Abstract: A method for firing a green honeycomb ceramic body in a kiln may include heating the green honeycomb ceramic body in four stages. The first stage may include heating the green honeycomb ceramic body from room temperature to a first temperature that at a first heating rate that is greater than or equal to about 75° C./hr. The second stage may include heating the green honeycomb ceramic body from the first temperature to a second temperature at a second heating rate that is less than or equal to the first heating rate. The third stage may include heating the green honeycomb ceramic body from the second temperature to a hold temperature at a third heating rate that is less than or equal to the first heating rate. The fourth stage may include holding the green honeycomb ceramic body at the hold temperature to remove residual carbon.

Abstract: Disclosed herein are methods for making a solid lithium ion electrolyte membrane, the methods comprising combining a first reactant chosen from amorphous, glassy, or low melting temperature solid reactants with a second reactant chosen from refractory oxides to form a mixture; heating the mixture to a first temperature to form a homogenized composite, wherein the first temperature is between a glass transition temperature of the first reactant and a crystallization onset temperature of the mixture; milling the homogenized composite to form homogenized particles; casting the homogenized particles to form a green body; and sintering the green body at a second temperature to form a solid membrane. Solid lithium ion electrolyte membranes manufactured according to these methods are also disclosed herein.

Abstract: A method for firing a green honeycomb ceramic body including heating the green honeycomb ceramic body from room temperature to a first temperature of about 300° C. The green honeycomb ceramic body is then heated from the first temperature to a second temperature of greater than or equal to about 800° C. at a heating rate of greater than or equal to about 90° C./hr. The green honeycomb ceramic body may have a diameter of from greater than or equal to about 4.0 inches to less than or equal to about 9.0 inches, and it may include a carbon-based pore former in a concentration of from greater than or equal to about 10% to less than or equal to about 45% by weight.

Abstract: Disclosed herein are methods for making a solid lithium ion electrolyte membrane, the methods comprising combining a first reactant chosen from amorphous, glassy, or low melting temperature solid reactants with a second reactant chosen from refractory oxides to form a mixture; heating the mixture to a first temperature to form a homogenized composite, wherein the first temperature is between a glass transition temperature of the first reactant and a crystallization onset temperature of the mixture; milling the homogenized composite to form homogenized particles; casting the homogenized particles to form a green body; and sintering the green body at a second temperature to form a solid membrane. Solid lithium ion electrolyte membranes manufactured according to these methods are also disclosed herein.

Abstract: Methods of firing a cordierite green body to form a fired cordierite body. The green body comprises cordierite-forming raw materials and organic material, the body having a core portion and a skin portion. The green body is pre-heated to a pre-heat temperature that is less than a thermal decomposition temperature of the organic material. The green body is maintained at the pre-heat temperature for a period of time sufficient to minimize a temperature differential between the core portion and the skin portion. The green body is heated to a low firing temperature in a firing atmosphere sufficient to reduce a content of the organic material and to substantially remove chemically bound water from hydrous alumina. The green body is heated to a high firing temperature in a firing atmosphere sufficient to reduce the content of the organic material prior to a substantial removal of chemically bound water from clay.

Abstract: A method for making a cordierite filter article, including: firing an extruded green body batch composition according to: a first temperature ramping from ambient temperature up to a first soaking temperature; a first soaking at a temperature of at least 1255° C. for at least 2 hours; a second temperature ramping from the first soak temperature down to a second soak temperature; and a second soaking at a temperature of at least 1250° C. and at least 5° C. below the first soaking temperature, as defined herein.

Abstract: A method for firing a green honeycomb ceramic body including heating the green honeycomb ceramic body from room temperature to a first temperature of about 300° C. The green honeycomb ceramic body is then heated from the first temperature to a second temperature of greater than or equal to about 800° C. at a heating rate of greater than or equal to about 90° C./hr. The green honeycomb ceramic body may have a diameter of from greater than or equal to about 4.0 inches to less than or equal to about 9.0 inches, and it may include a carbon-based pore former in a concentration of from greater than or equal to about 10% to less than or equal to about 45% by weight.

Abstract: A method for firing a green honeycomb ceramic body in a kiln may include heating the green honeycomb ceramic body in four stages. The first stage may include heating the green honeycomb ceramic body from room temperature to a first temperature that at a first heating rate that is greater than or equal to about 75° C./hr. The second stage may include heating the green honeycomb ceramic body from the first temperature to a second temperature at a second heating rate that is less than or equal to the first heating rate. The third stage may include heating the green honeycomb ceramic body from the second temperature to a hold temperature at a third heating rate that is less than or equal to the first heating rate. The fourth stage may include holding the green honeycomb ceramic body at the hold temperature to remove residual carbon.

Abstract: Methods of firing a cordierite green body to form a fired cordierite body. The green body comprises cordierite-forming raw materials and organic material, the body having a core portion and a skin portion. The green body is pre-heated to a pre-heat temperature that is less than a thermal decomposition temperature of the organic material. The green body is maintained at the pre-heat temperature for a period of time sufficient to minimize a temperature differential between the core portion and the skin portion. The green body is heated to a low firing temperature in a firing atmosphere sufficient to reduce a content of the organic material and to substantially remove chemically bound water from hydrous alumina. The green body is heated to a high firing temperature in a firing atmosphere sufficient to reduce the content of the organic material prior to a substantial removal of chemically bound water from clay.

Abstract: A method for making a cordierite filter article, including: firing an extruded green body batch composition according to: a first temperature ramping from ambient temperature up to a first soaking temperature; a first soaking at a temperature of at least 1255° C. for at least 2 hours; a second temperature ramping from the first soak temperature down to a second soak temperature; and a second soaking at a temperature of at least 1250° C. and at least 5° C. below the first soaking temperature, as defined herein.

Abstract: A method of firing a green structure to produce a ceramic structure may comprise heating a firing environment during a first stage of firing of a green structure over a first timed temperature cycle having an average ramp rate sufficient to substantially complete burnout of organic material prior to initiation of clay dehydration proximate a core of the ceramic structure. The method may further comprise heating the firing environment during a second stage of the firing over a second timed temperature cycle having an average ramp rate that is faster than the average ramp rate of the first timed temperature cycle.

Abstract: A method for making porous articles, including: depositing a powder mixture layer comprising a binder powder, and at least one structural powder; contacting the powder mixture layer and an aqueous liquid to selectively activate the binder powder and form a green layer; repeating the depositing and the contacting sequence at least one time; and de-powdering and drying of the resulting green body. The binder powder can include, for example, a protein that is soluble in water at or below about 25° C. The disclosure also provides articles, having high porosity and optionally intricate 3D structures, as defined herein.

Abstract: A method of firing a green structure to produce a ceramic structure may comprise heating a firing environment during a first stage of firing of a green structure over a first timed temperature cycle having an average ramp rate sufficient to substantially complete burnout of organic material prior to initiation of clay dehydration proximate a core of the ceramic structure. The method may further comprise heating the firing environment during a second stage of the firing over a second timed temperature cycle having an average ramp rate that is faster than the average ramp rate of the first timed temperature cycle.