Abstract: A structure comprising a mixture of metals and metal alloys which are sintered into a hard porous body is presented. The structure can be useful for many different chemical and physical purposes, such as for catalysis, desorption and absorption, and selective leaching of the structure components into solutions.

Abstract: Laminated extruded thermal shock resistant composite articles formed from sinterable particulate or powdered materials such as ceramics are disclosed. The laminated extruded composite articles have multiple discrete layers of at least a first and second sintered material, where the first and second sintered materials are different and are selected from high strength sintered particulate or powdered materials and where the layers of each of said first and second sintered materials are substantially uniformly distributed throughout the article.

Abstract: A monolithic ceramic structure, useful as a support for catalytic material or as a fluid filter, has a high surface area phase which consists essentially of a porous metal oxide material, at least 50% by weight of which is alumina, titania, and/or zirconia, and phosphate dispersed substantially througout the porous metal oxide material. The presence of the phosphate stabilizes the porous metal oxide material against thermal degradation during sintering or exposure to elevated temperatures encountered in catalytic service and thereby aids in the retention of higher overall surface area in the monolithic structure.

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: 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 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 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: High surface area agglomerates of a porous oxide for the support of catalysts are provided. The agglomerates, in coarse particulate form, are incorporated into a sinterable ceramic structure as a discrete discontinuous phase. The agglomerates provide the high surface area necessary for effective catalyst support within the ceramic structure, which is sintered to provide appreciable density and strength.

Abstract: A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.

Abstract: Monolithic catalyst support structures in which a support phase of high surface area oxide material is disposed on or within a sintered ceramic material are improved by using a mixture of alumina and silica as the high surface area oxide support phase. The mixtures of alumina and silica retain higher surface area, after firing or exposure to elevated service temperatures, than does either component individually, and thereby impart higher overall surface area to the monolithic support structures.

Abstract: A method of forming a monolithic ceramic catalyst support having a high surface area phase of porous oxide embedded within the monolith structure is provided. The porous oxide phase is incorporated into a sinterable ceramic structure as a discrete discontinuous phase. The high surface area necessary for effective catalyst support is thereby provided within the ceramic structure, which is sintered to provide appreciable density and strength.

Abstract: A catalyst support having both substantial high strength and high surface area can be produced by heating a shaped mixture of a porous oxide having a surface area of at least 20 m.sup.2 /g and the precursor of an inorganic binder for the porous oxide. The binders are precursors of alumina, silica, or titania, and are capable of imparting substantial strength to the support at relatively low firing temperatures.

Abstract: This invention is concerned with the production of catalyst-coated, ceramic honeycomb structures wherein the ceramic contains microcracks and wherein a washcoat is applied to the honeycomb structures prior to the application of the catalyst. The invention contemplates depositing an organic material in the microcracks and, preferably, carbonizing said organic material prior to application of the washcoat, and which is burned out after application of the washcoat.

Abstract: This invention is directed to the production of sintered ceramic articles wherein aluminum titanate and mullite constitute the predominant crystal phases and wherein the microstructure thereof evidences grain boundary and intracrystalline microcracking. The articles have base compositions encompassed within the area I, J, K, L, M, I of the drawing to which 0.5-5% Fe.sub.2 O.sub.3 and/or 0.5-5% rare earth metal oxide may be added.

Abstract: Impervious, unglazed, sintered ceramic products of primarily cordierite crystal phase, exhibiting low coefficients of thermal expansion and having analytical molar composition of about 1.7-2.4 RO . 1.9-2.4 Al.sub.2 O.sub.3 . 4.5-5.2 SiO.sub.2, are formed of mineral batch compositions that are: (a) wholly raw ceramic material wherein RO comprises about 55-95 mole % MnO and 5-45% MgO, or (b) at least about 50 wt.% prereacted cordierite material and the balance thereof raw ceramic material, and wherein RO comprises about 5-40 mole % MnO and 60-95 mole % MgO.

Abstract: Glass-ceramic products having a manganese-containing cordierite crystal structure and being impervious void free bodies exhibiting low coefficients of thermal expansions of .about.15.times.10.sup.-7 /.degree.C. (25.degree.-1000.degree. C.) and high electrical resistivity are obtained by the sintering of glass or glass-ceramic powders having the molar composition of about 2RO.2Al.sub.2 O.sub.3.5SiO.sub.2, wherein RO is a combination of MgO and MnO.

Abstract: The addition of zirconium hydroxide to zirconia ceramic material in amounts >11 wt. % of the ceramic batch material plus hydroxide results in the development of a porous sintered zirconia-containing body for use as catalyst substrates and insulating refractories.

Abstract: Glass-ceramic products having a manganese-containing cordierite crystal structure and being impervious void free bodies exhibiting low coefficients of thermal expansions of .about.15.times.10.sup.-7 /.degree. C. (25.degree.-1000.degree. C.) and high electrical resistivity are obtained by the sintering of glass or glass-ceramic powders having the molar composition of about 2RO.2Al.sub.2 O.sub.3.5SiO.sub.2, wherein RO is a combination of MgO and MnO.

Abstract: Cracking of large monolithic cordierite segments and in particular monolithic honeycombed substrates having a matrix of thin walls forming a multiplicity of open ended cells extending from one end of the substrate to the other end is reduced or eliminated by limiting the amount of raw clay used in formulating the clay-talc-alumina raw material batch. The raw clay may be eliminated entirely but is preferably at least 10% of the whole batch and not more than 31% of the whole batch with the balance of the clay constituent to the raw material batch being calcined clay. The raw material batch is preferably formulated to yield at least 90% cordierite phase upon reaction during sintering.

Abstract: Coarse porosity is imposed in fired ceramic bodies containing cordierite (2MgO.2Al.sub.2 O.sub.3.5SiO.sub.2) primary phase by substituting pyrophillite, kyanite, quartz, or fused silica in the batch composition in place of the usual raw talc or clay or a portion thereof.