Abstract: The present invention relates to novel methods for shaping a filler material into a porous preform and subsequently filling at least a portion of the porous preform with a second material to form a composite body. Specific aspects of the invention include novel combinations of materials to form the preform in combination with novel processing techniques for shaping the combinations of materials into a porous preform.

Abstract: This invention relates to the discovery of organometallic ceramic precursor binders used to fabricate shaped bodies by different techniques. Exemplary shape making techniques which utilize hardenable, liquid, organometallic, ceramic precursor binders include the fabrication of negatives of parts to be made (e.g., sand molds and sand cores for metalcasting, etc.), as well as utilizing ceramic precursor binders to make shapes directly (e.g., brake shoes, brake pads, clutch parts, grinding wheels, polymer concrete, refractory patches and liners, etc.). In a preferred embodiment, this invention relates to thermosettable, liquid ceramic precursors which provide suitable-strength sand molds and sand cores at very low binder levels and which, upon exposure to molten metalcasting exhibit low emissions toxicity as a result of their high char yields of ceramic upon exposure to heat. Another preferred embodiment of the invention involves the fabrication of preforms used in the formation of composite articles.