Abstract: An open-cell glass crystalline porous material made from hollow microspheres which are cenospheres obtained from fly ash, having an open-cell porosity of up to 90 vol. % is produced. The cenospheres are separated into fractions based on one or more of grain size, density, magnetic or non-magnetic, and perforated or non-perforated. Selected fractions are molded and agglomerated by sintering with a binder at a temperature below the softening temperature, or without a binder at a temperature about, or above, the softening temperature but below the temperature of liquidity. The porous material produced has an apparent density of 0.3-0.6 g/cm3, a compressive strength in the range of 1.2-3.5 MPa, and two types of openings: through-flow wall pores in the cenospheres of 0.1-30 micrometers, and interglobular voids between the cenospheres of 20-100 micrometers.

Abstract: A method of manufacturing a ceramic body and a gas sensor is disclosed. The method comprises mixing a ceramic material and an organometallic material with a solvent to form a mixture. The organometallic material comprises both a metallic component and an organic ligand. The mixture is disposed onto a surface, dried, and removed to form the ceramic body. The sensor is made by disposing the ceramic body adjacent to an unfired electrolyte body having an electrode disposed on each side thereof to form a green sensor. The green sensor is co-fired to form the sensor.

Abstract: A process for producing inorganic molds involving molding a kneaded mixture containing a particulate inorganic material and water, which process comprises adding water-soluble hemicellulose to the kneaded mixture. The process provides inorganic molds with excellent dispersion stability of the inorganic material particles and improved plasticity, workability including fillability and shape retention, as well as strength.

Abstract: An improved submerged entry nozzle is provided which is useful in the casting of aluminum killed molten steel. The nozzle has an improved slagline sleeve or collar which surrounds the outer portion of the nozzle to protect it from corrosion during the casting process. The slagline sleeve is made from resin bonded zirconia/graphite which has been formulated so that upon curing of the resin to form resite, there is a reduction in the contractile tendency which results in a reduction in stress fracturing. The reduction of the contractile tendency and the resulting resistance to stress fracturing is achieved by adding an effective amount of calcium oxide to the resin-zirconia-graphite mixture which is used to form the sleeve.

Abstract: A method for producing a powder-molded body is provided, including the steps of casting a slurry containing a powder of at least one of a ceramic and a metal, and organic dispersion medium, and a gelling agent into a mold, and solidifying the slurry by gelling the slurry to obtain a molded body. The slurry is solidified by chemically bonding an organic dispersion medium having reactive functional groups and a gelling agent. The method is capable of improving gelling (solidification) efficiency and obtaining a molded body having a high density, a small firing shrinkage, and high shape precision, and which hardly experiences cracks during drying and firing.

Abstract: In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.

Abstract: Exemplary silicon carbide ceramic bodies having inclusions therein are produced according to the invention. An exemplary ceramic body includes silicon carbide in major amounts and unreacted particles of an additive in minor amounts which are bonded to the matrix. The particles are dispersed throughout the silicon carbide, and are preferably selected from one or more of the group consisting of boron nitride, aluminum nitride and titanium diboride.

Abstract: Carbon fiber bundles may be dispersed into substantially single mono-filaments in pitch by stirring a mixture of fibers and pitch at a temperature at which the pitch has a viscosity of about 0.1 to about 5 poise. The resulting fiber pitch binder contains about 0.5 to about 10.0 wt. % carbon fibers substantially dispersed as substantially single mono-filaments which are randomly oriented which may then be used directly as a binder for producing carbon bodies, for example, graphite electrodes, pinstock or specialty graphite articles. This unique binder using an economical amount of carbon fibers has the capacity to increase the strength and reduce the coefficients of thermal expansion of the resulting carbon products in more than one direction due to the random orientation of the carbon fibers.

Abstract: Provided are a method for producing ceramic green sheets used for making a ceramic substrate which is reduced in cracking failure and improved in adhesion between laminated layers and is high in lamination property, high in strength and excellent in surface roughness, said method including heat-treating the ceramic powder having a specific particle size by dry grinding a ceramic powder to prepare ceramic powder having a specific average degree of aggregation and preparing a slurry using the ceramic powder so that a green density of the resulting ceramic green sheets is in a desired range, and a method for making a ceramic laminated substrate having excellent various properties by laminating the above ceramic green sheets and firing the laminate.

Abstract: A powder injection molding process involves providing a melt mixture that includes a powder and a binder. The melt mixture is pressurized in an injection molding machine and a gas is injected into the melt mixture. The melt mixture and gas are injected into at least one mold to form a green part and the binder is removed from the green part.

Abstract: A method of making a product which is generally impervious to water including the steps of making a generally homogenous mixture of slate particles and clay, setting the mixture as necessary to produce a formable composition, forming the wet mixture to a desired configuration, at least partially drying the formed mixture and subjecting the dried formed mixture to a temperature of at least 1145° C. for a time sufficient for at least some of the clay to convert into a binder to bind together the slate particles.

Abstract: The present invention relates to a molding composition based on sinterable materials, comprising a) from 80 to 99.5% by weight of sinterable powder having a maximum particle size of 2000 &mgr;m, b) from 0.5 to 20% by weight of metallocene polyolefin wax, c) if desired, up to 19.5% by weight of a further dry lubricant, and to its use for producing shaped ceramic and powder metallurgical parts by pressing.

Abstract: A microabrasive tool is formed from a slurry including liquid, abrasive grains, a bonding material, and a polymer—for example, gellan gum. The slurry is cast in a mold, and the polymer is ionically cross-linked. Cross-linking the polymer fixes the structure of the bonding material and the abrasive grains, wherein the abrasive grains are dispersed substantially uniformly within the bonding material. The ionically cross-linked structure of bonding material and abrasive grains can then be fired to form a microabrasive tool.

Abstract: A method for producing a silicon nitride filter, which comprises heat-treating in nitrogen a green body comprising from 35 to 90 mass % of silicon nitride particles having an average particle diameter of from 1 to 30 &mgr;m, from 5 to 60 mass % of a pore-forming agent and from 0.

Abstract: The present invention includes a method for producing high-alumina bodies with superior chemical properties at reduced sintering temperatures. One form of the method includes the steps of providing an alumina powder precursor, adding about 2 wt. % magnesia powder precursor and about 2 wt. % titania powder precursor, mixing the resultant green powder precursor, pressing a green body from the green powder precursor, removing residual moisture and organic material from the green body, and firing the green body to about cone 13.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware comprising a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and comprises a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.

Abstract: A method for producing a powder-molded body,includes: casting a slurry containing a powder of a ceramic and/or a metal, a dispersion medium, and a gelling agent; and solidifying the slurry by gelling the slurry to obtain a molded body. The slurry is solidified by chemically bonding an organic dispersion medium having reactive functional groups and a gelling agent. The method is capable of improving gelling (solidification) efficiency and obtaining a molded body with a high density, a small firing shrinkage, and a high shape precision while scarcely causing cracks at the time of drying and firing.

Abstract: Building material wastes containing harmful asbestos and inorganic wastes are subjected to sintering reaction treatment to obtain asbestos-free products which are provided for recycling of waste materials. The asbestos containing building materials inorganic wastes are crushed to be mixed such that the mixture is subjected to a sintering step at a temperature of 600° C. through 1500° C. to allow the same to react thereto, thus obtaining sintered reaction products which is asbestos-free and non-hazardous. The inorganic wastes includes incineration ash from sewerage sludge which has so far used for reclamation purpose only. Sherd, glass wastes or the like can also mixed therewith for sintering reaction to obtain non-hazardous permeable blocks, thus contribution to establishing recycling systems. The method of producing such asbestos-free non-hazardous products are also provided.

Abstract: In insulator including alumina as a main component, a Na component in the insulator is set in the range of 0.07 to 0.5 wt % as Na2O. While the Na component content is as high as to have conventionally been regarded to be beyond the common sense, with this range of the Na component content, insulation resistance, mechanical strength and the like at high temperature are unexpectedly not reduced and an insulator with performances comparable to those of an insulator from conventional low soda alumina lower in Na component content than the above described range can be obtained. As a result, medium soda alumina and regular soda alumina that are much lower in cost than conventionally used low soda alumina can be used instead of the low soda alumina, so that dramatic reduction in production costs of insulator 2 for a spark plug 100 and in addition, of the spark plug 100 using the insulator 2 are realized.

Abstract: A method of making a component of a ceramic discharge chamber comprising the steps of forming a ceramic composition including an aluminum powder, a binder and a grain growth inhibitor. The alumina powder has a tap density greater than 1.0 gram per cc. The ceramic composition is then die pressed to form a component preform. Next, the component preform is heated to remove at least a substantial portion of the binder.

Abstract: Superconductor containing filaments having embedments of superconducting material surrounded by a rayon matrix are formed by preparing a liquid suspension which contains at least 10 weight percent superconducting material; forming a multicomponent filament having a core of the suspension and a viscose sheath which contains cellulose xanthate; and thereafter, regenerating cellulose from the cellulose xanthate to form a rayon matrix.

Abstract: Disclosed is sintered ceramic article that exhibits a primary crystalline phase of cordierite and analytical oxide composition, in weight percent, of 49-53% SiO2, 33-38% Al2O3, 12-16% MgO and exhibits a coefficient of thermal expansion no greater than about 4.0×10−7/° C. over the temperature range of about 25° C. to about 800° C. and a transverse-I ratio of not less than about 0.92. Also disclosed is a method for producing a sintered cordierite ceramic article involving preparing a plasticizable raw material, comprising a magnesium source, a SiO2-forming source and an additional component of either: (a) a clay-free, Al2O3-forming source having a surface area of greater than about 5 m2/g; or, (b) a clay and Al2O3-forming source combination wherein the clay comprises no greater than about 30%, by weight, of the total inorganic mixture, and the Al2O3-forming source exhibits a surface area of greater than about 40 m2/g.

Abstract: A method of firing a green cordierite-ceramic honeycomb structural body containing a carbonaceous material, for example, an organic binder, comprising a two phase process. The first phase comprises firing the green honeycomb structural body in a firing atmosphere to a temperature and for a time sufficient to initiate and sufficiently achieve release of the carbonaceous material while introducing into the firing atmosphere a fluorine-free low-oxygen gas comprising less than about 20% O2, by volume. Once the carbonaceous material is sufficiently released, the second phase involves conventionally firing the green body for a time and a temperature sufficient to initiate and sufficiently achieve the conversion of the green ceramic honeycomb structural body into a fired honeycomb body.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware comprising a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and comprises at least a portion of a branched chain paraffin exhibiting a 90% recovered distillation temperature ranging between 205° C. to about 225° C. and a carbon chain length comprised predominantly of carbon chain distributions ranging from 12 to 14. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: Composition for preparing water-repellent coatings on optical substrates, comprising a porous, electrically conductive molding and an organosilicon compound, obtainable by mixing an electrically conductive or semiconductive support material with a binder and subjecting the mixture to compression molding to form a compression molding, sintering the compression molding at preferably 1100 to 1500° C. in air to form a porous molding, impregnating the molding with the organosilicon compound, and ageing the impregnated molding by storage in air for at least 3 days.

Abstract: A method comprising incorporation of an inorganic polymer precursor of a grain growth inhibitor into nanostructured materials or intermediates useful for the production of nanostructured materials. The precursor/nanostructured material composite is optionally heat treated at a temperature below the grain growth temperature of the nanostructured material in order to more effectively disperse the precursor. The composites are then heat treated at a temperature effective to decompose the precursor and to form nanostructured materials having grain growth inhibitors uniformly distributed at the grain boundaries. Synthesis of the inorganic polymer solution comprises forming an inorganic polymer from a solution of metal salts, filtering the polymer, and drying. Alloying additives as well as grain growth inhibitors may be incorporated into the nanostructured materials.

Abstract: A ceramic composition is provided to insulate ceramic matrix composites under high temperature, high heat flux environments. The composition comprises a plurality of hollow oxide-based spheres of various dimensions, a phosphate binder, and at least one oxide filler powder, whereby the phosphate binder partially fills gaps between the spheres and the filler powders. The spheres are situated in the phosphate binder and the filler powders such that each sphere is in contact with at least one other sphere. The spheres may be any combination of Mullite spheres, Alumina spheres, or stabilized Zirconia spheres. The filler powder may be any combination of Alumina, Mullite, Ceria, or Hafnia. Preferably, the phosphate binder is Aluminum Ortho-Phosphate. A method of manufacturing the ceramic insulating composition and its application to CMC substrates are also provided.

Abstract: There is provided a process for obtaining a cordierite honeycomb structural body with thin cell walls and no molding defects such as cell breakage or the like. Cell breakage is prevented by limiting the maximum particle size of the cordierite starting material powder to no greater than 85% of the slit width of the extrusion molding die so that the starting material particles will not clog inside the slits or the introduction port of the slits. As one cordierite starting material, talc with a mean particle size of 5 &mgr;m or greater is used to give a honeycomb structural body with a void volume of greater than 30%, for production of a honeycomb structural body, with good moldability, having a small thickness and a low heat capacity. It is preferred to add to the starting material at least a lubricant/humectant, a binder and/or a mixture of a water-soluble polyhydric alcohol derivative and a polyhydric alcohol.

Abstract: A method for providing improved compaction, green density, green strength and surface finish properties in simulated stone and mineral-like materials from ceramic green bodies, based on addition of selected polymer additives during ceramic processing, is disclosed. Polymer additives having weight-average molecular weights from 30,000 to 1,000,000, glass transition temperatures from −50 to +90° C., and low hygroscopicity are particularly useful in providing enhanced properties of ceramic products involving processing of large-size granule intermediates.

Abstract: The invention concerns binders for ceramic materials, in particular water soluble sugars and sugar alcohols.

Abstract: A process for the production of faujasite X agglomerates containing at least 95% of faujasite LSX, that is to say with an Si/Al ratio equal to 1, constituting the active adsorbent. The agglomerate is formed from zeolite LSX and from a binder which can be converted to zeolite, the conversion of which to active zeolite is obtained by conversion to zeolite in a sodium hydroxide/potassium hydroxide or sodium hydroxide liquor.

Abstract: The present invention relates to a molding composition based on sinterable materials, comprising

Abstract: The invention concerns a composite body consisting of a hard metal, cermet or ceramic substrate body and at least one layer of a mechanically resistant material, a ceramic substance, a diamond-like layer, amorphous carbon and/or hexagonal boron nitride. The invention also concerns a method of producing this composite body, wherein, when the green compact has been dewaxed, with its pores still open and whilst it continues to be heated as from a temperature of between 600° C. and 1100° C., it is acted upon by sublimable solids and/or reaction gases which are necessary for coating purposes. The temperature of the green compact is then further increased and the latter is fully compressed by sintering, before one or more layers of the above-mentioned type is/are applied.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware including a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and includes a low molecular weight oil having a 90% recovered distillation temperature range of between about 220 to 400° C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: A gelcasting composition has improved drying behavior, machinability and shelf life in the dried and unfired state. The composition includes an inorganic powder, solvent, monomer system soluble in the solvent, an initiator system for polymerizing the monomer system, and a plasticizer soluble in the solvent. Dispersants and other processing aides to control slurry properties can be added. The plasticizer imparts an ability to dry thick section parts, to store samples in the dried state without cracking under conditions of varying relative humidity, and to machine dry gelcast parts without cracking or chipping. A method of making gelcast parts is also disclosed.

Abstract: A method and composition for combining ceramic powder and binder to form green elements suitable for shaping and firing uses dry blending techniques. The binder includes a particulate wax component that is not melted in order to combine it with the ceramic powder, but rather, the wax component is combined in particulate form with the ceramic powder. The particulate wax is mixed in conventional blender apparatus in a relatively short time period. The binder composition may also include a lubricity enhancer or slip agent and a dispersion or colloidal binder.

Abstract: A fired body and method for producing the body that involves compounding the components of powder materials, binder, aqueous solvent for the binder, and non-solvent with respect to at least the solvent, binder, and powder materials. The non-solvent is made up of a high molecular weight organic portion having a molecular weight of greater than 200, and a low molecular weight organic portion having a molecular weight of up to 200. The components are mixed and plasticized to form a plasticized mixture which is then shaped to form a green body. The green body is then dried and fired.

Abstract: A method for forming an article involves forming a mixture of components of powder materials, organic binder, solvent for the binder, non-solvent with respect to at least the binder, the solvent, and the powder materials, wherein the non-solvent is lower in viscosity than the binder combined with the solvent, and an agent for retarding the oxidation of the organic components. The components are mixed and plasticized, and shaped into a green structure which is then fired to impart strength and form the product article. The product article has fewer cracks than it would have absent the oxidation-retarding agent.

Abstract: A method of making a whisker-reinforced ceramic body by hot pressing a preform to a disc, cutting the disc into blanks and grinding the blanks to bodies of desired shape and dimension is disclosed. The preform is prepared by dispersing 10-60% by volume of a ceramic powder mixture containing conventional sintering aids and/or grain growth inhibitors in water or an organic solvent adding 1-15 wt-% starch to the dispersion; pouring the dispersion into a mold with desired shape; heating the suspension to 50°-100° C. for 2-4 hours while covering the mold to avoid water evaporation to form a preform; removing the preform from the mold; and presintering the preform in air for 10 h at a maximum temperature of about 600° C.

Abstract: The present invention provides a silicon nitride sintered body having characteristics such as excellent wear resistance, a method for manufacturing the sintered body, and a cutting insert formed thereof. The silicon nitride sintered body is formed of a polycrystalline sintered body of predominantly .beta.-Si.sub.3 N.sub.4, wherein the oxygen content is 1.2-1.5 wt. %. The method for manufacturing the silicon nitride sintered body includes the following steps: adding an organic binder to a composition containing silicon nitride as an essential component and exhibiting a theoretical oxygen content of 2.0-3.0 wt. %; heating to remove the binder; introducing an oxygen-containing gas so as to control the carbon content to 0.10-0.60 wt. %; and sintering a resultant compact in an nitrogen atmosphere to control the oxygen content to 1.2-1.5 wt. %. The cutting insert of the present invention has excellent wear resistance.

Abstract: A process for increasing the particles size of fines of a titaniferous mineral containing more that 45% by weight of titanium. The process comprises mixing the fines with a binding agent and water to produce an agglomerate. The agglomerate is then dried and sintered.

Abstract: A binder system for use in the formation of ceramic or other powder-formed greenware which includes a binder, a solvent for the binder, a surfactant, and a component that is non-solvent with respect to the binder and solvent. The non-solvent component exhibits a lower viscosity than the solvent when containing the binder and includes at least a portion of an organic liquid having a 90% recovered distillation temperature of no greater than about 225.degree. C. and more preferably less than 220.degree. C. Also disclosed is a process of forming and shaping plasticized powder mixtures and a process for forming ceramic articles utilizing the binder system.

Abstract: Novel C/N-- and B/C/N polymers which can be obtained by reaction of (a) a carbodiimide having the formula R.sub.3 E--NCN--ER.sub.3, in which R includes a group selected from the group consisting of alkyl groups and aryl groups, and E comprises a component selected from the group consisting of Si, Ge, and Sn, and (b) a halogenotriazine. Methods for making and using said polymers.

Abstract: A method for forming and shaping powder mixtures involves compounding, homogenizing, and plasticizing components to form a mixture. The components are powder materials, binder, solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder materials. The non-solvent is lower in viscosity than the binder combined with the solvent. The components are chosen to result in improved wet green strength in the subsequently formed green body. The compounding is done by the steps of dry-mixing the powder material, surfactant and binder to form a uniform blend, adding the solvent to the resulting dry blend, and thereafter adding the non-solvent to the blend. The mixture is shaped by passing it through a low to moderate shear extruder, and then through a die to form a green body. The compounding and shaping steps are carried out at a temperature of no greater than ambient temperature. The method is especially suitable for RAM extrusion.

Abstract: The present invention relates to a method for ore pelletization including the step of adding binder polymer to particulate ore and moisture to form an intimate mixture. Green pellets are formed from the mixture and fired. A water soluble treatment polymer having a molecular weight of 1,000 to 20,000 is included in the intimate mixture in an amount of at least 0.001% by weight. The water soluble treatment polymer is formed by polymerization of water soluble ethylenically unsaturated monomer blend containing at least 50% by weight of anionic monomer.

Abstract: A method for preparing high strength and high thermal shock-resistant china for ceramic whiteware which comprises the steps of molding a china-forming raw material which mainly comprises a natural ore material capable of forming corundum through firing or a material obtained by calcining the natural ore material to form corundum, a natural ore material capable of forming mullite through firing or a material obtained by calcining the natural ore material to form mullite, a clayey material and a flux such as feldspar, nepheline or dolomite; and then firing the molded china-forming raw material. The method permits the production of cheaper china for ceramic whiteware having high strength and excellent thermal shock resistance as compared with those prepared by the conventional techniques.

Abstract: A method of firing a green cordierite-ceramic honeycomb structural body containing a carbonaceous material, for example, an organic binder, comprising a two phase process. The first phase comprises firing the green honeycomb structural body in a firing atmosphere to a temperature and for a time sufficient to initiate and sufficiently achieve release of the carbonaceous material while introducing into the firing atmosphere a fluorine-free low-oxygen gas comprising less than about 20% O.sub.2, by volume. Once the carbonaceous material is sufficiently released, the second phase involves conventionally firing the green body for a time and a temperature sufficient to initiate and sufficiently achieve the conversion of the green ceramic honeycomb structural body into a fired honeycomb body.

Abstract: Provided are a conductive resin composition having little negative impact on the environment, a resin molding which includes conductive parts of the conductive resin composition and insulating parts, and their methods of production. The production costs for the resin molding are low. The conductive resin composition is formed by kneading a thermoplastic or thermosetting resin with a low melting point alloy, wherein the low melting point alloy is moldable with the resin and consists essentially of tin and is free of lead. An insulating body is formed through primary molding of a thermoplastic or thermosetting resin, and is integrated with conductive parts of the conductive resin composition through secondary molding; or alternatively, conductive parts are formed through primary molding of the conductive resin composition and an insulating body is formed while being integrated with the conductive parts through secondary molding.

Abstract: A polycrystalline alumina ceramic material which is resistant to a fluorine-comprising plasma is produced by forming a green body including alumina and a binder, and sintering the green body at a temperature ranging from about 1400.degree. C. to about 1700.degree. C. for a time from about 8 to about 12 hours. The area % of unsintered particles in the polycrystalline alumina ceramic material does not exceed 0.1 area %, resulting in reduced emission of particles from the material after exposure to plasma fluorine.