Abstract: A thermal barrier coating (TBC 26) and method for forming the TBC (26) on a component (10) characterized by a stabilized microstructure that resists grain growth, sintering and pore coarsening or coalescence during high temperature excursions. The TBC (26) contains elemental carbon and/or a carbon-containing gas that increase the amount of porosity (32) initially within the TBC (26) and form additional fine closed porosity (32) within the TBC (26) during subsequent exposures to high temperatures. A first method involves incorporating elemental carbon precipitates by evaporation into the TBC microstructure. A second method is to directly incorporate an insoluble gas, such as a carbon-containing gas, into an as-deposited TBC (26) and then partially sinter the TBC (26) to entrap the gas and produce fine stable porosity within the TBC (26).

Abstract: A composite material includes an SiC porous ceramic sintered body, which is formed by preliminarily sintering a porous body, having a coefficient of thermal expansion lower than the coefficient of thermal expansion of copper to construct a network therein. A copper alloy impregnating the porous ceramic sintered body includes copper and one or more additive elements which are prepared to impart a coefficient of thermal conductivity of 160 W/mK or higher to the composite material. The additive elements include up to 5% of at least one element selected from Be, Al, Si, Mg, Ti, Ni, Bi, Te, Zn, Pb, Sn, and mish metal, and also contain unavoidable impurities and gas components.

Abstract: Process for a fiber-reinforced ceramic material whose reinforcing fibers are present in the form of at least one of woven fabrics, short fibers and long fibers, wherein the mass ratio of the fibers in the form of woven fabrics, short fibers and long fibers is 0-35:25-80:0-45 and at least a part of the reinforcing fibers has at least one protective layer of carbon produced by pyrolysis of resins or pitches, boron compounds or phosphorus compounds or combinations thereof which have been deposited thereon, a process for producing it and its use as material for brake linings

Abstract: Graphite is placed in a case, and the case is set in a furnace. The interior of the furnace is subjected to sintering to produce a porous sintered member of graphite. After that, the case with the porous sintered member therein is taken out of the furnace, and is set in a recess of a press machine. Subsequently, molten metal of metal is poured into the case, and then a punch is inserted into the recess to forcibly press the molten metal in the case downwardly. Open pores of the porous sintered member are infiltrated with the molten metal of the metal by the pressing treatment with the punch.

Abstract: A composite rigid foam structure that has a skin or coating on at least one of its surfaces. The skin is formed in situ by thermal spray techniques. The skin is bonded substantially throughout the surface of the porous substrate to the peripheries of the pores. The skin on the average does not penetrate the surface of the substrate by more than the depth of about 2 to 5 pores. Thus, thermal spraying the skin onto the rigid foam produces a composite that is tightly and uniformly bonded together without unduly increasing the weight of the composite structure. Both thermal conductivity and bonding are excellent.

Abstract: The invention concerns a heat-stable ordered mesoporous or mesostructured material comprising a mineral phase wherein are dispersed particles of nanometric dimension at least partly crystaline, the global crystallinity index of said mesostructured or ordered mesoporous material being less than 10% in volume. The invention also concern a method for obtaining such a material.

Abstract: A method of electrochemically filling features on a wafer surface to form a substantially planar copper layer is provided. The features to be filled includes a first feature that is an unfilled feature with the smallest width and a second feature having the next larger width after the smallest feature. The first and the second features are less than 10 micrometers in width. The method comprises applying a first cathodic current to form a first copper layer on the wafer surface. The first copper layer has a planar portion over a first feature and a non-planar portion over a second feature. After a surface of the first copper layer is treated by applying a first pulsed current, a second cathodic current is applied to form a second copper layer on the first copper layer. The second copper layer has a planar portion over both the first and second features.

Abstract: Fiber-reinforced ceramic composites which comprise at least two layers of a multidirectional woven fiber fabric as reinforcement, with at least 5% of the area of each layer of woven fiber fabric being permeated by matrix material, friction disks comprising these composites as core zone or support zone, a process for producing them and their use as brake disks or clutch disks.

Abstract: A diamond foam article comprises diamond deposited material on a substrate having an open contiguous structure at least partially filled with a filler material. Methods for forming a diamond foam article comprise providing a foam substrate; preparing the foam substrate for diamond deposition; depositing diamond material on the foam substrate by one of several diamond deposition methods; and at least partially filling the diamond foam article with a filler material. Diamond foam articles are bonded to other components.

Abstract: A thermal barrier coating, or TBC (26), and method for forming the TBC (26). The TBC (26) is formed of a thermal-insulating material that contains yttria-stabilized zirconia (YSZ) alloyed with at least a third oxide. The TBC (26) is formed to also contain elemental carbon, and may potentially contain carbides and/or a carbon-containing gas that forms from the thermal decomposition of carbon. The TBC (26) is characterized by lower density and thermal conductivity, high temperature stability and improved mechanical properties. To exhibit the desired effect, the third oxide is more particularly one that increases the lattice strain energy of the TBC microstructure as a result of having an ion size that is sufficiently different than a zirconium ion.

Abstract: A thermal barrier coating for an underlying metal substrate of articles that operate at, or are exposed to, high temperatures, as well as being exposed to environmental contaminant compositions. This coating includes a porous outer layer having an exposed surface and comprising a non-alumina ceramic thermal barrier coating material, as well as alumina infiltrated within the porous outer layer in an amount sufficient to protect the coating at least partially against environmental contaminants that become deposited on the exposed surface. This coating can be used to provide a thermally protected article having a metal substrate and optionally a bond coat layer adjacent to and overlaying the metal substrate. The thermal barrier coating can be infiltrated with the alumina by treating the porous outer layer with a liquid composition comprising an alumina precursor and then converting the infiltrated alumina precursor to alumina.

Abstract: A turbine blade has an airfoil section with a root end and a tip end, and an attachment at the root end of the airfoil section. A blade tip seal is joined to the tip end of the airfoil section. The blade tip seal is formed as an open-cell solid aluminum oxide foam made of aluminum oxide cell walls having intracellular volume therebetween. The blade tip seal has a blade interface region adjacent to the tip end of the airfoil section. The blade interface region is formed of the aluminum oxide foam and a nickel-base alloy within the intracellular volume. The blade tip seal also has a contact region remote from the blade interface region and comprising the aluminum foam wherein the intracellular volume is porosity.

Abstract: A composite material that consists mainly of ceramic and semi-metal, that is high in thermal conductivity, that is light in weight, and that has high compatibility in coefficient of thermal expansion (CTE) with a semiconductor element and another member comprising ceramic; a member comprising this composite material; and a semiconductor device comprising the member. The composite material has a structure in which the interstices of a three-dimensional network structure comprising ceramic are filled with a semi-metal-containing constituent produced by deposition after melting, has a CTE of 6 ppm/° C. or less, and has a thermal conductivity of 150 W/m·K or more. The semiconductor device comprises the composite material. The composite material can be obtained by filling the pores of a porous body consisting mainly of ceramic with a semi-metal-containing constituent.

Abstract: A non-single crystalline semiconductor material includes coordinatively irregular structures characterized by distorted chemical bonding, reduced dimensionality and novel electronic properties. A process for forming the material permits variation of the size, concentration and spatial distribution of coordinatively irregular structures. The electronic properties of the material can be changed by controlling the characteristics of the coordinatively irregular structures.

Abstract: A turbomachine component includes a silicon nitride substrate and a protective coating on the substrate. The protective coating includes a porous silicon nitride matrix and a noble metal infiltrated in the porous silicon nitride matrix.

Abstract: A method of carbonizing cellulose-containing plants is disclosed. Wood is used as a precursor material which is carbonized under controlled temperature and atmosphere conditions to produce a porous carbon product having substantially the same cellular structure as the precursor wood. The porous carbonized wood may be used for various applications such as filters, or may be further processed to form carbon-polymer or carbon-carbon composites. The carbonized wood may also be converted to a ceramic such as silicon carbide. Additional processing may be used to form ceramic-metal or ceramic-ceramic composites.

Abstract: The object of the present invention is to provide a ceramic body that can support a required amount of a catalyst component, without lowering the characteristics such as strength, being manufactured without forming a coating layer and providing a high performance ceramic catalyst that is excellent in practical utility and durability.

Abstract: Metal oxide coated substrates are disclosed comprising a three dimensional inorganic porous diatomite substrate having a coating of metal oxide on at least a portion of all three dimensions thereof, produced by a unique process having particular applicability to the manufacture of tin oxide coated three dimensional substrates. Certain novel coated substrates, such as flakes, spheres and porous substrates are disclosed. The coated substrates are useful in polymers, catalysis, heating and shielding applications.

Abstract: The disclosed invention relates to the field of ceramics and concerns an open-cell expanded ceramic which may be used in the form of a deep-bed filter, and a process for the production thereof. The primary object is to produce an open-cell expanded ceramic by a simple and economical process. This object is attained by an open-cell expanded ceramic in which the inner cavities, cracks and the porosity of the ceramic members are filled partially or completely by one or a plurality of metal and/or ceramic phases and/or glass phases. The open-cell expanded ceramic is also produced in that during or after sintering the cavities, cracks and the porosity of the ceramic members are partially or completely filled with a melt or a suspension which melt below the melting temperature of the expanded ceramic, have a coefficient of expansion similar to the coefficient of expansion of the expanded ceramic, and a very good wetting capacity, and only react partially or not at all with constituents of the expanded ceramic.

Abstract: Multilayered metal oxide coated substrates are disclosed comprising a three dimensional inorganic substrate having a coating of metal oxide on at least a portion of all three dimensions thereof, produced by a unique process having particular applicability to the manufacture of tin oxide coated three dimensional substrates. Certain novel coated substrates, such as flakes, spheres and porous substrates are disclosed. The coated substrates are useful in polymers, catalysis, heating and shielding applications.

Abstract: Metal oxide coated substrates are disclosed comprising a three dimensional inorganic nano substrate having a coating of metal oxide on at least a portion of all three dimensions thereof, produced by a unique process having particular applicability to the manufacture of tin oxide coated three dimensional substrates. Certain novel coated substrates, such as flakes, spheres and porous substrates are disclosed. The coated substrates are useful in polymer, catalysis, heating and shielding applications.

Abstract: An article of manufacture includes a metallic nonfoam region, and a ceramic foam region joined to the metallic region. The ceramic foam region is an open-cell solid ceramic foam made of ceramic cell walls having an intracellular volume therebetween. The ceramic is preferably alumina. The intracellular volume may be empty porosity, or an intracellular metal such as an intracellular nickel-base superalloy.

Abstract: The present invention is a method for fabricating shaped monolithic ceramics and ceramic composites, and the ceramics and composites made thereby. The method of the present invention includes three basic steps: (1) Synthesis or other acquisition of a porous preform with an appropriate composition, pore fraction, and overall shape is prepared or obtained. The pore fraction of the preform is tailored so that the reaction-induced increase in solid volume can compensate partially or completely for such porosity. It will be understood that the porous preform need only be sufficiently dimensionally stable to resist the capillary action of the infiltrated liquid reactant; (2) Infiltration: The porous preform is infiltrated with a liquid reactant; and (3) Reaction: The liquid reactant is allowed to react partially or completely with the solid preform to produce a dense, shaped body containing desired ceramic phase(s).

Abstract: A highly thermally conductive composite material is characterized in that it contains 20-75 Vol % of SiC, with the balance being Cu, and further contains a reaction preventive layer interposed on the interface between SiC and Cu for preventing a reaction between the two substances. Specifically, the reaction preventive layer is a thin film having a thickness of 0.01-10 microns, consisting of carbon or a carbide of at least one element selected from the group consisting of Cr, Nb, Ta and W. In particular, the composite material has a thermal expansion coefficient of 4.5-10×10−6/K and a thermal conductivity of 200 W/mK or higher.

Abstract: A silicon carbide composite which is a flat composite comprising a porous preform of silicon carbide and a metal containing aluminum as the main component, infiltrated into the porous preform, said composite having a warpage of at most 250 &mgr;m per 10 cm of the principal plane length of the composite.

Abstract: Aluminum alloy comprising an anodic oxidation coating and a ceramic coating formed on a surface of the anodic oxidation coating, wherein the anodic oxidation coating contains one or more elements selected from the group consisting of C, N, P, F, B and S at a content of each element in an amount of 0.1 mass % or more, and wherein the ceramic coating comprises one or more selected from the group consisting of oxide, nitride, carbonitride, boride and silicide, wherein when the anodic oxidation coating contains S only, the surface of the aluminum alloy or of the anodic oxidation coating has an average roughness Ra of 0.3 &mgr;m or more.

Abstract: The process of the present invention comprises a method for fabricating shaped monolithic ceramics and ceramic composites through displacive compensation of porosity, and ceramics and composites made thereby. The method of the present invention includes three basic steps: 1) Synthesis or other acquisition of a porous preform: A porous preform with an appropriate composition, pore fraction, and overall shape is prepared or obtained. The pore fraction of the preform is tailored so that the reaction-induced increase in solid volume can compensate partially or completely for such porosity. It will be understood that the porous preform need only be sufficiently dimensionally stable to resist the capillary action of the infiltrated liquid reactant; 2) Infiltration: The porous preform is infiltrated with a liquid reactant; and 3) Reaction: The liquid reactant is allowed to react partially or completely with the solid preform to produce a dense, shaped body containing desired ceramic phase(s).

Abstract: A structure that is suitable for partial or full use in a spacer of a flat-panel display. The structure may be formed with a porous body having a face along which multiple primary pores extend into the porous body. A coating consisting primarily of carbon and having a highly uniform thickness overlies the porous body's face, extending along the primary pores to coat their surfaces and converting the primary pores into further pores. The coating can be created by removing non-carbon material from carbon-containing species provided along the pores. A solid porous film whose thickness is normally no more than 20 &mgr;m has a resistivity of 108-1014 ohm-cm. A spacer for a flat-panel display contains a support body and an overlying, normally porous, layer whose resistivity is greater parallel to a face of the support body than perpendicular to the body's face.

Abstract: The invention relates to a composite material, manufactured by dynamic densification of an amount of granular or powdered relatively brittle material or a mixture of one or more of such materials, wherein a continuous porous product is obtained, whereafter, by infiltration thereof with a second material, the brittle material particles are embedded in a continuous network of the second material. The invention further relates to a composite comprising ceramic particles embedded in a continuous matrix of a second material, obtainable by a method according to the invention, and to products manufactured from such composite.

Abstract: A friction body of porous carbon, which is infiltrated with silicon and reinforced with carbon fibers, includes at least one separate friction layer on a core body. In order to protect the friction layer against damage by outbreaking, carbon fibers in the friction layer are shorter than carbon fibers of the core body. Accordingly, different possibilities for producing a friction body with short fibers in the friction layer are possible.

Abstract: A metal-ceramics composite comprising a porous inorganic structure and a metal containing aluminum as the main component, infiltrated into the porous inorganic structure, wherein a part of the porous inorganic structure is made of an inorganic fiber and a hardened product of a hydraulic inorganic substance.

Abstract: The present invention provides an odor and moisture removing apparatus and method of manufacturing the same which is suitable for insertion in a shoe or boot. The apparatus includes an outer shell which encloses layers of a woven porous fabric. A porous and absorbent felted material such as “silence cloth” is enclosed between the top/bottom layers and the layers holding the desiccant material. Further, a desiccant material is included between the second and third layers. As embodied, the apparatus is designed to resemble an animal-like creature for added novelty value and customer appeal. Further, an essential oil or fragrance such as vanilla or cinnamon is infused within a portion of the apparatus to mask or further eliminate any remaining odors in the footwear.

Abstract: A strong, porous article comprising a strong porous carrier having an outer surface defining a shape having a bulk volume and having pores defining interconnecting fluid flow openings extending throughout the bulk volume and opening through said surface. A second porous material, the mean pore size of which is at least an order of magnitude less than the mean pore size of the porous carrier, is nested within and structurally supported by the pore walls of the carrier so that the second porous material maintains its porous configuration and its pores are accessible to a fluid flowing through the pores of the porous carrier.

Abstract: Polyelectrolyte coated permeable composite materials are prepared by coating a polyelectrolyte onto a composite material comprising an inorganic component composed of at least one compound of a metal, semimetal or mixed metal with at least one element from main groups 3 to 7, disposed on at least one side and on inner surfaces of a permeable support. The surface of the composite material is charged, and at least one, or a plurality of polyelectrolyte layers are deposited on the composite material to provide a polyelectrolyte coated permeable composite material.

Abstract: The present invention relates to electronic components and in particular relates to ceramic-based electronic components wherein a portion of the component comprises a metal-infiltrated ceramic. In a preferred embodiment, the metal-infiltrated ceramic comprises copper metal.

Abstract: A gas filter, a process for producing a gas filter and the use of the gas filter. The filtration of gases, in particular of gases which are contaminated by solids, e.g. automobile exhaust gases, is difficult since the solids which have been filtered out block the filter over the course of time. The gas filter of the invention can be used over relatively long periods of time since it is regenerable. The improvement achieved by the invention compared to conventional gas filters is that the filter comprises a composite material which can be heated in a simple manner by application of a voltage to the electrically conductive support material of the composite material and thermally decomposable substances which can block the filter can be decomposed. The filter of the invention can be used wherever gases which are contaminated by thermally decomposable solids have to be cleaned.

Abstract: The invention relates to a permeable composite material, a method for producing said composite material, and the use of the composite material. The inventive composite material contains essentially a porous, permeable support, another constituent having been solidified on and in or on or in said support. Said other constituent essentially contains metallic compounds with elements of the 3rd to the 6th main group. The constituent is solidified to, on or in the support by heating a suspension of the constituent suspended in a metal oxide sol applied on and in or on or in the support. The invention hereby provides a means of producing a permeable composite material in very mild conditions, either by heating strongly for a short period or by heating more moderately for a longer period. The resulting permeable composite material is excellently suited to applications in filtration and membrane technology.

Abstract: The invention relates to a catalytically active, permeable composite material, a method for producing said composite material, and the use of the composite material. The inventive composite material can be used for separating mixtures of materials. The fact that various catalytically active substances can be incorporated into the material in various ways makes it highly flexible in terms of possible applications with properties which can be adapted to the particular purpose of an application. The inventive composite material can be used as a catalytically active membrane electrode, for example. According to the invention, the material is obtained by solidifying a suspension on and in a porous, permeable support. The production of the material requires either a very short period of heat treatment at temperatures of around 400° C. or treatment for a longer period at very mild temperatures of below 100° C.

Abstract: A process for producing a ceramic-metal composite, includes (1) mixing TiO2, and optionally Ti, with at least one of a boron-containing or carbon-containing material to give a green body mix; (2) heat treating the green body mix to a temperature from 900° C. to 1900° C. and below a temperature which leads to an autocatalytic reaction; (3) carrying out an exchange reaction between the material and the TiO2 to give a reaction product comprising at least one of TiBx and TiCy, wherein 0≦x 23 2 and 0≦y≦1; (4) producing a porous green body from the reaction product; (5) filling the porous green body with liquid aluminum after the exchange reaction; and (6) carrying out a reaction between the reaction product in the green body and the aluminum to form the ceramic-metal composite comprising a ceramic phase selected from the group consisting of TiBx-, TiCy-, TiCN- and Al2O3 and a comprising a metallic phase comprising an intermetallic compound of Ti and Al.

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: The method serves for the sealing of porous layers (10) at body surfaces (11), in particular of thermal spray layers of a ceramic coating material. Communicating capillary spaces (12) in the layer (10) have openings at the surface (11). A liquid (2) is used as a sealing medium which consists of a solvent and at least one oxidizable metal which is contained therein.

Abstract: A novel construction board composition is disclosed comprising a unique combination of synthetic binders selected for their ability to establish a strengthened permanent bond in the final dry state for use in a construction board composition comprising primarily gypsum, and in a construction board composition comprising an expanded mineral such as Perlite which largely reduces the amount of gypsum over current gypsum construction board formulations, thus reducing the weight while maintaining the strength of the construction board structure. In a preferred embodiment, the lightweight, strengthened gypsum construction board of the present invention also comprises an optional covering veneer that is applied to provide increased strength, moisture resistance, and fire retardency, and the back paper top ply is treated to provide increased flexural strength.

Abstract: The present invention converts the regions of the graphite components in a CZ apparatus that are most prone to erosion to silicon carbide, forming a protective treatment (or “coating”). The coating may cover the entire component or preselected areas of the component. The resulting coating slows erosion of the graphite component and prolongs the lifetime of the component. The method of the invention includes applying a silicon-containing paste to a graphite (or other carbon) component and heating the component so that the silicon combines with carbon from the graphite component to form a protective coating. The paste is preferably a mixture of a silicon-containing powder and a carbon-containing liquid.

Abstract: A cutting insert which comprises a rake face and a flank face wherein there is a cutting edge at the juncture of the rake face and the flank face. The cutting insert has a coating and a substrate wherein the coating is adherently bonded to the substrate. The substrate is a tungsten carbide-based cemented carbide wherein there is a zone of non-stratified cobalt enrichment beginning near and extending inwardly from a peripheral surface of the substrate. The bulk substrate has a porosity of greater than C00 and less than or equal to C04.

Abstract: A wheel rut-resistant carriageway and process for obtaining a wheel rut-resistant carriageway. The wheel rut-resistant carriageway includes at least one rigid base layer, at least one intermediate layer, and a rough upper layer. The at least one rigid base layer has a thickness in the range of approximately 6 cm to approximately 8 cm. The at least one intermediate layer is disposed over the at least one rigid base layer and has a thickness in the range of approximately 4 cm to approximately 5 cm. The at least one intermediate layer has a high void rate allowing for the evacuation of heat by ventilation. The rough upper layer is disposed over the intermediate layer and has a thickness in the range of approximately 2 cm to approximately 3 cm. The process includes applying the at least one rigid base layer having a thickness in the range of approximately 6 cm to approximately 8 cm to a surface.