Abstract: The present invention relates to a method of producing tungsten carbide by gas phase direct carburization of a tungsten-oxide containing starting material, wherein the starting material is reacted with a reaction gas at an increased temperature. The starting material is first heated to a first temperature greater than or equal to 600° C., before reacting with a reaction gas while increasing the temperature to a second temperature that does not exceed 850° C., wherein the reaction gas is selected from the group consisting of CO and a COH2 gas mixture comprising up to 20% by volume H2.

Abstract: A carbon material for producing endohedral metallofullerenes in a high yield is made of a mixture of a metal or metal compound with a carbonaceous material and is used in producing a endohedral metallofullerenes, wherein said carbon material contains a metal carbide and a bulk density of said carbon material is set to 1.80 g/cm3 or less.

Abstract: A magnetic cluster includes a (CoC2)4 tetragonal structure with Co—C2—Co bonds, and a molecular formula (CoC2)x (x: natural number).

Abstract: A method and apparatus for making alloys or ceramics by the subsurface injection of an equilibrium vapor of a boiling liquid of the ceramic or alloys constituents is disclosed. Various powders and products are disclosed.

Abstract: Layered metal non-oxide coated substrates are disclosed comprising a three dimensional inorganic substrate having a coating of metal non-oxide derived from a pre-associated coating on at least a portion of all three dimensions thereof, produced by a unique process having particular applicability to the manufacture of metal boride, carbide and nitride coated three dimensional substrates. Certain novel coated substrates, such as flakes, spheres and porous substrate are disclosed. The coated substrates are useful in polymer catalysis, heating and shielding applications.

Abstract: The invention relates to a method of synthesizing high-temperature melting materials. More specifically the invention relates to a containerless method of synthesizing very high temperature melting materials such as borides, carbides and transition-metal, lanthanide and actinide oxides, using an Aerodynamic Levitator and a laser. The object of the invention is to provide a method for synthesizing extremely high-temperature melting materials that are otherwise difficult to produce, without the use of containers, allowing the manipulation of the phase (amorphous/crystalline/metastable) and permitting changes of the environment such as different gaseous compositions.

Abstract: A composite which is easy to manufacture and has excellent catalytic activity and mechanical strength is obtained by heating and drying a mixture of a carrier in powder form and a metal hydroxide in powder form or in molten form under a gas flow or under reduced pressure. The composite can be used as a catalyst for the isomerization of an olefin or for the oxidation reaction of an alcohol.

Abstract: The invention comprises a chemical composition with the structure shown below. The composition can be polymerized or pyrolyzed, forming transition metal nanoparticles homogeneously dispersed in a thermoset or carbon composition. The size of the nanoparticles can be controlled by manipulating the number and arrangement of functional groups in the composition and by changing the conditions of the polymerization or pyrolysis. The resulting thermosets and carbon compositions have useful magnetic, electric, mechanical, catalytic and/or optical properties.

Abstract: A method of continuously producing a non-oxide ceramic formed of a metal constituent and a non-metal constituent. A salt of the metal constituent and a compound of the non-metal constituent and a compound of the non-metal constituent are introduced into a liquid alkali metal or a liquid alkaline earth metal or mixtures to react the constituents substantially submerged in the liquid metal to form ceramic particles. The liquid metal is present in excess of the stoichiometric amount necessary to convert the constituents into ceramic particles to absorb the heat of reaction to maintain the temperature of the ceramic particles below the sintering temperature. Ceramic particles made by the method are part of the invention.

Abstract: A process is provided for producing a fine tungsten carbide powder, which comprises the steps of drying a slurry, which is obtained by mixing an aqueous ammonium tungstate solution with a carbon powder, at low temperature, to form a precursor, mixing a reduction and carburization product, which is obtained by reducing and oxidizing the precursor in an inert gas, with a carbon powder in a proportion required to substantially carburize the entire tungsten component into tungsten carbide (WC), and carburizing the mixture; and a high-performance fine tungsten carbide powder produced by the process, which has an average particle size of 0.8 ?m or less and is free of a coarse power having a particle size of more than 1 ?m, and which also contains less metal impurities and contains oxygen and nitrogen in a predetermined amount.

Abstract: Compositions including oxycarbide-based nanorods and/or carbide-based nanorods and/or carbon nanotubes bearing carbides and oxycarbides and methods of making the same are provided. Rigid porous structures including oxycarbide-based nanorods and/or carbide based nanorods and/or carbon nanotubes bearing carbides and oxycarbides and methods of making the same are also provided. The compositions and rigid porous structures of the invention can be used either as catalyst and/or catalyst supports in fluid phase catalytic chemical reactions. Processes for making supported catalyst for selected fluid phase catalytic reactions are also provided. The fluid phase catalytic reactions catalyzed include hydrogenation, hydrodesulfurisation, hydrodenitrogenation, hydrodemetallisation, hydrodeoxigenation, hydrodearomatization, dehydrogenation, hydrogenolysis, isomerization, alkylation, dealkylation and transalkylation.

Abstract: Methods for the production of monometal carbides are disclosed. A metal source and a carbon source are reacted under conditions suitable to produce a reaction product. The reaction product may comprise fully carburized monometal carbide and excess carbon, or an intermediate product comprising partially carburized monometal carbide in the presence or absence of excess carbon. The carbon content in the reaction product may then be adjusted in a controlled removal or addition process to produce a product the fully carburized monometal carbide having near stoichiometric carbon.

Abstract: Any one of a Ti-containing water-soluble salt, metatitanic acid (TiO(OH)2) Slurry and ultra fine titanium oxide powder, and a transition metal containing metal salt are dissolved in water to prepare a raw material mixture. The raw material is spray-dried to obtain precursor powder, which is calcined to form ultra fine Ti/transition metal complex oxide and is then mixed with nano-sized carbon particles and subjected to reduction and carburization in a non-oxidizing atmosphere.

Abstract: Nanophase WC powder is produced by preparing a precursor including tungsten; producing gas by vaporizing or sublimating the precursor; carbonizing the gas in the atmosphere without oxygen while maintaining pressure below atmospheric pressure; and condensing the carbonized gas

Abstract: A method for the synthesis of method for the manufacture of carbide cermet powders, comprises high energy ball milling a mixture of precursor powders and a carbon source, followed by annealing the milled powder mixture. The precursor powders are selected from materials suitable for the formation of cermets, for example silicon, titanium, thorium, hafnium, vanadium, chromium, tungsten, tantalum, niobium, and zirconium-containing materials. The precursors further include a source of carbon. Tungsten cobalt carbide powders produced by this method are submicron-sized (0.2 to 0.4 microns) with internal nanograins (10 to 40 nanometers in diameter).

Abstract: A method of continuously producing a non-oxide ceramic formed of a metal constituent and a non-metal constituent. A salt of the metal constituent and a compound of the non-metal constituent and a compound of the non-metal constituent are introduced into a liquid alkali metal or a liquid alkaline earth metal or mixtures to react the constituents substantially submerged in the liquid metal to form ceramic particles. The liquid metal is present in excess of the stoichiometric amount necessary to convert the constituents into ceramic particles to absorb the heat of reaction to maintain the temperature of the ceramic particles below the sintering temperature. Ceramic particles made by the method are part of the invention.

Abstract: Disclosed herein is a method for economically manufacturing high quality TiC powder, TiCN powder or ultrafine nanophase TiC+Ni (Co, Al) and TiCN+Ni (Co, Al) composite powders by means of metallothermic reduction. The method comprises the steps of preparing a starting solution of titanium tetrachloride (TiCl4) in a carbon chloride, feeding the starting solution into a closed container containing molten magnesium (Mg) under inert atmosphere, vacuum-separating unreacted liquid-phase Mg and magnesium chloride (MgCl2) remaining after reduction of magnesium from the closed container, and collecting a TiC compound from the closed container.

Abstract: The present invention relates to thermal reactions performed at rapid transient temperatures, and a furnace (1) able to perform such reactions. The method and the furnace may suitably be applied to perform reactions between reactants where significant losses normally occur at certain transient temperatures or temperature ranges. One practical application of the present invention relates to a carbothermic method for producing Refractory Hard Metal powders, such as borides, nitrides and carbides, and a furnace designed for the performance of the method. In accordance with this method Refractory Hard Metal powders, such as boride powders can be produced with reduced loss of reactants such as C and B2O3. This can be achieved by rapid heating of the mixture containing the reactants in a critical temperature range.

Abstract: A process is described for the preparation of tungsten and/or molybdenum metal powder or carbide by reducing and optionally carburizing treatment of tungsten and/or molybdenum oxide powder in the presence of alkali metal compounds, wherein at least two alkali metal compounds are used in a ratio so that mixed alkali tungstate or molybdate potentially formed in an intermediate step ((Li, Na, K)2 WOZ, (Li, Na, K)2MoOZ) has a melting point of less than 550° C., wherein z is from 3 to 4.

Abstract: The present invention relates to a method of producing tungsten carbide by gas phase direct carburization of a tungsten-oxide containing starting material, wherein the starting material is reacted with a reaction gas at an increased temperature. The starting material is first heated to a first temperature greater than or equal to 600° C., before reacting with a reaction gas while increasing the temperature to a second temperature that does not exceed 850° C., wherein the reaction gas is selected from the group consisting of CO and a COH2 gas mixture comprising up to 20% by volume H2.

Abstract: Methods for producing molybdenum carbide. An embodiment of the method may comprise heating a precursor material in a first heating zone in the presence of a reducing gas and a carbonizing gas, the first heating zone having a first temperature. Moving the precursor material into a second heating zone to form the molybdenum carbide from the precursor material, the second heating zone having a second temperature, the second temperature being at least 100° C. hotter than the first temperature.

Abstract: Molybdenum carbide (MoC and Mo2C) produced by heating a precursor material in a first heating zone to a first temperature in the presence of a reducing gas and a carbonizing gas and moving the precursor material to a second heating zone that is heated to a second temperature that is at least 100° C. hotter than the first heating zone to form said molybdenum carbide.

Abstract: The present invention relates to a method of producing nanophase powder, which can be used as materials for high-strength and wear-resistance cemented carbide. It purports to provide a method of producing WC powder of a 10˜20 nm grade by using vapor phase reaction with a precursor containing tungsten. For achieving said objectives, the method of producing WC-based powder according to the present invention comprises preparing a precursor containing tungsten; producing gas by vaporizing said precursor in a reactor; and carburizing said gas in a non-oxidizing atmosphere. The nanophase WC powder produced as such has high-strength and excellent wear-resistance, which can be suitably used as materials for carbide tools, carbide cement, wear-resistance components, or metal molds.

Abstract: A method for the manufacture of a structure from a carbide of a group IIa, group IIIa, group IVa, group IVb, group Vb, group VIb, group VIIb or group VIIIb carbon reactive element including the steps of: mixing the element with the carbon; and heating the carbon and the element to melt the element so that it reacts with the carbon to form the carbide; wherein, the carbon and element are heated by means of electromagnetic radiation having a frequency below the infrared spectrum. The method does not waste energy by unnecessary heating of the furnace or surrounding mold. The mold itself may be more stable because it is only heated by hot contained material and not by other sources of heat. Resulting formed products are not a sintered product and may approach one hundred percent of theoretical density. The carbon may be in the form of a powder that is mixed with the element or may be a porous carbon structure such as a graphite fiber mat or sheet into which the carbon reactive element is melted.

Abstract: A thermal treatment system for thermally treating a sterile medium is controlled via a foot actuated switch to thermally treat the sterile medium to a desired temperature and/or form (e.g., slush). The thermal treatment system includes a basin recessed in a system top surface, while a surgical sterile drape is placed over the system and within the basin to form a drape container for containing the sterile medium. The basin may be configured to cool the sterile medium and form sterile surgical slush, or heat the sterile medium to provide warm sterile liquid. A dislodgment mechanism may be employed within a cooling basin to manipulate the drape and dislodge frozen pieces of sterile medium adhered to the drape. Information pertaining to the sterile medium and system operation may be displayed on a system display that has dimensions sufficient to provide visibility of the information to users located within extended ranges from the system.

Abstract: Apparatus and method for producing molybdenum carbide. An embodiment of the invention may comprise heating a precursor material to a first temperature in the presence of a reducing gas and a carbonizing gas, and ramping the first temperature at least once by at least 100° C. to form the molybdenum carbide.

Abstract: A supported tungsten carbide material is provided. The material has a unique structure as defined by its x-ray diffraction pattern and consists of extremely small crystallites on the order of about 15 to about 30 angstroms in size. The tungsten carbide material is supported on a high-surface-area support to allow for a greater number of active sites for catalysis. The support consists preferably of a high-surface-area carbon.

Abstract: A supported tungsten carbide material is provided. The material has a unique structure as defined by its x-ray diffraction pattern and consists of extremely small crystallites on the order of about 15 to about 30 angstroms in size. The tungsten carbide material is supported on a high-surface-area support to allow for a greater number of active sites for catalysis. The support consists preferably of a high-surface-area carbon.

Abstract: A process is provided for producing a fine tungsten carbide powder, which comprises the steps of drying a slurry, which is obtained by mixing an aqueous ammonium tungstate solution with a carbon powder, at low temperature, to form a precursor, mixing a reduction and carburization product, which is obtained by reducing and oxidizing the precursor in an inert gas, with a carbon powder in a proportion required to substantially carburize the entire tungsten component into tungsten carbide (WC), and carburizing the mixture; and a high-performance fine tungsten carbide powder produced by the process, which has an average particle size of 0.8 &mgr;m or less and is free of a coarse power having a particle size of more than 1 &mgr;m, and which also contains less metal impurities and contains oxygen and nitrogen in a predetermined amount.

Abstract: Tungsten carbide is formed from a tungsten material which is preferably tungsten carbide scrap. If scrap material is used, this is oxidized and acid leached to remove impurities and any binder material. This is then dissolved in a solution of sodium hydroxide and spray dried to form a precursor compound. A carbon compound such as citric acid can be added to the solution prior to spray drying to provide a carbon source for the tungsten carbide. The powder formed from the spray dried solution is calcined and carburized to form tungsten carbide.

Abstract: The present invention relates to a method of adding a grain growth inhibitor of WC/Co cemented carbide, which comprises adding a water-soluble salt of V, Ta, or Cr component as a grain growth inhibitor, at the time of mixing water-soluble salts of W and Co during the initial production process of WC/Co cemented carbides. As a result, the present invention leads to the production of powder of homogeneous distribution of grain growth inhibitors, which in turn results in the enhancement of the mechanical properties thereof by effectively controlling the abnormal growth of WC during sintering in the production process of said cemented carbides.

Abstract: A transition metal carbide is formed from a precursor mixture comprising at least one of the group consisting of: a transition metal, a transition metal carbide and a transition metal oxide. The precursor mixture may contain the desired transition metal carbide (e.g., WC), but if the desired transition metal carbide is present in the precursor mixture, there is necessarily a significant amount of another compound such as a transition metal oxide, undesired carbide (e.g., W2C) or transition metal.

Abstract: Forming metal and metalloid carbides by mechanically inducing a reduction reaction between a metal chloride (or a metalloid chloride) and a metal carbide. The reduction reactions are induced mechanically by milling the reactants. Alloy carbides may also be produced by mechanically inducing the co-reduction of metal chlorides or metalloid chlorides and a metal carbide according to the equation: M1chloride+M2chloride+M3carbide→M1M2carbide, where M1 is a metal or metalloid, M2 is a metal or metalloid and M3 is a suitable carbide reducing agent.

Abstract: The invention concerns a gas carburizing method for production of fine-grained tungsten carbide (WC) powder in installations for fluidized bed reaction starting from free-flowing tungsten or tungsten oxide-containing powder with an average particle size d50>10 &mgr;m in a single process step with a specific process temperature and process gas mixture with a carbon activity <1 and as close as possible to 1. The method is suitable for particularly economical WC production on an industrial scale.

Abstract: A process is described for the preparation of tungsten and/or molybdenum metal powder or carbide by reducing and optionally carburizing treatment of tungsten and/or molybdenum oxide powder in the presence of alkali metal compounds, wherein at least two alkali metal compounds are used in a ratio so that mixed alkali tungstate or molybdate potentially formed in an intermediate step ((Li, Na, K)2 WOZ, (Li, Na, K)2MoOZ) has a melting point of less than 550° C., wherein z is from 3 to 4.

Abstract: A method for preparing a carbon-containing composition is disclosed which comprises the steps of introducing, into a hot gas, a dispersion obtained by dispersing, in a decomposable carbon compound, a metal oxide and/or a metal compound which can be converted into the metal oxide by heating, to form a carbon-containing composition containing simple carbon and the corresponding metal oxide; and then collecting the formed carbon-containing composition. This carbon-containing composition is useful for the manufacture of a ceramic powder for sintering.

Abstract: A method for the production of fine-grain tungsten carbide (WC) powder comprising heating a tungsten precursor compound in contact with a gas mixture including a hydrocarbon such as methane (CH4). The method is preferably a one-step continuous method wherein the heating rate and reaction temperature is well controlled for the economical production of high quality tungsten carbide powder. The tungsten carbide powder advantageously has a high purity and a small crystallite size and can be used in the manufacture of products such as cutting tools having high wear resistance.

Abstract: A catalyst composition and process for preparing such catalyst composition which can be useful in contacting a hydrocarbon-containing fluid which contains a highly unsaturated hydrocarbon such as 1,3-butadiene, in the presence of hydrogen, with such catalyst composition in a hydrogenation zone under a hydrogenation condition effective to hydrogenate such highly unsaturated hydrocarbon to a less unsaturated hydrocarbon such as n-butene is disclosed. Such process for preparing a catalyst composition includes (1) combining a zeolite, a Group VIB metal, and an inorganic support to form a modified zeolite; (2) calcining such modified zeolite under a calcining condition to produce a calcined, modified zeolite; and (3) contacting such calcined, modified zeolite with a carburizing agent under a carburizing condition to provide such catalyst composition.

Abstract: The present invention relates to a process for the preparation of transition metal carbides from transition metal/magnesium chlorides and perchlorinated organic compounds.

Abstract: The present invention relates to a method of producing nanophase WC/TiC/Co composite powder by means of a mechano-chemical process comprising a combination of mechanical and chemical methods. For this purpose, the present invention provides a method of producing nanophase WC/TiC/Co composite powder, said method comprising as follows: a process of producing an initial powder by means of spray-drying from water-soluble salts containing W, Ti, and Co; a process of heating to remove the salts and moisture contained in the initial powder after spray-drying; a process of mechanically ball-milling to grind oxide powder after removing the salts and moisture therefrom, and to homogeneously mix the powder with an addition of carbon; and a process of heating the powder after milling, for reduction and carburization, in an atmosphere of reductive gas or non-oxidative gas.

Abstract: The invention relates to a silicon carbide or metal carbide foam to be used as a catalyst or catalyst support for the chemical or petrochemical industry or for silencers, as well as the process for producing the same. The foam is in the form of a three-dimensional network of interconnected cages, whose edge length is between 50 and 500 micrometres, whose density is between 0.03 and 0.1 g/cm3 and whose BET surface is between 20 and 100 m2/g. The carbide foam contains no more than 0.1% by weight residual metal and the size of the carbide crystallites is between 40 and 400 Angstroms. The production process consists of starting with a carbon foam, increasing its specific surface by an activation treatment using carbon dioxide and then contacting the thus activated foam with a volatile compound of the metal, whose carbide it is wished to obtain.

Abstract: A method for the synthesis of micron- and submicron-sized, nanostructured metal carbide powders, comprising high energy milling of metal oxide and carbon precursors followed by annealing of the as-milled powders. The annealing is preferably carried out under a flow of inert gas or subatmospheric pressure to drive the reaction to completion in one to two hours. The powders thus synthesized comprise high purity particles having a narrow particle size range.

Abstract: A molybdenum carbide compound is formed by reacting a molybdate with a mixture of hydrogen and carbon monoxide. By heating the molybdate powder from a temperature below 300° C. to maximum temperature 850° C., a controlled reaction can be conducted wherein molybdenum carbide is formed. A high surface area, nanograin, metastable molybdenum carbide can be formed when the reaction temperature is below 750° C. The metastable molybdenum carbide is particularly suitable for use as a catalyst for the methane dry reforming reaction.

Abstract: The present invention relates to a method for manufacturing transition metal carbides and/or transition metal carbonitrides and the use thereof together with novel transition metal xerogels.

Abstract: A nanoscale carbide article consisting essentially of covalently bounded elements M1, M2, and C having the molar ratio M1:M2:C::1:y:x, wherein the article has an aspect ratio of between 10 and 1000 and has a shorter axis of between 1 and 40 nanometers.

Abstract: A process for providing elemental metals or metal oxides distributed on a carbon substrate or self-supported utilizing graphite oxide as a precursor. The graphite oxide is exposed to one or more metal chlorides to form an intermediary product comprising carbon, metal, chloride, and oxygen. This intermediary product can be fiber processed by direct exposure to carbonate solutions to form a second intermediary product comprising carbon, metal carbonate, and oxygen. Either intermediary product may be further processed: a) in air to produce metal oxide; b) in an inert environment to produce metal oxide on carbon substrate; c) in a reducing environment to produce elemental metal distributed on carbon substrate. The product generally takes the shape of the carbon precursor.

Abstract: A process for producing phosgene is disclosed which involves contacting a mixture comprising CO and Cl.sub.2 (e.g, at about 300.degree. C. or less) with a silicon carbide catalyst having a surface area of at least 10 m.sup.2.g.sup.-1.

Abstract: Metal carbide-containing refractory materials are prepared by pyrolysing blanks comprising reactive metal sources and carbon-containing precursors under fluid pressure, e.g., using hot isostatic pressing techniques. Refractory composites containing ceramic fillers, reinforcing materials such as carbon fillers, excess carbon or excess metal are readily prepared thereby.

Abstract: A process utilizing a supported metal catalyst, a volatile species source, and a carbon source has been developed to produce carbide nanorods with diameters of less than about 100 nm and aspect ratios of 10 to 1000. The volatile species source, carbon source, and supported metal catalyst can be used to produce carbide nanorods in single run, batch, and continuous reactors under relatively mild conditions. The method employs a simple catalytic process involving readily available starting materials.

Abstract: An apparatus for producing solid fine particulates has a substantially closed reaction vessel and a hollow gas input conduit inside the vessel formed with a multiplicity of similar outlet apertures each having a flow cross section of at most 2 mm.sup.2. The conduit has an overall cross-sectional area equal to at least 100 times the flow cross section of a one of the apertures. A foraminous structure in the vessel surrounds the conduit and an electrode is provided in the vessel outside the foraminous structure. A direct-current power supply has a negative side connected to the foraminous structure and a positive side connected to the electrode while the input conduit is at ground potential so that a glow discharge is created in the vessel between the foraminous structure and the electrode.