die casting, pressing, etc.
    Type: Grant
    Filed: November 10, 1988
    Date of Patent: April 2, 1991
    Assignee: Lanxide Technology Company, LP
    Inventors: John T. Burke, Marc S. Newkirk
  • Patent number: 5000248
    Abstract: The present invention relates to modifying the properties of a metal matrix composite body by a post formation process treatment and/or a substantially contiguous modification treatment. The post formation process treatment may be applicable to a variety of metal matrix composite bodies produced by various techniques, and is particularly applicable to modifying the properties of a metal matrix composite body produced by a spontaneous infiltration technique. The substantially contiguous modification process may also be used primarily in conjunction with metal matrix composite bodies produced according to a spontaneous infiltration technique. Particularly, at least a portion of the matrix metal of the metal matrix composite body and/or the filler material of the metal matrix composite body is modified or altered during and/or after the formation process.
    Type: Grant
    Filed: November 10, 1988
    Date of Patent: March 19, 1991
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Andrew W. Urquhart, Michael K. Aghajanian, Mark G. Mortenson
  • Patent number: 4996176
    Abstract: A method for producing a self-supporting ceramic composite structure which includes a ceramic matrix embedding a filler, includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal with an oxidant and, optionally, one or more metallic constituents, and the filler embedded by the matrix. The method includes heating a first source of molten parent metal and a source of molten parent metal and contacting the first source of molten parent metal with a permeable bedding of filler. The first source of molten parent metal is reacted with the oxidant to form the oxidation reaction product and is replenished from the reservoir as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired extent and thereby embed at least a portion of the bedding of filler within the oxidation reaction product to form the ceramic composite structure.
    Type: Grant
    Filed: September 28, 1989
    Date of Patent: February 26, 1991
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, H. Daniel Lesher, Ratnesh K. Dwivedi, Robert C. Kantner
  • Patent number: 4956338
    Abstract: A complex oxidation reaction product of two or more metals in an oxidized state is formed by positioning a suitable precursor metal adjacent to a permeable mass of a metal-containing compound in an oxidizing atmosphere and heating the assembly to form a body of molten precursor metal. The molten metal infiltrates the permeable mass and reacts therewith and with the oxidizing atmosphere to form a complex oxidation reaction product. Methods for determining the shape of the resulting article are described. The disclosed methods can be used to form superconducting perovskites.
    Type: Grant
    Filed: July 6, 1988
    Date of Patent: September 11, 1990
    Assignee: Lanxide Technology Company, LP
    Inventors: Robert A. Rapp, Andrew W. Urquhart, Alan S. Nagelberg, Marc S. Newkirk
  • Patent number: 4948764
    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 poriton 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.
    Type: Grant
    Filed: September 16, 1986
    Date of Patent: August 14, 1990
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Adam J. Gesing
  • Patent number: 4923832
    Abstract: In the present invention, there is provided a method for producing a self-supporting ceramic or ceramic composite body by the oxidation of a parent metal to form a polycrystalline ceramic material comprising the oxidation reaction product of said parent metal with an oxidant, including a vapor-phase oxidant, and optionally one or more metallic constituents dispersed throughout the polycrystalline ceramic material. The method comprises the steps of providing at least a portion of said parent metal with a barrier means at least partially spaced from said parent metal for establishing at least one surface of the ceramic body, and heating said parent metal to a temperature above its melting point but below the melting point of the oxidation reaction product to form a body of molten metal. At that temperature, the molten metal is reacted with the oxidant, thus forming the oxidation reaction product.
    Type: Grant
    Filed: May 8, 1986
    Date of Patent: May 8, 1990
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Robert C. Kantner
  • Patent number: 4918034
    Abstract: A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix embedding a filler, includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal and, optionally, one or more metallic constituents. The method includes heating the parent metal to provide a source of molten parent metal and a reservoir of molten metal which is in communication with the parent metal having a chemical composition which is different from the parent metal and contacting the molten parent metal with a permeable bedding of filler. The molten parent metal reacts with the oxidant to form the oxidation reaction product and is replenished by the reservoir as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired extent and thereby embed at least a portion of the bedding of filler within the oxidation reaction product to form the ceramic composite structure.
    Type: Grant
    Filed: March 15, 1988
    Date of Patent: April 17, 1990
    Assignee: Lanxide Technology Company, LP
    Inventors: Jerry G. Weinstein, Robert C. Kantner, Marc S. Newkirk
  • Patent number: 4916113
    Abstract: A method of making self-supporting ceramic composite structures having filler embedded therein includes infiltrating a permeable mass of filler with polycrystalline material comprising an oxidation reaction product obtained by oxidation of a parent metal such as aluminum and optionally containing therein non-oxidized constituents of the parent metal. The structure is formed by placing a parent metal adjacent to a permeable filler and heating the assembly to melt the parent metal and provide a molten body of parent metal which is contacted with a suitable vapor-phase oxidant. Within a certain temperature region and optionally aided by one or more dopants in or on the parent metal, molten parent metal will migrate through previously formed oxidation reaction product into contact with the oxidant, causing the oxidation reaction product to grow so as to embed the adjacent filler and provide the composite structure.
    Type: Grant
    Filed: November 1, 1988
    Date of Patent: April 10, 1990
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Andrew W. Urquhart, Harry R. Zwicker, H. Daniel Lesher
  • Patent number: 4900699
    Abstract: A method for producing a self-supporting ceramic composite structure, which includes a ceramic matrix embedding a filler, includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal with an oxidant and, optionally, one or more metallic constituents, and the filler embedded by the matrix. The method includes heating a first source of molten parent metal and a reservoir source of molten parent metal and contacting the first source of molten parent metal with a permeable bedding of filler. The first source of molten parent metal is reacted with the oxidant to form the oxidation reaction product and is replenished from the reservoir as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired extent and thereby embed at least a portion of the bedding of filler within the oxidation reaction product to form the ceramic composite structure.
    Type: Grant
    Filed: September 16, 1986
    Date of Patent: February 13, 1990
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, H. Daniel Lesher, Ratnesh K. Dwivedi, Robert C. Kantner
  • Patent number: 4892786
    Abstract: A method of producing self-supporting ceramic or ceramic composite bodies having a polymer component, which includes first providing a self-supporting ceramic or ceramic composite body comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal with an oxidant, and (ii) interconnected porosity at least partially accessible from one or more surfaces of said ceramic body. The polymer is disposed or formed within the interconnected porosity. The polymer is situated so as to alter, modify or contribute to the properties of the ceramic or ceramic composite body originally formed.
    Type: Grant
    Filed: June 26, 1987
    Date of Patent: January 9, 1990
    Assignee: Lanxide Technology Company, LP
    Inventor: Marc S. Newkirk
  • Patent number: 4884737
    Abstract: Two or more ceramic bodies are bonded together by oxidizing with a vapor-phase oxidant molten metal obtained from a body of precursor metal to form an oxidation reaction product bond. The oxidation reaction product is formed between adjacent facing, substantially congruent surfaces of the ceramic bodies and bridges the surfaces, thus bonding the ceramic bodies to each other. Promoters may optionally be used to facilitate formation of the oxidation reaction product.
    Type: Grant
    Filed: May 21, 1987
    Date of Patent: December 5, 1989
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Robert C. Kantner, Eugene S. Park
  • Patent number: 4885131
    Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron donor material and a carbon material. The reactive infiltration typically results in a composite comprising a boron-containing compound, a carbon-containing compound and residual metal, if desired. The mass to be infiltrated may contain one or more inert fillers admixed with the boron donor material and carbon donor material. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal, ratios of one ceramic to another and porosity.
    Type: Grant
    Filed: January 13, 1989
    Date of Patent: December 5, 1989
    Assignee: Lanxide Technology Company, LP
    Inventor: Marc S. Newkirk
  • Patent number: 4882306
    Abstract: A method is provided for producing a self-supporting ceramic or ceramic composite body by oxidation of a parent metal, the self-supporting body having a graded microstructure characterized by a plurality of zones differing from each other in one or more properties. The zones in the body are attained by altering the process conditions during formation of the body such that a zone of the oxidation reaction product formed posterior to said altering has at least one property different from a zone of the oxidation reaction product formed anterior to said altering.
    Type: Grant
    Filed: September 16, 1988
    Date of Patent: November 21, 1989
    Assignee: Lanxide Technology Company, LP
    Inventors: Christopher R. Kennedy, Andrew W. Urquhart, Danny R. White, Marc S. Newkirk
  • Patent number: 4871696
    Abstract: A method for producing materials having a high purity, which comprises forming an oxidation reaction product of a parent metal and an oxygen-containing vapor-phase oxidant, comminuting the resulting ceramic body and leaching any non-oxidation reaction product and/or corresponding filler materials therefrom, and recovering said substantially pure materials.
    Type: Grant
    Filed: March 15, 1988
    Date of Patent: October 3, 1989
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Mark G. Mortenson
  • Patent number: 4868143
    Abstract: A method of producing self-supporting ceramic bodies having a modified metal-containing component includes first providing a self-supporting ceramic body comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a molten parent metal precursor with an oxidant, and (ii) an interconnected metal-containing component at least partially accessible from one or more surfaces of said ceramic body. The surface or surfaces of the ceramic body is contacted with a quantity of foreign metal different from said interconnected metal-containing component at a temperature and for a time sufficient to allow for interdiffusion, whereby at least a portion of said metal-containing component is displaced by said foreign metal. The resulting ceramic body, having an altered metal-containing component, exhibits modified or improved properties.
    Type: Grant
    Filed: August 13, 1986
    Date of Patent: September 19, 1989
    Assignee: Lanxide Technology Company, LP
    Inventors: Marc S. Newkirk, Andrew W. Urquhart, Harry R. Zwicker
  • Patent number: 4867758
    Abstract: In the present invention there is provided a method for producing abrasive ceramic and ceramic composite material characterized by an abrasive grain as the comminuted form of a polycrystalline ceramic material. The abrasive grains of the present invention consist essentially of the oxidation reaction product of a parent metal precursor with a vapor phase oxidant, and, optionally one or more metallic constituents such as non-oxidized constituents of the parent metal. There is also provided a method for producing abrasive grains which additionally consist of one or more inert filler materials.
    Type: Grant
    Filed: August 7, 1986
    Date of Patent: September 19, 1989
    Assignee: Lanxide Technology Company, LP
    Inventor: Marc S. Newkirk
  • Patent number: 4859640
    Abstract: A method for producing a self-supporting ceramic composite body having a negative pattern which inversely replicates the positive pattern of a parent metal precursor having thereon a positive pattern section which is emplaced in conforming engagement with a bed of conformable filler. The parent metal precursor, which also has a non-replicating section, is melted and reacted with an oxidant to form a polycrystalline oxidation reaction product which grows primarily only from the positive pattern section of the parent metal precursor and through the filler. The molten parent metal is drawn through the growing polycrystalline material and oxidized at the interface between the oxidant and previously formed oxidation reaction product. The reaction is continued for sufficient time to at least partially embed the filler within the oxidation reaction product and form the ceramic composite body containing a negative pattern which inversely replicates the positive pattern of the parent metal precursor.
    Type: Grant
    Filed: August 13, 1986
    Date of Patent: August 22, 1989
    Assignee: Lanxide Technology Company, LP
    Inventor: Marc S. Newkirk