Abstract: A composite milling component comprising a composite region of ceramic material and metal is disclosed. The milling component may comprise a lifting member such as a digger shoe of a vertical tower mill, a flight liner of a vertical tower mill, a shell liner of a horizontal axis mill, and/or an end liner of a horizontal axis mill. The composite region may be formed into a portion of the milling component that experiences greater wear than other portions to increase a wear-resistance of the milling component. The composite region may be formed integrally into the milling component during a casting processes of the milling component.

Abstract: A composite milling component comprising a composite region of ceramic material and metal is disclosed. The milling component may comprise a lifting member such as a digger shoe of a vertical tower mill, a flight liner of a vertical tower mill, a shell liner of a horizontal axis mill, and/or an end liner of a horizontal axis mill. The composite region may be formed into a portion of the milling component that experiences greater wear than other portions to increase a wear-resistance of the milling component. The composite region may be formed integrally into the milling component during a casting processes of the milling component.

Abstract: A composite milling component comprising a composite region of ceramic material and metal is disclosed. The milling component may comprise a lifting member such as a digger shoe of a vertical tower mill, a flight liner of a vertical tower mill, a shell liner of a horizontal axis mill, and/or an end liner of a horizontal axis mill. The composite region may be formed into a portion of the milling component that experiences greater wear than other portions to increase a wear-resistance of the milling component. The composite region may be formed integrally into the milling component during a casting processes of the milling component.

Abstract: Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

Abstract: Methods and processes are described that form ceramic wear surfaces on the outer surface of a cast part. A mold having a mold cavity is provided. The mold cavity may be washed using a refractory wash to provide for a smoother finish to the surface of the cast part and to maintain mold integrity. An adhesive is applied to predetermined locations in which increased wear during the use of the cast parts is anticipated to occur. Ceramic material may be applied to the predetermined locations by various means. A mask may be used to remove excess material from areas other than the predetermined locations. A molten metal is poured into the mold cavity and allowed to cool to form a cast part with a ceramic wear surface.

Abstract: An apparatus and methods for controlling the location and distribution of loose ceramic particles in a ceramic metal composite component formed via casting. A retaining structure that may include loose ceramic particles is placed in a casting mold at a desired location for ceramic particles in the composite component prior to pouring molten metal into the casting mold. Alternatively, the loose ceramic particles may be introduced into the mold concurrently with the molten metal.

Abstract: An apparatus and methods for controlling the location and distribution of loose ceramic particles in a ceramic metal composite component formed via casting. A retaining structure that may include loose ceramic particles is placed in a casting mold at a desired location for ceramic particles in the composite component prior to pouring molten metal into the casting mold. Alternatively, the loose ceramic particles may be introduced into the mold concurrently with the molten metal.

Abstract: Seam protected encapsulated arrays of solid ceramic elements are disclosed. Vulnerable seams between solid ceramic elements arranged adjacent to each other in encapsulated arrays of solid ceramic elements are protected by a seam protector arranged in-line with the vulnerable seams and fixed to the encapsulated array. A stiffener may be arranged in-line with the vulnerable seams and fixed to the encapsulated array opposite to the seam protector. The solid ceramic elements may be encapsulated in a barrier material to prevent the base metal from reacting with the ceramic material units during casting, and/or provide crush/compression protection during cooling.

Abstract: Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

Abstract: Composite wear parts including encapsulated preformed ceramic shapes are disclosed. Preformed ceramic shapes are embedded in a metal alloy to protect the base metal from abrasion. The preformed ceramic shapes may have a uniform, preformed geometry that provides for packing the preformed ceramic shapes together in a uniform way. The preformed ceramic shapes may be positioned at a location in the composite wear part exposed to an abrasion without using a binding agent. The preformed ceramic shapes may also be contained in a porous container. A truss structure may be integrated in the preformed ceramic shapes to compartmentalize the preformed ceramic shapes into multiple isolated sub regions to stiffen the composite wear parts.

Abstract: Composite wear parts including encapsulated preformed ceramic shapes are disclosed. Preformed ceramic shapes are embedded in a metal alloy to protect the base metal from abrasion. The preformed ceramic shapes may have a uniform, preformed geometry that provides for packing the preformed ceramic shapes together in a uniform way. The preformed ceramic shapes may be positioned at a location in the composite wear part exposed to an abrasion without using a binding agent. The preformed ceramic shapes may also be contained in a porous container. A truss structure may be integrated in the preformed ceramic shapes to compartmentalize the preformed ceramic shapes into multiple isolated sub regions to stiffen the composite wear parts.

Abstract: Anti-ballistic component including encapsulated preformed ceramic shapes are disclosed. Preformed ceramic shapes having a preformed geometry are encapsulated in a metal alloy to stiffen and lighten an anti-ballistic component. The preformed ceramic shapes may be arranged in layers of uniform arrays of preformed ceramic shapes and contained in a porous container to receive the metal alloy during a casting process. A truss structure may be integrated in the preformed ceramic shapes to compartmentalize the preformed ceramic shapes into multiple isolated sub regions to stiffen the anti-ballistic component.

Abstract: Seam protected encapsulated arrays of solid ceramic elements are disclosed. Vulnerable seams between solid ceramic elements arranged adjacent to each other in encapsulated arrays of solid ceramic elements are protected by a seam protector arranged in-line with the vulnerable seems and fixed to the encapsulated array. A stiffener may be arranged in-line with the vulnerable seems and fixed to the encapsulated array opposite to the seam protector. The solid ceramic elements may be encapsulated in a barrier material to prevent the base metal from reacting with the ceramic material units during casting, and/or provide crush/compression protection during cooling.

Abstract: Encapsulated arrays with tiles covered with a barrier layer are disclosed. Tiles formed of silicon carbide, and wrapped with a barrier layer, are encapsulated with a base metal formed of a steel alloy. During a casting process, to fabricate the encapsulated arrays, the barrier layer prevents the steel alloy and/or the silicon carbide from compromising each other.

Abstract: A composite ballistic armor or other composite component may be formed by encapsulating one or more ceramic elements in a casting shell and introducing molten base metal into the casting shell, such that the molten base metal encapsulates the one or more ceramic elements to form the composite component. Prior to the pouring process, the ceramic elements are pre-heated to, or near, the melting point temperature or pouring temperature of the encapsulating metal. Additionally, the cooling rate following the metal pour may be less than a predetermined rate for a predetermined period of time. The encapsulating metal may comprise, for example, a steel alloy, such as 4140 or 8630 AISI, a stainless steel alloy, or FeMnAl.

Abstract: Chutes and other components may include composite liners to improve performance. Composite liners generally comprise a base metal having a ceramic material embedded therein. The composite liners exhibit improved resistance to wear and, therefore, have a longer usable life than liners formed of the base metal alone.

Abstract: A composite ballistic armor or other composite component may be formed by encapsulating one or more ceramic elements in a casting shell and introducing molten base metal into the casting shell, such that the molten base metal encapsulates the one or more ceramic elements to form the composite component. Prior to the pouring process, the ceramic elements are pre-heated to, or near, the melting point temperature or pouring temperature of the encapsulating metal. Additionally, the cooling rate following the metal pour may be less than a predetermined rate for a predetermined period of time. The encapsulating metal may comprise, for example, a steel alloy, such as 4140 or 8630 AISI, a stainless steel alloy, or FeMnAl.

Abstract: A composite ballistic armor or other composite component may be formed by placing one or more ceramic cores in a mold and introducing molten base metal into the mold, such that the molten base metal encapsulates the one or more ceramic cores to form the composite component. The ceramic cores may comprise, for example, porous packed-particle ceramic cores or pre-cast porous ceramic cores. The base metal may comprise, for example, a steel alloy, such as FeMnAl.

Abstract: Methods and processes are described that form ceramic wear surfaces on the outer surface of a cast part. A mold having a mold cavity is provided. The mold cavity may be washed using a refractory wash to provide for a smoother finish to the surface of the cast part and to maintain mold integrity. An adhesive is applied to predetermined locations in which increased wear during the use of the cast parts is anticipated to occur. Ceramic material may be applied to the predetermined locations by various means. A mask may be used to remove excess material from areas other than the predetermined locations. A molten metal is poured into the mold cavity and allowed to cool to form a cast part with a ceramic wear surface.

Abstract: An apparatus and methods for controlling the location and distribution of loose ceramic particles in a ceramic metal composite component formed via casting. A retaining structure that may include loose ceramic particles is placed in a casting mold at a desired location for ceramic particles in the composite component prior to pouring molten metal into the casting mold. Alternatively, the loose ceramic particles may be introduced into the mold concurrently with the molten metal.