Abstract: A method for producing a self-supporting ceramic composite body which comprises preparing a polycrystalline material as the oxidation reaction product of a parent metal with a vapor-phase oxidant, comminuting the resulting material to a particulate, forming a permeable mass of said particulate as filler, and infiltrating said particulate with an oxidation reaction product of a parent metal with a vapor-phase oxidant, thereby forming said ceramic composite body.

Abstract: A method of producing shaped, self-supporting ceramic bodies includes preparing a mold by applying a permeable, conformable material to a shape-defining surface of an expendable pattern. The permeable, conformable material, when set or stable, provides a mold with a shaped surface which is defined by, and is therefore substantially congruent to, the shape-defining surface. Upon heating, the material of the expendable pattern combusts or volatilizes and thus establishes the shaped cavity mold. A molten parent metal is then oxidized with a vapor-phase oxidant in such a manner as to form a ceramic body which grows into the mold cavity, and is shaped by it. The ceramic body is recovered from the mold having a shaped surface replicating the shape-defining surface of the expendable pattern.

Abstract: A method of producing a self-supporting ceramic composite body having therein at least one cavity which inversely replicates the geometry of a positive mold of parent metal. The method, includes embedding the mold of parent metal within a conformable bed of filler to provide there in a cavity shaped and filled by the mold. The assembly is heated to melt the parent metal mold, e.g., an aluminum parent metal mold, and contacted with an oxidant to oxidize the molten parent metal to form a polycrystalline material which grows through the surrounding bed of filler, the molten metal being drawn through the growing polycrystalline material to be oxidized at the interface between the oxidant and previously formed oxidation reaction product whereby the cavity formerly filled by the mold of parent metal is eventually evacuated of the metal. There remains behind a cavity whose shape inversely replicates the original shape of the mold.

Abstract: A ceramic-reinforced aluminum matrix composite is formed by contacting a molten aluminum-magnesium alloy with a permeable mass of ceramic material in the presence of a gas comprising from about 10 to 100% nitrogen, by volume, balance non-oxidizing gas, e.g., hydrogen or argon. Under these conditions, the molten alloy spontaneously infiltrates the ceramic mass under normal atmospheric pressures. A solid body of the alloy can be placed adjacent a permeable bedding of ceramic material, and brought to the molten state, preferably to at least about 700.degree. C., in order to form the aluminum matrix composite by infiltration. In addition to magnesium, auxiliary alloying elements may be employed with aluminum. The resulting composite products may contain a discontinuous aluminum nitride phase in the aluminum matrix and/or an aluminum nitride external surface layer.

Abstract: A method of producing self-supporting ceramic structures includes providing a first self-supporting ceramic body comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a first molten parent metal with a first oxidant, and (ii) interconnected porosity at least partially accessible from one or more surfaces of said first ceramic body. A second ceramic body is used to form, by reaction with a vapor-phase oxidant, a second polycrystalline material which is infiltrated into the porosity of at least a zone of said first ceramic body.

Abstract: Ceramic bodies are bonded together via a layer of an oxidation reaction product of a molten metal, which metal is present in one or both of the ceramic bodies prior to bonding. At least one of the ceramic bodies comprises a ceramic product formed by the oxidation reaction of molten parent metal (e.g., alumina from molten aluminum) and grown as molten metal is transported through, and oxidized on the surface of, its own oxidation product. One or both of the ceramic bodies used in the bonding process contains surface-accessible channels of residual metal, i.e., metal channels which have resulted from molten-metal transport during the ceramic growth process. When the suitably assembled ceramic bodies are heated in an oxidizing atmosphere at a temperature above the melting point of the residual metal, molten metal at the surface of the ceramic body reacts with the atmosphereic oxidant so as to bond the facing surfaces together by a layer of the oxidation reaction product of the molten metal formed therebetween.

Abstract: A method of producing a composite comprising a self-supporting polycrystalline material obtained by oxidation reaction of a molten parent metal with a vapor-phase oxidant comprising infiltrating a filler exhibiting inter-particle pore volume with a parent metal under conditions which control the respective rates of said metal infiltration and said oxidation reaction.

Abstract: The present invention provides a method for producing a self-supporting ceramic composite by the oxidation of a parent metal to form a polycrystalline ceramic material consisting essentially of the oxidation reaction product of the parent metal with an oxidant, including a vapor-phase oxidant, and, optionally, one or more metallic constituents. A permeable filler material, such as a preform, with at least one surface bearing a permeable stratum, is contacted with a body of molten parent metal heated to a temperature above its melting point but below the melting point of the oxidation reaction product.

Abstract: A method is provided of producing a self-supporting ceramic composite structure having one or more encasement members, such as an encasing steel sleeve, joined to it by growth of the ceramic material to engagement surface(s) of the encasement member(s). A parent metal is contacted with a body of filler which is encased by the encasement member(s). The resulting assembly is heated to melt and oxidize the parent metal, e.g., aluminum, to form a polycrystalline material comprising an oxidation reaction product which grows through the doby of filler and stops at the engagement surface(s) of the encasement member(s) which thereby determines the surface geometry of the grown ceramic matrix. Upon cooling, the encasement member(s) is shrink-fitted about the ceramic composite body. The invention also provides the resultant articles, for example, a ceramic composite body having a stainless steel member affixed thereto.

Abstract: Production of composite ceramic articles using a porous bed or preform of filler material with a molten metal in the presence of a vapor phase oxident, for effecting infiltrating growth of a polycrystalline matrix of a metal-oxidant reaction product into the filler bed or preform, wherein the filler material bed or preform has a first pore system of coarse interconnected pores, and a second pore system of finer interconnected pores defined by portions of the filler material which remain structurally stable in pore-defining arrangement during infiltration.

Abstract: A method for producing an alumina of high purity, which comprises forming an oxidation reaction product of an aluminum parent metal and an oxygen-containing vapor-phase oxidant, comminuting the resulting ceramic body, and leaching any non-alumina materials therefrom, and recovering said substantially pure alumina material.

Abstract: There is disclosed a method of producing a self-supporting ceramic composite body having therein at least one cavity which inversely replicates the geometry of an expendable pattern. The method includes the steps of surrounding the expendable pattern with a filler material to thereby form a filled cavity within the filler material. The expendable pattern is chemically or physically removed from the filler material and a quantity of a parent metal is put into the cavity. The parent metal is heated to a temperature above its melting point and an oxidation reaction process begins whereby the oxidation reaction product infiltrates and embeds the surrounding filler material. Excess filler material and/or excess parent metal are removed, thus resulting in a self-supporting ceramic composite body having a cavity in the shape of the expendable pattern.

Abstract: There is disclosed a method for producing a self-supporting ceramic body by oxidation of a molten precursor metal with a vapor-phase oxidant to form an oxidation reaction product and inducing a molten flux comprising said molten precursor metal through said oxidation reaction product. A second metal is incorporated into said molten flux during the oxidation reaction. The resulting ceramic body includes sufficient second metal such that one or more properties of said ceramic body are at least partially affected by the presence and properties of said second metal in the metallic constituent.

Abstract: Ceramic foams in which the open cells are connected by a three-dimensional, substantially continuous ceramic matrix formed of interconnected hollow ligaments, are made from an open-cell, reticulated precursor metal, i.e. a metal foam. The precursor metal first is treated so as to allow a support coating to form thereon, and thereafter the coated precursor is heated above the melting point of the metal in the presence of an oxidant to form an oxidation reaction product.

Abstract: A method of producing self-supporting ceramic structures comprising (i) a polycrystalline oxidation reaction product formed upon oxidation of a body of molten parent metal with an oxidant, and (ii) interconnected porosity at least partially accessible from one or more surfaces of said ceramic body. A second polycrystalline ceramic material is incorporated into the porosity of said ceramic body to modify or contribute to its properties.

Abstract: The invention relates to a rubber-like ball having an elastic fabric attached thereto. The ball is thrown by grasping the elastic fabric at a point distant from the ball and swinging the ball in a circular motion by the elastic fabric and subsequently releasing the elastic fabric resulting in the ball and the elastic fabric becoming a catchable projectile. The elastic fabric is fixed to the ball by inserting the same into a hole in the ball such that the fabric assumes a U-shape therein, wherein a bottom of the "U" is substantially flush with an outer forward surface of the ball.