Abstract: The described development is directed to a coating formulation for filling surface irregularities in graphite articles such as molds, crucibles, and matched die sets used in high-temperature metallurgical operations. The coating formulation of the present invention is formed of carbon black flour, thermosetting resin and a solvent for the resin. In affixing the coating to the article, the solvent is evaporated, the resin cured to bond the coating to the surface of the article and then pyrolyzed to convert the resin to carbon. Upon completion of the pyrolysis step, the coating is shaped and polished to provide the article with a surface restoration that is essentially similar to the original or desired surface finish without the irregularity.

Abstract: The present invention is directed to the fabrication of boron carbide articles having length-to-diameter or width ratios greater than 2 to 1. The process of the present invention is practiced by the steps comprising hot pressing boron carbide powder into article segments or portions in which the segments have a length-to-diameter or width ratio less than 1.5, aligning a plurality of the initially hot-pressed segments in a hot-pressing die with the end surfaces of the segments placed in intimate contact with one another, and then hot pressing the aligned segments into an article of the desired configuration. The resulting article exhibits essentially uniform density throughout the structure with the bonds between the segments being equivalent in hardness, strength, and density to the remainder of the article.

Abstract: The present invention is directed to an anisotropic thermal insulator formed of carbon-bonded organic or inorganic fibers and having a thickness or cross section greater than about 3 centimeters. Delaminations and deleterious internal stresses generated during binder curing and carbonizing operations employed in the fabrication of thick fibrous insulation of thicknesses greater than 3 centimeters are essentially obviated by the method of the present invention. A slurry of fibers, thermosetting resin binder and water is vacuum molded into the selected insulator configuration with the total thickness of the molded slurry being less than about 3 centimeters, the binder is thermoset to join the fibers together at their nexaes, and then the binder is carbonized to form the carbon bond.