Abstract: A foamed insulating refractory shape is made by: (1) preparing a slip of water, deflocculating agent, refractory aggregate, at least 7.5% by weight cement, and, optionally, clay; (2) forming a foam of water, foaming agent, and air having a density not over about 5 lbs per cubic foot (80 g/l); (3) admixing the slip and the foam to form a foamed slurry with a viscosity between 1000 and 30,000 centipoises, the amount of water in the slip being adjusted to yield the desired viscosity in the foamed slurry; (4) pouring the foamed slurry into molds; (5) curing the pieces so formed at a temperature not over about 72.degree. F. (about 22.degree. C.) for about 16 to 24 hours; (6) drying the pieces at a temperature not over about 200.degree. F. (about 93.degree. C.); and (7) firing the pieces. The method of this invention produces insulating refractory shapes with higher strength-to-weight ratios than those produced by prior art methods.

Abstract: A heat-resistant composite material reinforced with continuous silicon carbide fibers is produced by forming a powdery ceramics matrix and the fibers into a composite, and pressing and heating the composite into a sintered composite. The composite material is excellent in the mechanical strength at a high temperature, heat resistance, oxidation resistance and corrosion resistance.

Abstract: A method of controlling the bulk or pour density of carbon black without altering its rubber reinforcing properties, by wet micropulverizing prior to pin mixing.

Abstract: A method of controlling the bulk or pour density of carbon black without altering its rubber reinforcing properties, by wet micropulverizing prior to pin mixing.

Abstract: A method for fabricating a ceramic prosthesis of high aluminum oxide suite for the tibial plateau of a knee joint with the superior (upper) portion of the prosthesis being of a high density Al.sub.2 O.sub.3 having a very low porosity and the inferior (lower) portion being of high density Al.sub.2 O.sub.3 having a high degree of porosity capable of accepting bone growth. The method of fabricating the prosthesis comprises mixing a powdered batch of high aluminum oxide material to produce a viscous slip, adding a foaming agent to the slip, adding a catalyst to the slip to decompose the foaming agent, infiltrating the slip into a sponge, drying the composite, producing a planar surface on the porous layer, fabricating a second denser layer, placing a slurry between the two layers, drying and sintering the laminate.

Abstract: A method of agglomerating fine ore powders. The invention is used to agglomerate extremely fine flue dust particles in a collection bin and process them before sending the resultant agglomeration to storage or a further processing location. From its collection bin, the dust particles are discharged by gravity upon a lower rapidly rotating smooth horizontal disc. The bin discharge is offset slightly from the disc's center so that the particles are subjected to centrifugal force to move them to the disc's outer periphery. At the point where the particles are discharged on the disc, a liquid binder, like water, is sprayed on the particles to cause them to begin to agglomerate. After being sprayed, the wetted particles are agglomerated under the influence of centrifugal and tangential forces. A scraper may be used to aid in pushing the particles towards the disc's raised outer edge.

Abstract: A multi-sectional filter tip assembly is initially made with two charcoal filter sections and alternate sections of cellulose acetate fibrous material with a fibrous section at each end. The filter tip assembly is then compacted by a pin compactor which punches a recess into each fibrous end of the filter tip assembly while at the same time forcing the displaced acetate fibrous material into the charcoal sections to compact the charcoal. Upon removal of the pins of the pin compactor, a recess is formed in each end of the filter tip assembly.

Abstract: A method of forming a flange on a thermoplastic pipe wherein the end of the pipe is heated, the wall of the pipe is turned back on itself and the turned-back portion is turned outwardly to form a flange.

Abstract: An improved method or process for the continuous manufacture of mats to be processed into composition boards is disclosed, the board-forming process being a dry process involving hot-pressing of the mats and curing of the binder. The mats comprise a fibrous or particulate material or materials, and a binder, the mats being dry. The mat material is laid onto a conveyor by formers or felters. In order to ensure that the resulting composition board has a uniform strength distribution and uniform specific gravity or density, a beta ray density measuring device measures successively the weight of air-borne material passing through a conduit or conduits to the forming apparatus, and the measured value is used to regulate the speed of the conveyor.

Abstract: Uniaxial hot-pressing of ceramic powders to produce monolithic shapes of non-uniform thickness is accomplished by employing a form, preformed to a shape which when properly oriented and uniaxially compressed to final density will deform orderly to assume the final desired shape, and hot-pressing it in a mold against preformed parts having surfaces exactly mating with the surfaces of the preform. Such mold parts have the same compaction ratio as the preform, and a coefficient of thermal expansion substantially equal to that of the preform, and are formed of a powdered composition which is non-reactive with the preform material under hot-pressing conditions. Suitable compositions for the mold part preforms are temporarily bonded mixtures of carbon or graphite powder and a powder material of the preform. The shapes may be slip cast or cold pressed and temporary binders of organic or inorganic material may be employed to give green strength to the parts.

Abstract: Methods of making finely divided product from fly ash compositions, including both dry fly ash compositions and aqueous suspensions of fly ash in combination with alkaline earth metal compounds. The fly ash composition, preferably including 10 to 50% combined alkaline earth metal oxides, is heated to molten condition while collecting gases evolving therefrom, including sulfur oxide gases. The top portion of the melt is then poured in a manner causing a molten stream thereof to be divided into a multiplicity of fractions and cooled to solid form while encompassed by a fluid cooling medium in a manner to produce either a shot or a granulated aggregate product. The bottom portion of the melt is nearly pure metallic iron which is recovered, as such, for other uses. Preferably, the molten stream impinges on a rotating member in a manner to produce shot, or is quenched in a water bath to form a granulated type product.

Abstract: A green ceramic sheet material adaptable for accelerated sintering comprising a high alumina ceramic green sheet having an average particle size greater than one micron with a close particle size distribution and being formed into a solid integrated circuit interconnection substrate by heating the ceramic green sheet directly to its sintering temperature, absent the binder burn-off step.

Abstract: Metallated graphite filament-wound structures are prepared by coating a continuous multi-filament carbon yarn with a metal carbide, impregnating the carbide coated yarn with a polymerizable carbon precursor, winding the resulting filament about a mandrel, partially curing the impregnation in air, subjecting the wound composite to heat and pressure to cure the carbon precursor, and thereafter heating the composite in a sizing die at a pressure loading of at least 1000 psi for graphitizing the carbonaceous material in the composite. The carbide in the composite coalesces into rod-like shapes which are disposed in an end-to-end relationship parallel with the filaments to provide resistance to erosion in abrasive laden atmospheres.

Abstract: A process for producing solid, irregular shaped sulfur nuggets from molten sulfur. The process includes the steps of: gravity flowing molten sulfur at a temperature preferably in the range of about 240.degree.-270.degree. F. to a distributor head positioned closely above or below the surface of a cooling liquid; discharging the molten sulfur from the distributor head in ribbon-shaped streams into a cooling liquid, preferably water, having a temperature in the range of about 170.degree.-190.degree. F.; passing the molten sulfur streams through the cooling liquid until the streams are subdivided and thereafter solidified into nuggets of irregular shape and size; and removing the solid sulfur nuggets from the cooling liquid.

Abstract: An improvement in the method of operating a molding apparatus for use in molding plastic and other materials is provided. The inner mold surfaces of the apparatus are flooded, during operation, with a dehumidified gas such as dry air to minimize condensation of moisture onto these surfaces. This dry air forms a field in the area of the mold surfaces to keep out the normally moist ambient air. The field is exhausted and recirculated to the supply source where it is regenerated and returned to the area of the mold surfaces. In this way, a continuous concentration of dry air is maintained in contact with the mold surfaces. One or more dry air curtains are also established around the dry air field to prohibit moist air from entering the field. The air curtain may be established from the same supply source as the dry field or from a separate source and may also be recirculated. A cloud of dry gas may be emitted outside of the air curtains to further inhibit the flow of moist ambient air to the mold surfaces.

Abstract: A ferrite for magnetostrictrive vibrators is produced by the simple process of press forming a preformed structure formed from starting powder of magnetite or a mixture of magnetite and ferric oxide, said powder having an average particle size d (.mu.) of from 0.02 to 5.0 .mu., sintering this structure in an atmosphere wherein the partial pressure of oxygen is from 10.sup.-1 to 10.sup.-11 atmosphere at a temperature of from 1,000.degree. to 1,350.degree. C. and which will meet the requirement:140 log d+1,305.gtoreq.T(.degree.C.).gtoreq.160 log d+1,180and thereafter cooling the structure thus sintered to room temperature at a cooling rate m (.degree.C./min.) <0.5f where f(KHz) is a corresponding resonance frequency thereby to produce a macroscopically homogeneous ferrite structure containing as its principal constituent a sintered magnetite having an oxygen/iron (O/Fe) atomic ratio of 4.0/3<0/Fe<4.1/3, and a density of at least 90% of the theoretical density.

Abstract: A method of producing a beta-alumina ceramic article containing a doping addition of magnesium oxide or of magnesium oxide and lithium oxide, comprising the steps of wet-milling a precursor material or emulsification of an already powdered precursor material to form an aqueous slurry, spray-drying the slurry to produce a powder, forming the powder into a green shape and sintering the shape, wherein the precursor material contains at least some of the magnesium oxide in the form of magnesium aluminate.

Abstract: This application relates to a process for making ceramic shapes from nonplastic size graded ceramic materials comprising the formulation of a unique batch. The batch is processed in a water-cooled pug mill-extruder to prepare a deaired and densified column. The column is cut into constant volume billets. The billets are then pressed or reformed at low pressures into uniformly sized shapes which are thereafter dried and fired to develop a ceramic bond.

Abstract: For the manufacture of a dielectric with inner blocking layers on the basis of barium titanate smooth fragments, that is a finely ground material after sintering whose composition is equal to or approximately equal to the composition of titanate powder, is added to the titanate powder, which is then transformed through pre-baking before pressing of the desired solids. The addition of such smooth fragments reduces the tolerance on electrical parameters of the dielectric.

Abstract: A flexible building sheet product is prepared by dry molding a slurry comprising predominantly at least one binder component selected from the group consisting of thermoplastic resin emulsions and aqueous solutions of water-soluble polymers, said solutions containing cross-linking agents for said water-soluble polymers, and a matrix component comprising a calcium sulfate dihydrate powder.