Abstract: Powder mixtures and a method of forming and shaping the mixtures. The method involves compounding the components of 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 solvent is present in an amount that is less than the amount that would be present otherwise. The components are mixed and plasticized, and shaped to form a green body. The choice of components results in improved wet green strength in the green body. The method is especially useful for extrusion processing of aqueous binder systems such as water and cellulose ethers and hydrophobic non-solvents, to form structures such as honeycombs. In the body, the ratio, upon subsequent firing, of the isostatic strength to the A-axis strength is at least about 20% higher than in bodies made without the mixture composition of the invention.

Abstract: A method for making ink jet print head base elements which includes the steps of making a sacrificial mold of the ink jet print head, binder coagulation casting a ferroelectric, piezoelectric ceramic slurry into the sacrificial mold to form a green ceramic base element, and sintering the green ceramic base element while in the sacrificial mold to thereby burn off the sacrificial mold and yield a sintered, net shape, molded ink jet print head. complex shapes to thereby reduce the numbers of complex manufacturing steps. A three dimensional jet printing process can be used to form the sacrificial molds. Once the sacrificial mold has been made, a ferroelectric material (and preferably a piezoelectric material) is prepared using a binder coagulation process. The slurry of the ferroelectric material, preferably lead zirconium titinate (PbZrTiO.sub.3 hereinafter referred to as PZT) is poured into the mold. Once the ferroelectric material is poured into the mold, a chemical initiator is added.

Abstract: A method for forming molded articles in any shape from ceramic, glass, or metal powders which comprises: preparing a slurry by dispersing more than one powder selected from a group consisting of ceramic, glass, and metal materials in a dispersing medium using a dispersing agent, and curing by adding a reactive substance that reacts with the dispersing agent to make the dispersibility of the dispersing agent disappear or lower.

Abstract: A method of fabricating a cordierite ceramic honeycomb structural body which includes the following steps: formulating a batch of raw materials comprising a mixture of kaolin clay, talc, alumina and other cordierite-forming materials, each included in the batch in an effective amount such that the batch is capable of yielding a fired honeycomb body whose predominant crystal phase is cordierite; intimately blending the raw materials with an effective amount of vehicle and forming aids to impart plastic formability and green strength to the raw materials and to form a plastic mixture; forming the raw materials into a green honeycomb structural body by extrusion and thereafter drying and firing the green honeycomb structural body. The firing of the green honeycomb structural body is accomplished through a four-phase heating process as follows (1) heating the green body to a first temperature ranging between about 750-850.degree. C.; (2) heating to a second temperature ranging between about 1250 to 1350.degree.

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: An implant component adapted for bone attachment or replacement is molded from a feed stock which contains a soluble major binder, a backbone binder and structural powder material. After the feed stock is injection molded to form a compact or preform, the major binder is removed from the green article, leaving a structure of interconnected porosity or texture, while the backbone binder remains until the component is sintered. Preferably, the amount of the soluble binder is set to increase the porosity, or reduce the stiffness, of the finished component, thus introducing a biocompatible or growth-enhancing level of porosity or stiffness during the molding process. In further or alternative embodiments, the component may be injection molded onto or about a solvent-leachable spacer preform and/or adjacent to another injected or molded portion of the component which serves as a structural body, frame or shell.

Abstract: A powder injection molding composition or feedstock is made of 70% or more by weight of a powdered metal or ceramic and 30% or less by weight of a binder system. The binder system contains a sufficient amount of polypropylene or polyethylene to hold the so-called brown preform of the molded metal or ceramic powder together for the sintering step of the injection molding process and a sufficient amount of partially hydrolyzed cold water soluble polyvinyl alcohol water and plasticizer to facilitate molding of the composition into the so- called green preform of the article to be manufactured. The debinding step of the injection molding process for transforming the green preform into the brown preform consists simply of immersing the green preform in water at ambient temperature to dissolve the polyvinyl alcohol. The binder system is nonhazardous, safe, harmless and fully degradable.

Abstract: A sintered metal mould formed by plastically forming a material consisting of a metal powder or ceramic powder being mixed with a binder consisting of agar powder, and sintering the material.

Abstract: A ceramic layer system including at least two layers having respective ion conductivities which are substantially different includes a substrate layer composed of a ceramic material and having substantially no ion conductivity; and at least one conducting layer positioned adjacent to the substrate layer, containing coated ceramic particles composed of ceramic particles composed of a ceramic material having no substantial ion conductivity which are coated with a material having a substantial ion conductivity so that each conducting layer of the at least one conducting layer has a continuous phase after sintering composed of the material which has a substantial ion conductivity and so that the at least one conducting layer has an ion conductivity effective to conduct ions.

Abstract: A method of manufacturing a ceramic multilayer component, comprising electrically conductive and electrically insulating layers which are stacked in alternate arrangement in a multilayer structure, which method comprises the following steps:providing three extrudable polymeric mixtures, each mixture comprising a binder and a particulate filler, whereby:(a) a first mixture comprises a ceramic filler;(b) a second mixture comprises a metallic filler and a first binder;(c) the third mixture comprises a metallic filler and a second binder;with the aid of an extrusion device having an extrusion channel which is provided with a layer-multiplication element, manufacturing an extruded multilayer stack comprising a plurality of the basic units abac, in which layers a,b,c correspond respectively to the first, second and third mixtures, the stack having two oppositely situated side walls along which part of each layer is exposed;with the aid of a first solvent, dissolving away part of each layer b exposed along a first s

Abstract: A process for production of a moulded ceramic and/or metallic body from a ductile material comprising one or more ceramic and/or metallic components, which material is fed into the pre-heated mould cavity (1) of a moulding tool. The moulded tool includes at least two mould parts (4, 5) of which at least one wholly or partly consists of a microporous material with communicating micropores. At least one mould cavity (1) comprising at least one mould surface (2, 3) exhibiting closed micropores is arranged in the microporous mould part (4, 5) or in a microporous section (6) thereof. The microporous mould part (4, 5) or the microporous section (6) thereof is pre-heated by supply of warm fluid, such as a heated gas. Said part (4, 5) or section (6) is after terminated moulding cooled by supply of cold fluid, such as a condensed gas. the invention includes in a further aspect a moulded body produced according to the process.

Abstract: A method of injection molding ceramic or metal parts having an internal cavity or other complicated shape. A fugitive core is formed of a particulate and a first binder. The core is then suspended in a conventional injection molding cavity. The part is then injection molded by injecting a ceramic or metal powder mixed with a second binder while in a plastic state into the mold cavity and around the suspended core. Once the second different binder hardens or gels, the molded part together with the core are removed from the mold cavity. The molded part and core are then subject to a debinding process to debind the first binder to thereby remove the core. Because two different binders were used for the core and molding, the binder used to form the molded part remains unaffected when removing the core.

Abstract: The invention relates to the field of ceramic and hard metal industries and concerns a process for manufacturing hard metal parts, in particular th having a complex geometry, such as those used for example as machining tools and wear elements. The object of the invention is to create a process which allows the manufacture of hard metal parts with a complex geometry by using a stable dispersed hard metal-binder suspension, wherein the binder is a thermoplastic binder having a viscosity of 3 to 6 mPa s, and without using an organic solvent to eliminate the binder. For that purpose, a process is disclosed wherein a hard metal powder having an average grain size smaller than 2.0 .mu.m is mixed with a liquefied thermoplastic binder, with viscosity of the mixture being set upon a value of at least 100 mPa s and up to 4,000 mPa s during the whole production and treatment process.

Abstract: Disclosed is a molding method for powder particles, which is excellent in molding performance, and which makes it possible to obtain a preliminary molded product excellent in strength by enhancing mutual bonding between particles in the preliminary molded product. A molding apparatus for powder particles includes an outer frame die having a mold space with a lower punch and an upper punch to be slidably fitted thereto. Slight clearances exist between the outer frame die and the lower and upper punches. A mixture is prepared by mixing a powdery raw material with a liquid additive to cause an exothermic reaction therewith.

Abstract: The present invention is a method of producing a ceramic article. The method includes forming an intercalated or exfoliated solution of smectite clay and a polymer selected from polyvinyl alcohols, polyethylene oxides, polystyrene sulfonates, polyacrylamides, polymers of styrene, alkyl acrylates, alkyl methacrylates, olefins, acrylonitriles, polyurethanes and polyester ionomers. The solution is mixed with zirconia stabilized with at least one rare earth oxide element selected from Mg, Ca, Y, Sc and Ce to form a mixture. The mixture is molded into a green part. The green part is sintered to form the ceramic article.

Abstract: A method of making a shaped article involves forming an aqueous mixture comprising inorganic powder material, supercritical fluid, organic binder component a portion of which is essentially insoluble in water, and aqueous vehicle, and extruding the mixture into a shaped article.

Abstract: A ceramic spinneret used for producing manufactured fibers and formed from a fine grained, essentially pure structural ceramic such as aluminum oxide, zirconium oxide, composites of aluminum oxide and zirconium oxide known as toughed ceramics, silicon nitride, silicon carbide, or any fine grained essentially pure structural ceramic. Such spinnerets are formed as a single piece and contain non-circular capillaries suitable for forming shaped or void containing fibers.

Abstract: In a method of manufacturing ceramic, metallic shaped bodies or layers a castable moldable material mass consisting of sugar and/or urea-containing compounds as well as metal components is produced and from that material mass a shaped body is formed or the material mass is applied to a material structure and the shaped body or material structure is then heated and sintered. The sugar material mass includes for example sugar syrup, sugar or beets, cane sugar, fruits, honey, alcohol-sugar solutions and beer.

Abstract: A process of molding inorganic materials into desired shapes comprises mixing the material with a dispersant, milling, molding the mixture, drying the mixture and sintering.

Abstract: A method of preparing ceramics having the steps of forming an aqueous slurry of deflocculant, ceramic powder and binder and causing the slurry to get into a semi-rigid solid by adding a chemical initiator and/or increasing the temperature of the slurry.

Abstract: Disclosed is a method of forming an aluminum nitride article. The method includes the steps of adding platinum to a composition including a binder, aluminum nitride particles and a sintering aid; forming the composition into an article; placing the article in a substantially non-carbonaceous container; and sintering the article in a reducing atmosphere to cause removal of the binder and densification of the aluminum nitride article, wherein the platinum catalyzes the removal of the binder.

Abstract: Raw material powder for a bismuth oxide superconductor is molded with addition of an organic vehicle, and the molded raw material is heat treated for removing the organic vehicle before the molded raw material is metal-coated. In this heat treatment, conditions not more than those expressed as T=-1.5.times.logH+600 are applied as to relation between temperature (T) and time (H). Thus, phase transformation of 2212 phases mainly composing the raw material is suppressed so that a large amount of 2223 phases having a relatively high critical temperature are formed when heat treatment is performed after metal coating.

Abstract: A single crystal silicon sheet is formed from a polycrystalline sheet by melting a relatively small portion of the sheet at an initial location and defining a single crystallographic orientation for the silicon by placing a small silicon seed crystal in contact with the melted silicon at the initial location. The melted portion is then moved from the initial location throughout the sheet to move impurities in the sheet to the edges of the sheet and to extend the crystallographic orientation of the silicon established at the initial location to the whole sheet, inwardly of the edges. The edges containing impurities and any remaining polycrystalline structure are removed to produce a sheet of single crystal silicon. A polycrystalline sheet may be formed by spreading a slurry of a silicon powder, a binder, and solvent on a surface and allowing the solvent to evaporate to form a sheet. The sheet is moistened to cause it to expand and sheer clear of the surface.

Abstract: A method of engraving pre-sintered ceramic articles involves providing a source of laser energy for forming a polyester mask having a predetermined spiral pattern etched therein. To form the polyester mask, means are provided for computationally communicating a predetermined engraving pattern to the source of laser energy. Once the polyester mask is formed, it is overlaid onto the ceramic article forming a laminate and the laminate is bombarded with a hard alumina grit to form the spiral pattern in the ceramic article. After the ceramic article is engraved with the predetermined spiral pattern, the polyester mask is removed exposing an engraved ceramic article.

Abstract: A water soluble acrylate is polymerised to bind ceramic particles in a dispersion. The polymer is then burned away.

Abstract: Components whose palladium metal-containing constituent is not subject to delamination and which exhibit very good dielectric properties are obtained by means of a method of manufacturing a ceramic electronic component. The ceramic electronic component is essentially composed of a dielectric oxide ceramic and at least one palladium-containing component, and is obtained by firing and sintering of a green body containing an organic binder with the firing process including a first step in which the binder is removed from the binder-containing green body by means of a water-gas reaction in a water vapor-containing, essentially oxygen-free, atmosphere at temperatures between 20.degree. and 880 .degree. C., and a second step in which the dielectric oxide ceramic is re-oxidized in an atmosphere having an oxygen content of 10 to 100% by volume at a temperature in the range from 880 .degree. C. to 900 .degree. C.

Abstract: This manufacturing method of a powder injection molded part includes the steps of using a binder composition containing at least 2 kinds of thermoplastic binder components having an evaporation temperature higher than the injection molding temperature and a different evaporation initiating temperature from each other, elevating the temperature of a molded body above the evaporation initiating temperature of the binder component having the lowest evaporation initiating temperature rapidly, removing the binder component having the lowest evaporation initiating temperature from the molded body by holding this temperature, and thereafter, removing all binder components by elevating up to a temperature not lower than the evaporation initiating temperature of the binder component having the highest evaporation initiating temperature. By this method, the form unstability of final parts, which is a problem of the prior art, is resolved, dimensional accuracy is satisfied, and it is possible to shorten debinding times.

Abstract: A ceramic green sheet includes ceramic particles having a spherical diameter of 0.01-0.5 .mu.m of a primary particle as a ceramic component, an average degree of aggregation of 10 or less, wherein the ceramic green sheet contains at most 1 vol % of secondary particles having a diameter of 20 .mu.m or more and has a surface roughness (Ra) of 0.2 .mu.m or less. A method for producing a ceramic substrate having a thickness of 30 .mu.m or less includes the steps of: preparing a ceramic slurry by mixing a ceramic powder with an organic binder and at least one organic solvent, and adjusting a viscosity to be within the range of 100-10,000 mPa's; removing coarse aggregated particles from the ceramic slurry; molding the ceramic slurry into a ceramic green sheet by a reverse roll coater method; and firing the ceramic green sheet so that an average crystal grain size be 2 .mu.m or less.

Abstract: A method of making an article which includes a suboxide of titanium, the method involving binding Magneli phase powder into the shape of an article and subjecting the bonded shape to heat treatment including the step of controlling the temperature and pressure of the heat treatment so that the heat treated article is substantially corrosion resistant and non-wicking in use.

Abstract: The present invention is a method for injection molding fine particulate inorganic materials which includes the steps of, compounding a particulate inorganic material and a magnesium-X silicate, wherein X represents lithium, sodium, potassium or other monovalent ion, containing binder, injecting the compounded material at low pressure and ambient temperature into a mold to form a green part, and sintering the green part to form the final molded part.

Abstract: A method for forming parts from inorganic particulate materials is diclosed. The method utilizes a two-component binder composition which is removable at a faster rate than conventional binder compositions, thereby reducing the formation of voids and cracks that occur during binder removal. No toxic materials are required and the method does not rely on solvents. The method may be used with ceramics, metals, and cermets.

Abstract: A sintered ITO compact having an ultra-high density of at least 7.08 g/cm.sup.3 is produced by a process wherein an aqueous slurry comprised of indium oxide, tin oxide, a binder, a dispersant and an aqueous medium is cast in a mold, and the thus-obtained cast green body is sintered. The aqueous slurry used is prepared by the steps of:dispersing uniformly a tin oxide powder and a dispersant in an aqueous medium to give an aqueous slurry;allowing the aqueous slurry to stand whereby coarse particles of tin oxide are sedimented;separating by decantation an upper liquid layer of the aqueous slurry containing finely divided particles of tin oxide (preferably, the secondary particle sizes of which are not larger than 4 .mu.m) and the dispersant from a lower liquid layer containing the sedimented coarse particles; and then,incorporating an indium oxide powder and a binder in the separated upper liquid layer containing finely divided tin oxide particles and the dispersant to give an aqueous slurry.

Abstract: The present invention relates to novel methods for shaping a filler material into a porous preform and subsequently filling at least a portion of the porous preform with a second material to form a composite body. Specific aspects of the invention include novel combinations of materials to form the preform in combination with novel processing techniques for shaping the combinations of materials into a porous preform.

Abstract: The invention relates to a process for manufacturing brickworks mouldings by mixing a compound containing a granular clay-containing material with a lean material and, if required, other additives from which moulding compound green products are moulded, dried and burnt. This process permits a recycling of residual materials by using as clay-containing material a residual material consisting predominantly of clay minerals, especially a dry fraction, predominantly composed of annealed clay minerals, of an ash, preferably brown coal ash, and by producing the moulding compound by mixing the fraction with the lean material and other additives as well as water, where water is used in such a quantity as to produce an earth-moist moulding compound which is then pressed in portions on a press to form individual, inherently stable green products.