Abstract: This invention is directed to the preparation of articles exhibiting catalytic activity and, in particular, to articles which are exceptionally suitable for catalytically converting gases from organically fueled power plants, internal combustion engines, and other fluid and gaseous catalysis. The inventive articles comprise a unitary composite structure consisting essentially of a catalytically active precious metal and/or a base metal which, the base metals in particular, become catalytically active upon oxidation. The catalysts are integrally combined with a supporting structural metal.

Abstract: A system is disclosed for externally locating the geometric center of an internal lens element which requires that an external reference surface be accurately formed so as to lie concentrically with the central axis of the internal lens element. This is a accomplished in a pressing operation by precisely aligning and securing a ring element to a plunger member. Three points are then selected on the outer reference surface which are not only utilized for positioning the internal lens element for grinding an outer surface to a desired thickness, but also are utilized for aligning and affixing an external lens system in geometric alignment with the internal lens.

Abstract: Secondary discharge slots are cut into the face of newly made or used extrusion dies such that the secondary discharge slots communicate transversely and longitudinally with primary discharge slots but do not communicate with the feed holes. The novel extrusion die arrangement is set forth for the production of ceramic honeycomb structures which produce a greater number of cells per square inch, protrusions on the cell walls, or a combination of both dependent upon the Primary Slots' Volume to Secondary Slots' Volume ratio. The secondary discharge slots can produce honeycomb substrates with much greater surface areas, using an extrusion die with a significantly reduced number of feed holes and a greater number of discharge slots.

Abstract: A reference and support system for a flat CRT tension shadow mask is disclosed which includes a support frame which is frit sealed or shink fitted onto a peripheral surface surrounding a target area of a flat panel. An upper edge of the support frame is finished so as to provide the desired Q-spacing between the target area and the top of the support frame. Alignment holes are drilled in the sidewalls of the support frame at a given distance from the upper edge to form a reference plane relative thereto. A temporary fixture has a tensioned mask initially secured thereto and is provided with a plurality of pins extending through sidewalls thereof at a given distance from an upper reference surface such that the pins engage the holes in the support frame and precisely position the shadow mask in the plane of the top edge of the support surface.

Abstract: An apparatus for use in liquid-phase, gas-phase and mixed-phase reactions is disclosed for providing an efficient flow-through design within which results a low pressure drop. The apparatus may be used as a catalyst or electrocatalyst and consists essentially of a ceramic substrate having thin walls with open porosity wherein said walls define a plurality of cells extending substantially longitudinally parallel through-and-through the substrate. The substrate includes an electrically conductive layer, having a resistivity of no greater than about 100 ohm-cm. The apparatus exhibits an improved structural geometry and provides greater meniscus control.

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

Abstract: A rigid mini-monolith structure formed by extrusion from a die. Such structures are useful as catalyst supports for treating exhaust gases from automobile. The structure is in the shape of a right circular cylinder with a plurality of internal cells extending along the substrate and an opening on both ends. In order to provide maximum crushing strength of the structure, as well as permitting uniform intercell wall thickness at the downstream face of the extrusion die which forms the structure, the majority of the cells are formed in the transverse cross section of a truncated (circular) sector and have the property that they each possess the same hydraulic diameter, although not all are of the same transverse cross sectional shape. The invention also is defined by a novel extrusion die formed by a plurality of concentric, collared tubes provided with longitudinally running slots in the tubes and notches on the collars, the tubes being radially spaced from each other.

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

Abstract: An apparatus and process for producing liquid droplets having a narrow size distribution. Thin liquid streams are forced under pressure through a plurality of orifices in an orifice plate, the largest of which orifices has a diameter not greater than about three times the diameter of the smallest of those orifices. Also the thin liquid streams are vibrated to cause the breakup of each stream into droplets having a narrow size distribution.

Abstract: An improved method for encasing objects in metal is disclosed as are the novel encased objects so prepared. An object is wrapped with a sheet comprising sinterable particulate or powdered metal and an organic binder, and is the fired to volatilize the binder and to sinter the particulate metal into a unitary metal structure. In the preferred embodiment of this invention, the object to be encased is a green sinterable particulate object which undergoes sintering simultaneously with the particulate metal casing during the firing step.

Abstract: Magnesia partially-stabilized zirconia ceramic materials can be prepared from "unpurified" zirconia which contains at least about 0.05 weight percent silica. Despite the relatively high silica content, a thermal shock resistant material can be produced by a firing schedule which includes heating to a top temperature at a specified rate and cooling back to room temperature at specified rates and which incorporates a thermal aging step at 1000-1200.degree. C. Differences in microstructure and monoclinic zirconia content, with consequent differences in physical properties of the ceramic material, can be attained by variations in the firing and thermal-aging schedules.

Abstract: A method is provided of preparing high-purity mixtures of zirconia and another metal oxide substantially free of sodium oxide impurity. Trioxydizirconium ion and a salt of another metal in an aqueous solution are added to a highly basic solution, resulting in the homogeneous precipitation of the combined hydroxides or hydrous oxides. The precipitate is recovered, washed with the water and then with an organic solvent, and then dried, most preferably employing an azeotropic distillation procedure. The resulting material is then calcined to provide a mixture of zirconia with the other metal oxide. In a preferred embodiment, the zirconia mixtures are in the form of fine powders which can be sintered to form a product having greater than 99% of its theoretical density.

Abstract: A method is provided of crystallizing strong-bound zeolites on the surfaces of a monolithic ceramic substrate by hydrothermally treating the substrate, in the presence of active silica, with a caustic bath to zeolitize the silica. According to various embodiments of the invention, the active silica can be present as a component of the caustic bath, in the form of a dried coating pre-deposited on the substrate, or as a separate phase of the monolithic substrate, homogeneous dispersed within the ceramic material.

Abstract: Disclosed is a method for producing substantially unagglomerated submicron metal oxide particles having uniform size distribution. The process is readily adaptable to the production of multicomponent metal oxide particles.

Abstract: Mono-sized barium titanate powders which have high density and substantially pure stoichiometry are provided. The powders can be produced by reacting barium hydroxide with titanium dioxide in a protic solvent at a temperature of at least 100.degree. C. for a period of at least 48 hours, or by reacting barium hydroxide with a titanium alkoxide in a protic solvent at a temperature of about the boiling point of the alkyl alcohol corresponding to the alkoxide for a period of at least about 240 hours.

Abstract: This invention is concerned with the production of hard, porous, sintered bodies consisting essentially of Al and Fe with, optionally, Sn and/or Cu and/or Cr. The mechanism of the invention relies upon the presence of a small amount of Mg and/or Ca to act as a getter for oxygen. In the preferred embodiment, particles of the metals can be extruded into honeycomb structures which can then be fired in the presence of Mg and/or Ca to yield sound high cell density structures of controlled porosity.

Abstract: The invention is a flexible mask for use in charging a flowable material into selected cells of a honeycomb structure and is of particular utility in charging a sealing material into the ends of selected cells of such a structure during fabrication of solid particulate filter bodies and other selectively plugged honeycomb structures. The mask has a central body with a set of openings extending therethrough which allow passage of the flowable material through to the selected cells and a second set of protrusions extending from one of the surfaces of the mask which are used to align the mask to the end face of the structure and which extend into and sealably cover the cells which are not to receive the flowable material. The mask may be formed from a polymer, preferably an elastomer, using any of three disclosed die apparatuses.

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

Abstract: The resistance of a honeycombed structure to damage from asymmetric thermal shock occurring across its surface during use and formed with cells having anisotropic Young's moduli in the planes perpendicular the central longitudinal axis of each cell can be improved by varying the orientation of the anisotropic cells with respect to one another so as to minimize the number of such cells being oriented with an axis of maximum Young's moduli aligned with the direction of either the maximum temperature difference or maximum localized temperature gradient occurring across the cell.