Abstract: A method is disclosed for producing low density, ceramic bodies in the nature of hollow or solid beads which may be used as such or bonded into a unitary mass. The bodies are composed of ion-exchanged, synthetic mica crystals wherein large cations, such as K.sup.+, have been exchanged for lithium and/or sodium ions from the mica. The method involves forming a gel by dissolution of a synthetic mica in a polar liquid, releasing droplets of the gel into a fluid to form shaped bodies, effecting the indicated ion exchange, and drying the beads thus formed.

Abstract: Cellular ceramic bodies are produced by frothing a crystal-containing, ion-exchanged gel and setting the gel. An aqueous gel is prepared from a water-swelling mica and is blended in conjunction with a large cation donor, e.g., a potassium salt or silicate glass, and a surfactant to effect frothing of the gel by a shearing action and exchange of large cations with lithium and/or sodium ions from the mica to produce an ion-exchanged gel that sets in controllable manner.

Abstract: Sulphur compositions, particularly sulphur concretes, mortars and coatings, comprising a sulphur component and a particulate mineral aggregate in which the aggregate is bonded together in a matrix of the sulphur component having a plurality of fine entrained cells, particularly substantially spherical gas cells, uniformly dispersed throughout the matrix, and displaying improved durability under cyclical freezing and thawing.

Abstract: The disclosure describes ceramic foams, for example made of clay, and a process for preparing these foams. Once there is obtained a mixture defining a slip, the latter is caused to be foamed by the addition of controlled quantities of a gas, such as air, thus making it possible to reproduce foams having predetermined physical properties. It is preferable to dry the foam under conditions where the temperature is heterogeneous and in the absence of ventilation. This operation can be carried out by placing the foam under heating elements at a temperature between 30.degree. C. at the start to 100.degree. C. towards the end of the drying, while practically preventing any ventilation in the vicinity of the foam. This process is mainly advantageous in that it enables one to control the physical properties of the foam obtained thereby. This foam can be used as an industrial absorbent, acoustical insulating material, fire-wall, thermal insulating material, etc. by varying the density of the foam.

Abstract: A fabrication technique is described for making various devices in which a certain type of glass is used as a surface protection layer. The glass layers are formed by particle bombardment (generally sputtering or E-beam) of a glass target. Devices with such surface layers are also described. Such glass layers are highly advantageous as encapsulating layers, diffusion barrier layers, etc., particularly for optical type devices and certain semiconductor devices. Particularly important is the preparation procedure for the glass target used in the bombardment process. The glass layers are moisture stable, act as excellent barriers against diffusion, and are usable up to quite high temperatures (i.e., in diffusion doping procedures) without cracking or peeling. The glass layers also provide long-term protection against atmosphere components including water vapor, oxygen, atmosphere pollution contaminants, etc., and can be removed by standard etching techniques.

Abstract: An inorganic, phosphate-containing cellular material is manufactured from Portland cement, polyphosphoric acid and an expanding agent acting in an acidic medium. There may be added furthermore aluminous cement, oxides of calcium, zinc, aluminum, iron, hydroxides of aluminum and iron, fillers and reinforcing agents. By intense intermixing of the starting products a mixture is prepared which has an equivalent ratio of (Al+Mg+CA+Fe) to phosphate of 0.8:1 to 3.0:1. The mixture foams, is charged to a mold, heated if necessary to a temperature of 80.degree. C., and after completed exothermal reaction hardened under heat.

Abstract: A heat resistant protective coating is comprised of a composition including 14 to 21 percent by weight of an alkali metal silicate; 20 to 35 percent by weight of magnesium silicate; a blowing agent; and water. The composition upon heating intumesces to form a closed cell structure which provides insulation to a coated substrate.The coating composition is particularly useful in coating steel pipe to form an intumesced closed cell composition on the steel pipe. The pipe can be used as an oxygen lance in producing steel or as an aluminum flux rod.

Abstract: The present invention concerns rigid, water-resistant phosphate ceramic materials which may be prepared from components comprising metal oxide, calcium silicate, and phosphoric acid. By prereacting a portion of the metal oxide with the phosphoric acid and/or by adjusting the temperature of the acid solution when it is combined with the other ingredients, the character of the resulting product can be controlled to give foamed or unfoamed phosphate ceramic material.

Abstract: Ceramic fiber is co-dispersed in a liquid medium together with a heat curable organic binder, and the mixture is beaten preferably with small amounts of a crystallizable salt and fillers. Upon beating, the mixture is foamed, and the foam is then heated to cure the binder, evaporate the liquid, and stabilize the foam. The foam may be used as is, but is preferably further heated to decompose most of the organic binder and to cause bonding between intersecting fibers by the salt, thereby resulting in a stable foam that has excellent high temperature properties.

Abstract: A lightweight, porous, ceramic material is made by mixing a slurry containing a foaming agent until a constant volume of foam is achieved. The foam is then pumped or poured into a mold or form where it sets up into a cellular structure. The formed foam is then cured, dried and heated at elevated temperatures. The slurry used in making the foam is made from ceramic particles, water, foaming agent and bonding materials. The bonding materials function to provide an initial bond as the foam is generated to prevent foam collapse, a low temperature bond after the foam structure is set, cured and dried, and a final bond after heating to elevated temperatures. In a preferred embodiment, the ceramic particles used are alumina.

Abstract: An unfired foamed-in-place two component insulating refractory and the method for preparing the same. The composition is composed of hydraulic cement, water and an acid, though it can also include an aggregate and/or fine grain inert filler. In the process, the dry ingredients are mixed with the water to form a slurry and thereafter the acid is added to the slurry and passed through a passive mixer before the acid-slurry mixture is discharged and allowed to foam and set.

Abstract: This invention provides a lightweight ceramic composition which is characterized by an average bulk density between about 10-105 PCF, and a compressive strength between about 300-10,000 psi.In a preferred embodiment, this invention provides an extruded structural cellular clay product having pores which are substantially non-interconnected and elongated in a single directional configuration, and having a density gradient in at least one cross-sectional plane, in which gradient the higher density is in proximity to the outer surfaces.

Abstract: Foamable particulate cement is capable of forming sintered cordierite foamed ceramic masses. It consists essentially, by weight, of 1-40% cordierite grog, 99-60% ceramic base material and foaming agent, such as SiC. The ceramic base material is raw ceramic material that has an analytical molar composition consisting essentially of about 1.7-2.4 MO . 1.2-2.4 Al.sub.2 O.sub.3 . 4.5-5.4 SiO.sub.2 wherein MO comprises about 0-55 mole % MgO and at least 45 mole % MnO. The grog is ceramic material that has been previously fired and comminuted, and that has an analytical molar composition consisting essentially of about 1.7-2.4 RO . 1.9-2.4 Al.sub.2 O.sub.3 . 4.5-5.2 SiO.sub.2 wherein RO comprises MnO in an amount of 0 mole % up to a mole % that is about 20 mole % lower than the mole % of MO that is MnO and the balance is substantially MgO.

Abstract: Foamable particulate cement is capable of forming sintered cordierite foamed ceramic masses. It consists essentially, by weight, of 1-40% cordierite grog, 99-60% ceramic base material and foaming agent, such as SiC. The ceramic base material is raw ceramic material that has an analytical molar composition consisting essentially of about 1.7-2.4 MO.1.2-2.4 Al.sub.2 O.sub.3.4.5-5.4 SiO.sub.2 wherein MO comprises about 0-55 mole % MgO and at least 45 mole % MnO. The grog is ceramic material that has been previously fired and comminuted, and that has an analytical molar composition consisting essentially of about 1.7-2.4 RO.1.9-2.4 Al.sub.2 O.sub.3.4.5-5.2 SiO.sub.2 wherein RO comprises MnO in an amount of 0 mole % up to a mole % that is about 20 mole % lower than the mole % of MO that is MnO and the balance is substantially MgO.