Abstract: A porous cordierite substrate and a method of forming a porous cordierite substrate including providing a fiber that includes at least one cordierite precursor material and providing at least one organic binder material. The fiber and the organic binder material are mixed with a fluid. The mix of fiber, organic binder material and fluid is extruded into a green substrate. The green substrate is fired to enable the formation of bonds between the fibers and to form a porous cordierite fiber substrate.

Abstract: A porous cordierite substrate and a method of forming a porous cordierite substrate including providing a fiber that includes at least one cordierite precursor material and providing at least one organic binder material. The fiber and the organic binder material are mixed with a fluid. The mix of fiber, organic binder material and fluid is extruded into a green substrate. The green substrate is fired to enable the formation of bonds between the fibers and to form a porous cordierite fiber substrate.

Abstract: A fibrous silicon carbide substrate is disclosed that is formed from a reaction between carbon fibers and silicon additives, to provide in-situ silicon carbide fibers. The fibrous structure is formed from a paper-making process of carbon or organic fibers that form a plurality of lamination members. The lamination members, each having a plurality of through holes, that when aligned in a lamination direction, form a honeycomb array of channels. The lamination members can be adapted into a wall-flow configuration for use in filtration of the exhaust of internal combustion engines.

Abstract: A fibrous silicon carbide substrate is disclosed that provides porosity through an open network of pores resulting from an intertangled arrangement of silicon carbide fibers. The fibrous structure is formed from mixing carbon or organic fibers with silicon based additives, and forming a honeycomb substrate. The carbon or organic fibers are heated in an inert environment to form silicon carbide through a reaction of the carbon in the fibers and the silicon-based additives.

Abstract: A fibrous silicon carbide substrate is disclosed that provides porosity through an open network of pores resulting from an intertangled arrangement of silicon carbide fibers. The fibrous structure is formed from mixing carbon or organic fibers with silicon based additives, and forming a honeycomb substrate. The carbon or organic fibers are heated in an inert environment to form silicon carbide through a reaction of the carbon in the fibers and the silicon-based additives.

Abstract: A method is disclosed for repairing damage to an airfoil. The method provides for the removal of a section of the airfoil that substantially encompasses the damaged area, which consequently leaves a void and a cut-away surface in the airfoil. A replacement piece larger than the residual void is provided for use in replacing the section removed from the airfoil. A joining operation welds or otherwise joins the replacement piece to the airfoil at the cut-away surface to form a joined airfoil. The joined airfoil has a seam between the airfoil and the replacement piece. At least a portion of the seam is processed by laser shock peening to induce compressive residual stresses therein.

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: This invention relates to novel macrocomposite bodies. More particularly, it has been discovered that the properties of a ceramic, ceramic matrix composite or metal matrix composite body may be improved by providing on at least a portion of the surface of the body a polymer-based material which serves to protect the body from damage which might occur in the absence of the polymer-based material. One particularly preferred embodiment of the present invention is a macrocomposite shaft sleeve. Another particularly preferred embodiment is a macrocomposite apex used in a hyrocyclone separator.

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: A self-supporting ceramic body produced 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: A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix embedding a filler, includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal and, optionally, one or more metallic constituents. The method includes heating the parent metal to provide a source of molten parent metal and a reservoir of molten metal which is in communication with the parent metal and contacting the molten parent metal with a permeable bedding of filler. The molten parent metal reacts with the oxidant to form the oxidation reaction product and is replenished by the reservoir as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired extent and thereby embed at least a portion of the bedding of filler within the oxidation reaction product to form the ceramic composite structure.

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: A method of producing a self-supporting ceramic or ceramic composite structures which includes providing a first self-supporting ceramic or ceramic composite 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 an oxidant, a second polycrystalline material which is infiltrated into the porosity of at least a portion of said first ceramic body.

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: A fired ceramic core for use in aluminum investment casting, which will withstand steam autoclaving and which may be rendered water disruptible; comprising from about 20 to 50% by weight of one or more water soluble salts, together with inert ceramic fillers selected to meet desired thermoexpansion compatability for the shell with which said core is to be used; said core being vacuum impregnated with ethyl silicate and a cured phenolic resin.

Abstract: A method for producing a self-supporting ceramic composite structure comprising a ceramic matrix embedding a filler, includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal and, optionally, one or more metallic constituents. The method includes heating the parent metal to provide a source of molten parent metal and a reservoir of molten metal which is in communication with the parent metal having a chemical composition which is different from the parent metal and contacting the molten parent metal with a permeable bedding of filler. The molten parent metal reacts with the oxidant to form the oxidation reaction product and is replenished by the reservoir as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired extent and thereby embed at least a portion of the bedding of filler within the oxidation reaction product to form the ceramic composite structure.

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.