Abstract: A structure with encapsulated catalyst-agglomerate bodies which are integral to a porous structure is presented. The catalysts may be singly and/or multiply dispersed on and/or throughout a high surface area material and subsequently mixed with batch material prior to firing the structure. This results in a structure wherein encapsulated catalyst-agglomerate bodies in a porous structure exhibit the same catalytic activity as in a break in aged catalyst coated substrate.

Abstract: This invention is directed to the production of oxide-boride-silicon nitride ceramics consisting essentially of ceramic bodies of oxide and boride phases which have silicon nitride added to improve the properties of the ceramic body for use as wear material, durable interface material, and cutting tool inserts. The addition of Si.sub.3 N.sub.4 to the oxide-boride body provides a durable ceramic material which provides a range of cutting speeds that may be utilized in both turning and milling operations.

Abstract: Cermet body formed by reaction sintering at pressures ranging from subatmospheric to superatmospheric of admixed and shaped particulate exothermic reactants, which have maximum particle size substantially not greater than 150 .mu.m and can be elements, compounds, intermetallic compounds and/or alloys, in stoichiometric proportions to substantially form 40-95 mole percent of first phase or phases being boride, nitride, silicide, sulfide or combination thereof of one or more of the elements of Groups 2a, 3a exclusive of B, 4a, 2b, 3b including lanthanide and actinide series elements, 4b, 5b, 6b, 7b and 8, and 5-60 mole percent of second phase or phases being metal, alloy, intermetallic compound or combination thereof of one or more of the elements of Groups 3a exclusive of B, 4a, 2b, 4b, 5b, 6b, 7b, iron, cobalt and nickel, wherein the maximum grain size of the first phase or phases is substantially not greater than 10 .mu.m and which body contains 0 to 4 weight percent oxygen.

Abstract: A monolithic refractory honeycomb filter of zircon or zircon plus an oxide additive is useful to remove impurities from molten metal, particularly from molten steel. The filter has a frontal contact surface containing the openings of a plurality of through-and-through cells for passage of the molten metal. Impurities adhere to the frontal contact surface of the filter and to the cell walls themselves.

Abstract: A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.

Abstract: Ceramic body formed by reaction sintering at pressures ranging from subatmospheric to superatmospheric of admixed and shaped reactants, which can be elements, compounds, intermetallic compounds and/or alloys, in stoichiometric proportions to substantially form 10-90 mole percent of boride phase or phases of one or more of elements of Groups 3b including lanthanide and actinide series elements, 4b, 5b and 6b, and 10-90 mole percent of oxide phase or phases of one or more of elements of Groups 3a, 4a, 3b, 4b, 5b, 6b and 8, and which phases have a maximum grain size substantially not greater than 15 .mu.m. Body in a form for wear resistance and corrosion-erosion resistance has a virtual absence of open porosity, e.g. not greater than 5% or less than about 3%, and a Rockwell A hardness of greater than 90.

Abstract: Ceramic body formed by reaction sintering at pressures ranging from subatmospheric to superatmospheric of admixed and shaped reactants, which can be elements, compounds, intermetallic compounds and/or alloys, in stoichiometric proportions to substantially form 5-95 mole percent of nitride phase or phases of one or both of Al and Si, and 5-95 mole percent of second phase or phases being boride, carbide, silicide and/or sulfide of one or more of elements of Groups 3b including lanthanide and actinide series elements, 4b, 5b and 6b, which phases have a maximum grain size substantially not greater than 10 .mu.m and which body contains 0 to 4 weight percent oxygen.

Abstract: Component of electrowinning or electrorefining cell, which component in use is normally covered with molten aluminum or in electrical contact with another component which is in contact with molten aluminum. Surface and/or inner portion of component is made of ceramic body formed by reaction sintering at pressures ranging from subatmospheric to superatmospheric of reactants, which can be elements, compounds, intermetallic compounds and/or alloys, in stoichiometric proportions to substantially form 10-90 mole percent of first phase or phases being boride phase or phases of one or more of the elements of Groups 4b, 5b and 6b, and 10-90 mole percent of oxide phase or phases being predominantly Al.sub.2 O.sub.3 ; and which phases have a maximum grain size substantially not greater than 15 .mu.m. Also production cell, and method of producing aluminum in such cell, with the reaction sintered ceramic component.

Abstract: Component of electrowinning or electrorefining cell, which component in use is normally in contact with molten aluminum or in electrical contact with another component which is in contact with molten aluminum. Surface and/or inner portion of component is made of ceramic body formed by reaction sintering at pressures ranging from subatmospheric to superatmospheric of reactants, which can be elements, compounds, intermetallic compounds and/or alloys, in stoichiometric proportions to substantially from 5-95 mole percent of first phase or phases being boride, carbide, silicide, and/or sulfide of one or more of the elements of Groups 4b, 5b and 6b, which phases have a maximum grain size substantially not greater than 10 .mu.m. and which body contains 0 to 4 weight percent oxygen. Also production cell, and method of producing aluminum in such cell, with the reaction sintered ceramic component.

Abstract: Component of electrowinning or electrorefining cell, which component in use is normally in contact with molten aluminum or in electrical contact with another component which is in contact with molten aluminum. Surface and/or inner portion of component is made of cermet body formed by reaction sintering at pressures ranging from subatmospheric to superatmospheric of reactants, which can be elements, compounds, intermetallic compounds and/or alloys, in stoichiometric proportions to substantially form 30-95 mole percent of first phase or phases being boride, carbide, nitride, silicide, sulfide or combination thereof of one or more of the elements of Groups 4b, 5b and 6b, and 5-70 mole percent of second phase or phases being aluminum, alloy or intermetallic compound thereof, or combination thereof; and the maximum grain size of the first phase or phases is substantially not greater than 10 .mu.m. Also production cell, and method of producing aluminum in such cell, with the reaction sintered cermet component.

Abstract: In an electrolytic reduction cell for the production of molten metal, particularly aluminium, by electrolysis of a less dense salt monolayer of ceramic shapes is located on the floor of the cell. Such shapes are formed of a ceramic material, wettable by molten aluminium, but not wettable by the cell electrolyte. The spacing between adjacent shapes and/or the apertures in individual shapes is selected such that interfaced surface forces prevent entry of electrolyte between the shapes. The shapes may be tiles, honeycombs, cylinders, tubes, balls etc. The product metal may be collected in a sump for periodic withdrawal from the cell or withdrawn continuously or at short intervals through a selective filter that permits passage of molten metal, but not of molten cell electrolyte, at low withdrawal rates.

Abstract: A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.