Abstract: Certain examples of the present disclosure relate to a method for manufacturing a ceramic object, the method comprising: forming a ceramic structure by 3D printing the ceramic structure with a binder jetting 3D ceramic printer using a ceramic powder and an inorganic binder, wherein the ceramic powder comprises sintered ceramic material; and firing the ceramic structure to form the ceramic object.

Abstract: Certain examples of the present invention relate to a method for manufacturing a ceramic object derived from a 3D printed ceramic structure. The method comprises: carbonising the 3D printed ceramic structure. Such carbonising of the 3D printed ceramic structure may comprise introducing a network of carbon bonding into the 3D printed ceramic structure via: impregnating and/or coating the 3D printed ceramic structure with a carbon precursor, or printing the 3D printed ceramic structure using a ceramic printing medium comprising a carbon precursor. The resultant 3D printed ceramic structure which comprises a carbon precursor is pyrolysed so as to form a network of carbon bonding within/surrounding the 3D printed ceramic structure.

Abstract: A process for making a filter suitable for filtering molten metal comprising (i) forming a slurry comprising (a) particles of a refractory material, (b) a binder and (c) a liquid carrier, (ii) coating a disposable former with a slurry, (iii) drying the coated former, (iv) optionally applying one or more additional coats of a refractory material and/or a binder, optionally with liquid carrier, and drying the one or more additional coats, and (v) firing the coated former to produce the filter, wherein the binder is a carbon rich source selected from one or more of the following classes of materials: pitches, tars and organic polymers that degrade to form carbon on pyrolysis.

Abstract: The present invention relates to a ceramic filter device for molten metal filtration comprising a major ceramic phase and a minor carbon phase bonded by phosphate bond, a method for producing such filter devices, and the use of such filter devices for the filtration of molten steel.

Abstract: A filter for molten metal, the filter comprising a perforated surface and the perforated surface retaining a filter media for contact with a molten metal passing in use across the perforated surface between perforations of the perforated surface.

Abstract: The present invention relates to a fiber reinforced ceramic filter for molten metal filtration that comprises a bonded network of graphitized carbon and a method for producing such filters.

Abstract: A process for making a filter suitable for filtering molten metal comprising (i) forming a slurry comprising (a) particles of a refractory material, (b) a binder and (c) a liquid carrier, (ii) coating a disposable former with a slurry, (iii) drying the coated former, (iv) optionally applying one or more additional coats of a refractory material and/or a binder, optionally with liquid carrier, and drying the one or more additional coats, and (v) firing the coated former to produce the filter, wherein the binder is a carbon rich source selected from one or more of the following classes of materials: pitches, tars and organic polymers that degrade to form carbon on pyrolysis.

Abstract: The present invention relates to a ceramic filter device for molten metal filtration comprising a major ceramic phase and a minor carbon phase bonded by phosphate bond, a method for producing such filter devices, and the use of such filter devices for the filtration of molten steel.

Abstract: A filter for molten metal is an open-pored porous material comprising particles of refractory material embedded in and bonded together by a carbon matrix bonding material. The filter can be made by forming a porous article from refractory particles, e.g. refractory oxide, carbide or graphite, and a carbon-rich binder, e.g. tar, pitch or an organic (preferably aromatic) polymer that degrades to form carbon on pyrolysis, and then firing the porous article to generate the carbon matrix in which the refractory particles are embedded. The porous article is preferably made by coating a reticulated polyurethane foam with binder and refractory particles, and firing at preferably no higher than 800° C.

Abstract: A filter for molten metal is an open-pored porous material comprising particles of refractory material embedded in and bonded together by a carbon matrix bonding material. The filter can be made by forming a porous article from refractory particles, e.g. refractory oxide, carbide or graphite, and a carbon-rich binder, e.g. tar, pitch or an organic (preferably aromatic) polymer that degrades to form carbon on pyrolysis, and then firing the porous article to generate the carbon matrix in which the refractory particles are embedded. The porous article is preferably made by coating a reticulated polyurethane foam with binder and refractory particles, and firing at preferably no higher than 800° C.

Abstract: A filter for molten metal is an open-pored porous material comprising particles of refractory material embedded in and bonded together by a carbon matrix bonding material. The filter can be made by forming a porous article from refractory particles, e.g. refractory oxide, carbide or graphite, and a carbon-rich binder, e.g. tar, pitch or an organic (preferably aromatic) polymer that degrades to form carbon on pyrolysis, and then firing the porous article to generate the carbon matrix in which the refractory particles are embedded. The porous article is preferably made by coating a reticulated polyurethane foam with binder and refractory particles, and firing at preferably no higher than 800° C.

Abstract: The invention relates to a filter device for molten steel filtration and a process for the preparation thereof. The filter device (1) comprising a bonded network of graphitized carbon for molten steel filtration characterized by the presence of at least two sieve plates (2, 4) spaced apart to each other, in particular providing a reservoir chamber 7.

Abstract: The present invention relates to a fiber reinforced ceramic filter for molten metal filtration that comprises a bonded network of graphitized carbon and a method for producing such filters.

Abstract: Refractory articles and methods for producing refractory articles are provided. One method comprises producing a mix of particulate pitch, ceramic filler and water, spray drying the mix, pressing the spray dried mix to form an intermediate product and heating the intermediate product to product a refractory article comprising graphitisable carbon bond.

Abstract: A filter for molten metal is an open-pored porous material comprising particles of refractory material embedded in and bonded together by a carbon matrix bonding material. The filter can be made by forming a porous article from refractory particles, e.g. refractory oxide, carbide or graphite, and a carbon-rich binder, e.g. tar, pitch or an organic (preferably aromatic) polymer that degrades to form carbon on pyrolysis, and then firing the porous article to generate the carbon matrix in which the refractory particles are embedded. The porous article is preferably made by coating a reticulated polyurethane foam with binder and refractory particles, and firing at preferably no higher than 800° C.

Abstract: Ceramic compositions which are of particular value in the handling or casting of steel, for example as lining materials or for producing nozzles or shrouds used in continuous casting, comprise a mixture of particles of boron nitride, zirconium diboride and at least one other refractory material, bonded together by carbon produced by the decomposition of an organic binder such as a resin or pitch. The other refractory material may be for example a refractory metal, an oxide, a carbide, a boride or a nitride. Zirconium oxide containing compositions comprising 5-70% by weight boron nitride, 5-60% by weight zirconium diboride and 5-80% by weight of zirconium oxide are particularly suitable for forming at least that part of a nozzle which in use is at the slag line in a molten steel vessel.

Abstract: An improved ceramic composite material is provided based on zirconia and boron nitride that can be satisfactorily bonded without sintering.The material comprises a particulate mixture of boron nitride, stabilized zirconia and silicon nitride bonded together by whiskers of silicon nitride. The silicon nitride whiskers may conveniently be formed in-situ by heating the mixture of particulate boron nitride, stabilized zirconia and silicon nitride together with powdered metallic silicon in an atmosphere of nitrogen.

Abstract: The invention relates to grinding tools, particularly to grinding wheels having an annular band of abrasive material at their periphery and provides an improved method of manufacture. A mixture of abrasive material, temporary binder and ceramic bond is heated to paste-like consistency and then coated on to the desired part of a support member, e.g. on to hub (5) of wheel (4) in the form of an annular band (11). The coated support member is then fired to drive off the temporary binder whereby the coating is firmly bonded to the support member.