Abstract: Disclosed are cordierite bodies having relatively high porosity and controlled pore size. The porous cordierite bodies generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite bodies.

Abstract: A method is disclosed for manufacturing a zircon composition, the method comprising contacting a zircon powder with a sintering aid, wherein the sintering aid is in the form of a liquid, a sol, or a combination thereof. Also disclosed are methods for forming the zircon composition into a desired shape and for firing a composition to produce a ceramic body. The zircon composition and ceramic body produced by the described methods are also disclosed.

Abstract: Disclosed are cordierite bodies having relatively low thermal mass with good mechanical strength. The porous cordierite bodies generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite bodies.

Abstract: A method for strengthening an extruded catalyst honeycomb filter body, including: contacting an extruded catalyst honeycomb filter body and a siliceous formulation including at least one siliceous source comprising a silicone emulsion, a silica sol, or a combination thereof; drying the contacted filter body; and firing the dried contacted filter body to provide the filter body. Also disclosed are zeolite-based honeycomb filter articles, including a matrix of walls of: a primary phase material homogeneously distributed throughout the walls, as defined herein.

Abstract: Disclosed are ceramic honeycomb articles which are composed predominately of a crystalline phase cordierite composition. The porous cordierite ceramic honeycomb articles has a plurality of cell channels and intersecting porous walls and possess a microstructure characterized by a pore size distribution wherein greater than or equal to 75% of the pore size distribution of the porosity of the porous walls, by volume, have a pore diameter (dv) wherein dv<10.0 ?m and less than or equal to 35% of the pore size distribution have dv?4.0 ?m. Additionally, the pore diameter dv90?14.0 ?m, and CTE?12.0×10?7/° C. from 25° C. to 800° C. The articles exhibits high filtration efficiency coupled with low pressure drop across the filter. Additionally, high porosity articles having porosity greater than or equal to 40% and low surface roughness of Ra<4.0 ?m are described.

Abstract: Glass-bonded ceramics made of non-microcracked non-oxide or oxide ceramic particles which are bound together by glass into a unitary non-microcracked structure are disclosed. Such ceramics are suitable for use in substrates and filters, such as a diesel particulate filter.

Abstract: A method for manufacturing a refractory ceramic body is disclosed. The method comprises contacting a zirconia precursor, a silica precursor, a sol-gel forming agent, and a preformed zircon. The method can further comprise forming the composition into a desired shape and firing the desired shape to form a dense, creep resistant refractory body. An article made by the methods above is disclosed, wherein a fine particle zircon is formed within and/or between grains of a preformed zircon.

Abstract: Disclosed are cordierite bodies having relatively high porosity and controlled pore size. The porous cordierite bodies generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite bodies.

Abstract: Disclosed are cordierite bodies having relatively low thermal mass with good mechanical strength. The porous cordierite bodies generally include a primary cordierite ceramic phase as defined herein. Also disclosed are methods for making and using the cordierite bodies.

Abstract: A composite material consisting essentially of ZrSiO4 and sintering additives selected from Type I, Type II and Type III sintering additives and combinations thereof in amounts indicated below: Type I: 0.0-0.1 wt % selected from Fe2O3, SnO2, oxide glasses, and mixtures and combinations thereof Type II: 0.1-0.8 wt % selected from TiO2, SiO2, VO2, CoO, NiO, NbO, and mixtures and combinations thereof Type III: 0.0-0.8 wt % selected from Y2O3, ZrO2, CaO, MgO, Cr2O3, Al2O3, and mixtures and combinations thereof wherein the amount of sintering additives are weight percentages on an oxide basis of the total weight of the composition, as well as method for making such composite material. The present invention is particularly useful for making large-size refractory bodies resistant to creep at an elevated operating temperature, such as an isopipe for fusion draw glass making processes.

Abstract: Disclosed are cement compositions for applying to honeycomb substrates. The cement compositions contain an inorganic powder batch composition; a binder; a liquid vehicle; and an elastic modulus reducing additive. The elastic modulus reducing additive can contain a ceramic fiber or a monohydrated alumina. The cement compositions are well suited for forming ceramic diesel particulate wall flow filters. Also disclosed herein are end plugged wall flow filters that include the disclosed cement compositions and methods for the manufacture thereof.

Abstract: A method is disclosed for manufacturing a zircon composition, the method comprising contacting a zircon powder with a sintering aid, wherein the sintering aid is in the form of a liquid, a sol, or a combination thereof. Also disclosed are methods for forming the zircon composition into a desired shape and for firing a composition to produce a ceramic body. The zircon composition and ceramic body produced by the described methods are also disclosed.

Abstract: Disclosed are ceramic honeycomb articles which are composed predominately of a crystalline phase cordierite composition. The porous cordierite ceramic honeycomb articles has a plurality of cell channels and intersecting porous walls and possess a microstructure characterized by a pore size distribution wherein greater than or equal to 75% of the pore size distribution of the porosity of the porous walls, by volume, have a pore diameter (dv) wherein dv<10.0 ?m and less than or equal to 35% of the pore size distribution have dv?4.0 ?m. Additionally, the pore diameter dv90?14.0 ?m, and CTE?12.0×10?7/° C. from 25° C. to 800° C. The articles exhibits high filtration efficiency coupled with low pressure drop across the filter. Additionally, high porosity articles having porosity greater than or equal to 40% and low surface roughness of Ra<4.0 ?m are described.

Abstract: A method for manufacturing a refractory ceramic body is disclosed. The method comprises contacting a zirconia precursor, a silica precursor, a sol-gel forming agent, and a preformed zircon. The method can further comprise forming the composition into a desired shape and firing the desired shape to form a dense, creep resistant refractory body. An article made by the methods above is disclosed, wherein a fine particle zircon is formed within and/or between grains of a preformed zircon.

Abstract: Glass-bonded ceramics made of non-microcracked non-oxide or oxide ceramic particles which are bound together by glass into a unitary non-microcracked structure are disclosed. Such ceramics are suitable for use in substrates and filters, such as a diesel particulate filter.

Abstract: Composite cordierite honeycomb structures especially suitable for diesel exhaust filtration applications comprise a non-oxide polycrystalline phase constituting 10-70% by weight, with the remainder of the ceramic material constituting a cordierite phase, the non-oxide polycrystalline phase being selected from the group consisting of carbides, nitrides, and borides. Preferably the non-oxide phase is either polycrystalline silicon carbide or polycrystalline silicon nitride and has a particle aspect ratio of less than 3. Inventive ceramic bodies are porous with an open porosity of at least 30%, preferably between 40% and 60%, and a median pore size of at least 5 micrometers, more preferably greater than 8 micrometers and less than 12 micrometers.

Abstract: A process for forming a silicon nitride-bonded silicon carbide honeycomb monolith by a) forming a plasticizable mixture which includes (1) about 60% to 85% by weight, powdered silicon carbide with a median particle size of about 10-40 micrometers; (2) about 15% to 40% by weight, powdered silicon metal with a median particle size of about 5-20 micrometers; and, (3) organic components; b) extruding the plasticizable mixture to form a green honeycomb monolith; c) drying the green honeycomb monolith; and, d) heating the honeycomb monolith to 1450° C. with a hold of 1 hour in an atmosphere of argon; and, e) nitriding the honeycomb monolith between 1450° C. to 1600° C. for a time sufficient to obtain a silicon nitride-bonded silicon carbide body.

Abstract: Composite cordierite honeycomb structures especially suitable for diesel exhaust filtration applications comprise a non-oxide polycrystalline phase constituting 10-70% by weight, with the remainder of the ceramic material constituting a cordierite phase, the non-oxide polycrystalline phase being selected from the group consisting of carbides, nitrides, and borides. Preferably the non-oxide phase is either polycrystalline silicon carbide or polycrystalline silicon nitride and has a particle aspect ratio of less than 3. Inventive ceramic bodies are porous with an open porosity of at least 30%, preferably between 40% and 60%, and a median pore size of at least 5 micrometers, more preferably greater than 8 micrometers and less than 12 micrometers.

Abstract: A process for forming a silicon nitride-bonded silicon carbide honeycomb monolith by a) forming a plasticizable mixture which includes (1) about 60% to 85% by weight, powdered silicon carbide with a median particle size of about 10-40 micrometers; (2) about 15% to 40% by weight, powdered silicon metal with a median particle size of about 5-20 micrometers; and, (3) organic components; b) extruding the plasticizable mixture to form a green honeycomb monolith; c) drying the green honeycomb monolith; and, d) heating the honeycomb monolith to 1450° C. with a hold of 1 hour in an atmosphere of argon; and, e) nitriding the honeycomb monolith between 1450° C. to 1600° C. for a time sufficient to obtain a silicon nitride-bonded silicon carbide body.