Abstract: A method for forming a porous barrier coating on a substrate without substantial chemical segregation includes the steps of providing or obtaining a barrier coating material in powdered form and spraying the barrier coating material onto the substrate using air plasma spraying. The air plasma spraying is performed using an average homologous surface temperature of the depositing particles in a range of about 1.25 to about 1.5 and a particle velocity in a range of about 300 m/s to about 500 m/s. The depositing particles are fully molten.

Abstract: The present disclosure relates to systems, methods and resins for additive manufacturing. In one embodiment, a method for additive manufacturing of a ceramic structure includes providing a resin including a preceramic polymer and inorganic ceramic filler particles dispersed in the preceramic polymer. The preceramic polymer is configured to convert to a ceramic phase. The method includes functionalizing inorganic ceramic filler particles with a reactive group and applying an energy source to the resin to create at least one layer of the ceramic phase from the resin.

Abstract: A molding apparatus includes a heating section, a spreading section, a molding section, a drawing section and a curing section. The heating section which heats a mold material including particles and a binder agent which bonds together the particles, to a temperature equal to or higher than the melting point of the binder agent and forms a fluid mold material. The spreading section forms a mold layer by spreading the fluid mold material. The molding section layers the mold layers. The drawing section applies UV ink to a desired region of the mold layer. The curing section cures the UV ink applied to the desired region of the mold layer.

Abstract: A composition for applying to a honeycomb body includes a refractory filler, an organic binder, an inorganic binder, and a liquid vehicle, wherein the refractory filler, the particle size distribution of the refractory filler, the organic binder, and the inorganic binder are selected such that, when the composition is applied to plug a plurality of channels of the honeycomb body, the plug depth variability is reduced.

Abstract: A bicontinuous non-porous microstructure comprising a refractory phase and a non-refractory phase, wherein the refractory phase substantially comprises one or more refractory elements and the non-refractory phase comprises a void filled by one or more materials that are different than a material comprising the non-refractory phase in a bicontinuous network from which the nanocomposite refractory material is formed and methods of making the same are disclosed.

Abstract: New methods for synthesizing boron-modified silazanes, their use as polymer-derived ceramic precursors, and polymer-derived ceramics and composites formed therefrom are disclosed. The polymeric ceramic precursors comprise a boron-modified silazane that is a room temperature liquid-phase polymer comprising a backbone having recurring monomeric repeat units comprising boron-nitrogen bonds. Nanocomposites comprising polymer-derived ceramics and carbon nanotubes are also disclosed.

Abstract: A process for manufacturing an article includes the steps of applying a quantity of a refractory metal sufficient to produce a coating on a carbon based felt; processing thermally a refractory metal coated carbon based felt at a temperature and for a period of time sufficient to form a ceramic based felt; and cooling the ceramic based felt under a controlled atmosphere.

Abstract: The method comprises: using chemical vapor infiltration to form a first continuous interphase on the fibers of a fiber structure made of refractory fibers, the interphase having a thickness of no more than 100 nanometers; impregnating the fiber structure with a consolidation composition comprising a carbon or ceramic precursor resin; forming a fiber preform that is consolidated by shaping the impregnated fiber structure and using pyrolysis to transform the resin into a discontinuous solid residue of carbon or ceramic; using chemical vapor infiltration to form a second continuous interphase layer; and densifying the preform with a refractory matrix. This preserves the capacity of the fiber structure to deform so as to enable a fiber preform to be obtained that is of complex shape, while nevertheless guaranteeing the presence of a continuous interphase between the fibers and the matrix.

Abstract: A thermal spray powder of the present invention contains a rare earth element and a diluent element that is not a rare earth element or oxygen, which is at least one element selected, for example, from zinc, silicon, boron, phosphorus, titanium, calcium, strontium, and magnesium. A sintered body of a single oxide of the diluent element has an erosion rate under specific etching conditions that is no less than 5 times the erosion rate of an yttrium oxide sintered body under the same etching conditions.

Abstract: A ceramic powder and method of forming the ceramic powder capable of being used in coatings to allow components to survive in high temperatures environments, such as the hostile thermal environment of a gas turbine engine. The ceramic powder includes powder particles each having an inner core formed of a first material and an outer region formed of a second material. The inner core has a lower thermal conductivity than the outer region, and the outer region is more erosion resistance relative to the inner core.

Abstract: A thermal spray powder of the present invention contains a rare earth element and a group 2 element, which belongs to group 2 of the periodic table. The thermal spray powder, which contains a rare earth element and a group 2 element, is formed, for example, from a mixture of a rare earth element compound and a group 2 element compound or from a compound or solid solution containing a rare earth element and a group 2 element. The thermal spray powder may further contain a diluent element that is not a rare earth element or a group 2 element and is not oxygen, which is at least one element selected, for example, from titanium, zirconium, hafnium, vanadium, niobium, tantalum, zinc, boron, aluminum, gallium, silicon, molybdenum, tungsten, manganese, germanium, and phosphorus.

Abstract: A pressure casting slip for producing a refractory ceramic for use as a heat shield, e.g. in the hot gas path of gas turbine units, includes a particulate mixture of at least two materials having different coefficients of thermal expansion and also organic and/or inorganic binders and floating agents. The particulate mixture has a multimodal particle size distribution divided into 10-20 percent by weight of coarse particles in the size range 1-5 mm in diameter, 10-20 percent by weight of medium particles in the size range 0.5-1 mm in diameter and 60-80 percent by weight of fine particles in the size range up to 0.5 mm in diameter which together make up 100 percent by weight of the particle mixture.

Abstract: The present invention relates to a novel process for producing ceramic materials, in particular refractory materials having a reduced relative density. In particular, the invention relates to a process for producing light, refractory materials having non-contiguous pores based on shaped and unshaped materials. These materials can be used as working lining in high-temperature applications. The process is based on the production of spherical, closed and isolated pores in the microstructure of the material. The pores having a pore diameter which can be set in a targeted manner are generated by use of polymer particles, in particular polymethacrylates, in particular polymers or copolymers prepared by means of suspension polymerization, as pore formers which can be burnt out. The polymers or copolymers are present in the form of small spheres having a defined diameter.

Abstract: Composite bodies made by a silicon metal infiltration process that feature a silicon intermetallic, e.g., a metal silicide. Not only does this give the composite material engineer greater flexibility in designing or tailoring the physical properties of the resulting composite material, but the infiltrant also can be engineered compositionally to have much diminished amounts of expansion upon solidification, thereby enhancing net-shape-making capabilities. These and other consequences of engineering the metal component of composite bodies made by silicon infiltration permit the fabrication of large structures of complex shape.

Abstract: Low-carbon monolithic refractories are provided. Methods of manufacturing glass employing low-carbon monolithic refractories are also provided. Methods and apparatuses for glass manufacture for reducing the formation of carbon dioxide blisters during glass manufacture are also provided.

Abstract: A reactive liquid ceramic binder suitable for the production of ceramic products from ceramic powders is provided. The reactive liquid ceramic binder contains organo-modified siloxane compounds, wherein the liquid organo-modified siloxane compounds contain organoalkoxysiloxane units according to general formula (I) wherein R1=alkyl radical and/or aryl radical, R2=H and/or alkyl radical with 1 to 4 carbon atoms, a?0 and ?2, and b>0 and ?3, with the proviso that a+b?1 and ?4.

Abstract: An object of the invention is to provide, in porous thermal insulating firebricks formed by molding and drying bubble-containing slurry obtained by foaming slurry containing a fire resistant powder and water, a thermal insulating firebrick superior in thermal insulating property in spite of the same composition and porosity. A porous thermal insulating firebrick formed by molding and drying bubble-containing slurry obtained by foaming slurry containing a fire resistant powder with a heat resistant temperature of 1,000° C. or higher and water has the porosity of 60% or more, and 80% or more volume with respect to a total pore volume of the inside of the thermal insulating firebrick consists of pores having a pore size of 200 ?m or less.

Abstract: Provided here is a method of producing a monolithic body from a porous matrix, comprising: (i) providing a porous matrix having interstitial spaces and comprising at least a first reactant; (ii) contacting the porous matrix with an infiltrating medium that carries at least a second reactant; (iii) allowing the infiltrating medium to infiltrate at least a portion of the interstitial spaces of the porous matrix under conditions that promote a reaction between the at least first reactant and the at least second reactant to provide at least a first product; and (iv) allowing the at least first product to form and fill at least a portion of the interstitial spaces of the porous matrix, thereby producing a monolithic body, wherein the monolithic body does not comprise barium titanate.

Abstract: A treatment process, an oxide-forming treatment composition, and a treated component are disclosed. The treatment process includes applying an oxide-forming treatment composition to a ceramic coating and heating the oxide-forming treatment composition to form an oxide within the ceramic coating. The oxide-forming treatment composition includes a solute and a corrosion inhibitor. The oxide-forming treatment composition is super-saturated with the corrosion inhibitor. The treated component includes a ceramic coating and one or both of a corrosion inhibitor and an oxide formed by an oxide-forming treatment composition having the corrosion inhibitor. The corrosion inhibitor and the oxide-forming treatment composition are within the ceramic coating.

Abstract: A refractory material that can withstand high temperatures in an oxidizing medium and containing at least: a first constituent corresponding to hafnium, or to a non-oxide compound of hafnium, or circular in a or a non-oxide compound of zirconium, or corresponding to a mixture of at least two metals and/or compounds selected from hafnium a non-oxide compound of hafnium, zirconium, and a non-oxide compound of zirconium; a second constituent corresponding to the boron or to a non-oxide compound of boron, or corresponding to a mixture of boron and a non-oxide compound of boron; and a third constituent corresponding to a rare earth RE or to a non-oxide compound of the rare earth RE, or corresponding to a mixture of rare earth RE and a non-oxide compound of the rare earth RE, where RE is selected from scandium, yttrium, and the lanthanides. The material contains neither silicon nor a compound of silicon.

Abstract: In order to achieve the object of providing a mixture by means of which, in particular, sintered moldings can be obtained that are virtually free of surface stains produced by soot particles, a mixture is proposed which comprises at least one pressing aid and at least one additive, wherein the additive is selected from a group of substances which have releasable carbon dioxide.

Abstract: Advanced environmental barrier coating bond coat systems with higher temperature capabilities and environmental resistance are disclosed. These bond coat systems can be applied to ceramic substrates such as SiC/SiC ceramic matrix composite substrates, and can provide protection from extreme temperature, mechanical loading and environmental conditions, such as in high temperature gas turbines. Example bond coat systems can include either an advanced silicon/silicide component, an oxide/silicate component, or a combination thereof.

Abstract: The invention relates to a heat sink comprising a diamond-containing composite material. In addition to a diamond content of 40-90% by volume, the composite material further comprises from 0.005 to 12% by volume of a silicon-carbon compound, from 7 to 49% by volume of an Ag-, Au- or Al-rich phase and less than 5% by volume of a further phase, with the volume ratio of the Ag-, Au or Al-rich phase to silicon carbide being greater than 4 and at least 60% of the diamond surface being covered by the silicon-carbon compound. Preferred production processes include atmospheric pressure and pressure-aided infiltration techniques. The component is suitable, in particular, as heat sink for semiconductor components.

Abstract: A reactive ceramic binder in liquid form suitable for producing ceramic products from ceramic powder. The reactive, liquid ceramic binder includes liquid organomodified siloxane compounds having organoalkoxysiloxane units of the general formula (I) where the radicals R1 are, independently of one another, identical or different alkyl, alkaryl or aryl radicals which may be interrupted by ether functions, the radicals R2 are, independently of one another, identical or different radicals selected from H and/or alkyl radicals having from 1 to 6 carbon atoms, the radicals R3 are, independently of one another, identical or different divalent, saturated or unsaturated hydrocarbon radicals which have from 1 to 30 carbon atoms and may be interrupted by ether functions, “a” is greater than or equal to 0 and less than or equal to 2.5, “b” is greater than 0 and less than or equal to 3, and 1?a+b?3.

Abstract: A low-water-content castable composition produces cast products with an increased modulus of rupture, an increased cold crushing strength, and decreased porosity. The composition employs closed fractions of constituent particles with specified populations and specified gaps in the particle size distribution to produce these properties. The composition is suitable for refractory applications.

Abstract: Catalysts are disclosed comprising fibrous substrates having silica-containing fibers with diameters generally from about 1 to about 50 microns, which act effectively as “micro cylinders.” Such catalysts can dramatically improve physical surface area, for example per unit length of a reactor or reaction zone. At least a portion of the silica, originally present in the silica-containing fibers of a fibrous material used to form the fibrous substrate, is converted to a zeolite (e.g., having a SiO2/Al2O3 ratio of at least about 150) that remains deposited on these fibers. The fibrous substrates possess important properties, for example in terms of acidity, which are useful in hydroprocessing (e.g., hydrotreating or hydrocracking) applications.

Abstract: An article which includes a structure of a ceramic material that has a composition SiOxMzCy, where Si is silicon, O is oxygen, M is at least one metal and C is carbon and wherein x<2, y>0 and z<1 and x and z are non-zero.

Abstract: The invention provides a vessel for molten metal comprising a vessel body formed of an alumina-silica-based material, and a protective layer formed of a silicon nitride- alumina-based material provided on the inner surface of the vessel body, wherein the material for the vessel body is adjusted to have an alumina content x of 72 to 95 parts by weight per 100 total parts by weight of alumina and silica, and the material for the protective layer is adjusted to have a silicon nitride content y per 100 total parts by weight of silicon nitride and alumina in such a manner that y applies to the following formulae: (1) y<?1.1x+128 and (2) y>?0.5x+62.5. The present invention provides a vessel for molten metal having excellent durability and corrosion resistance against hot molten metal.

Abstract: Disclosed are ceramic articles comprising ceramic honeycomb bodies and an aqueous composition, for example in the form of a cold-set plug, as well as processes for preparing ceramic articles and processes for making an aqueous composition for use with ceramic articles, for example as a cold-set plug composition.

Abstract: Methods are described that have the capability of producing submicron/nanoscale particles, in some embodiments dispersible, at high production rates. In some embodiments, the methods result in the production of particles with an average diameter less than about 75 nanometers that are produced at a rate of at least about 35 grams per hour. In other embodiments, the particles are highly uniform. These methods can be used to form particle collections and/or powder coatings. Powder coatings and corresponding methods are described based on the deposition of highly uniform submicron/nanoscale particles.

Abstract: A friction disc (2) with an anti-abrasion layer (1) and integrated wear indication, the friction disc (2) having a friction surface (2?) which is completely covered by the anti-abrasion layer (1). At least one indication surface element (3) which occupies a part of the friction surface (2?) and differs from at least one of the components friction surface (2?) and anti-abrasion layer (1) of the friction disc (2) in at least one of the features coloring and texture is provided between the anti-abrasion layer (1) and the friction disc (2). Compositions of the anti-abrasion layer (1) of the friction disc (2).

Abstract: The present invention provides a plate brick having a low amount of generation of smoke and a gas with a pungent odor during use, and exhibiting high durability. A plate brick of the present invention is obtained by: adding an organic binder to a refractory raw material mixture containing 0.5 to 20 mass % of aluminum and/or aluminum alloy; kneading the mixture with the organic binder; forming the kneaded mixture into a shaped body; and subjecting the shaped body to a heat treatment at a temperature of 400 to 1000° C., wherein the plate brick is obtained without being impregnated with a carbon-containing liquid material comprising tar or pitch, after the heat treatment. The plate brick has a compressive strength of 180 MPa or more, and a weight-increasing rate of 1% or less as measured in a hydration test using an autoclave.

Abstract: Disclosed is a method for making a refractory material from aluminum residues of aluminum recycling. At first, the aluminum residues is mixed with adhesive solution so that the percentage by weight of the adhesive solution is 5 wt % to 10 wt %. The mixture is granulated into grains. The grains are filled in a mold, pressed and then removed from the mold so that the grains are turned into a green body. The green body is heated in a furnace at a range of temperature from 1100° C. to 1400° C. so that the grains are sintered and become a refractory material.

Abstract: Composite bodies made by a silicon metal infiltration process that feature a silicon intermetallic, e.g., a metal silicide. Not only does this give the composite material engineer greater flexibility in designing or tailoring the physical properties of the resulting composite material, but the infiltrant also can be engineered compositionally to have much diminished amounts of expansion upon solidification, thereby enhancing net-shape-making capabilities. These and other consequences of engineering the metal component of composite bodies made by silicon infiltration permit the fabrication of large structures of complex shape.

Abstract: It is provided a high-temperature assembly that is favorable for increasing the sealing property at the boundary area between a first member and a second member that are used in a high-temperature environment. Further it is provided a method for producing the high-temperature assembly, and a heat-resistant sealing material. The heat-resistant sealing material, which is disposed at the boundary area between a first member and a second member, comprises ceramic particles made of a plurality of materials which form a ceramics the volume of which increases when the ceramics is synthesized.

Abstract: A refractory, porous ceramic composite including crystalline mullite (3Al2O3+2SiO2 or 3Al6Si2O11) and a crystalline phase of LaPO4 is formed from a mullite-LaPO4 sol-gel by annealing the dried gel. During the annealing process, particle sintering and self-foaming occur in the glassy state, and pores are produced due at least in part to the release of entrapped gases that form during the pyrolysis of the gel. The resulting crystalline composite, or crystalline nanocomposite, has a high porosity and is dimensionally and chemically stable at high temperatures. The composite also has a high degree of structural (e.g., mechanical) stability, related at least in part to the fine texturing and mixing of the mullite and LaPO4 during preparation of the sol. The resulting ceramic composite shows little or no shrinkage or expansion between about 1000C and about 1200° C.

Abstract: A method for producing a ceramic material is disclosed. A ceramic raw material mixture is produced by comminuting and mixing starting materials containing Pb, Zr, Ti, Nd and oxygen. Nickel or an nickel compound is introduced. The raw material mixture is calcined and a ceramic is sintered.

Abstract: A transparent polycrystalline ceramic having scattering and absorption loss less than 0.2/cm over a region comprising more than 95% of the originally densified shape and a process for fabricating the same by hot pressing. The ceramic can be any suitable ceramic such as yttria (Y2O3) or scandia (Sc2O3) and can have a doping level of from 0 to 20% and a grain size of greater than 30 ?m, although the grains can also be smaller than 30 ?m. Ceramic nanoparticles can be coated with a sintering aid to minimize direct contact of adjacent ceramic powder particles and then baked at high temperatures to remove impurities from the coated particles. The thus-coated particles can then be densified by hot pressing into the final ceramic product. The invention further provides a transparent polycrystalline ceramic solid-state laser material and a laser using the hot pressed polycrystalline ceramic.

Abstract: A refractory object can include at least 10 wt % Al2O3. In an embodiment, the refractory object can further include a dopant including an oxide of a rare earth element, Ta, Nb, Hf, or any combination thereof. In another embodiment, the refractory object may have a property such that the averaged grain size does not increase more than 500% during sintering, an aspect ratio less than approximately 4.0, a creep rate less than approximately 1.0×10?5 ?m/(?m×hr), or any combination thereof. In a particular embodiment, the refractory object can be in the form of a refractory block or a glass overflow forming block. The glass overflow forming block can be useful in forming an Al—Si—Mg glass sheet. In a particular embodiment, a layer including Mg—Al oxide can initially form along exposed surfaces of the glass overflow forming block when forming the Al—Si—Mg glass sheet.

Abstract: Methods of making and compositions of dense sintered ceramic nano- and micro-composite materials that are highly stable in a variety of conditions and exhibit superior toughness and strength. Liquid feed flame spray pyrolysis techniques form a plurality of nanoparticles (e.g., powder), each having a core region including a first metal oxide composition comprising Ce and/or Zr or other metals and a shell region including a second metal oxide composition comprising Al or other metals. In certain aspects, the core region comprises a partially stabilized tetragonal ZrO2 and the shell region comprises an ?-Al2O3 phase. The average actual density of the ceramic after sintering is greater than 50% and up to or exceeding 90% of a theoretical density of the ceramic.

Abstract: This invention relates to thermal spray composite coatings on a metal or non-metal substrate. The thermal spray composite coatings comprise a ceramic composite coating having at least two ceramic material phases randomly and uniformly dispersed and/or spatially oriented throughout the ceramic composite coating. At least a first ceramic material phase is present in an amount sufficient to provide corrosion resistance to the ceramic composite coating, and at least a second ceramic material phase is present in an amount sufficient to provide plasma erosion resistance to the ceramic composite coating. This invention also relates to methods of protecting metal and non-metal substrates by applying the thermal spray coatings. The composite coatings provide erosion and corrosion resistance at processing temperatures higher than conventional processing temperatures used in the semiconductor etch industry, e.g., greater than 100° C.

Abstract: A method for the production of a ceramic substrate for a semiconductor component, includes the steps of producing paper containing at least cellulose fibers, as well as a filler to be carbonized and/or SiC, pyrolizing the produced paper, and siliconizing the pyrolyzed paper.

Abstract: An article is provided that includes a plurality of layers. Each layer includes a sinterable mass having a sinter temperature that is less than about 1000 degrees Celsius, and an inner electrode proximate to the sinterable mass. The inner electrode includes a material having a melting point that is within a determined temperature range of about 10 degrees Celsius to about 200 degrees Celsius relative to the sintering temperature. A method to make the article is also provided.

Abstract: Compositions for making wettable cathodes to be used in aluminum electrolysis cells are disclosed. The compositions generally include titanium diboride (TiB2) and metal additives. The amount of selected metal additives may result in production of electrodes having a tailored density and/or porosity. The electrodes may be durable and used in aluminum electrolysis cells.

Abstract: A varistor pre-assembly includes an electrode formable structure and a sinterable mass proximate to electrode formable structure. The electrode formable structure includes a material having a melting point that may be within a determined temperature relative to a sintering temperature of the sinterable mass. The electrode formable structure and sinterable mass may form a varistor when simultaneously subjected to the sintering temperature, which may be less than about 1000 degrees Celsius. A method to make the article is also provided.

Abstract: A method of producing a boron suboxide composite material having improved fracture toughness.

Abstract: The present invention provides a fused ceramic particle, having the following chemical composition, in percentages by weight based on the oxides and for a total of 100%: 50%<ZrO2+HfO2<70%; 10%<SiO2<30%; 6.5%<MgO<9.5%; Al2O3 in a quantity such that the MgO/Al2O3 weight ratio is in the range 2.4 to 6.6; 0.1%<Y2O3; CeO2<10%; and less than 0.6% of other oxides. Use in particular as milling agents, wet medium dispersion agents, propping agents, heat exchange agents, or for the treatment of surfaces.

Abstract: A transparent polycrystalline ceramic having scattering and absorption loss less than 0.2/cm over a region comprising more than 95% of the originally densified shape and further provides a process for fabricating the same by hot pressing. The ceramic can be any suitable ceramic such as yttria (Y2O3) or scandia (Sc2O3) and can have a doping level of from 0 to 20% and a grain size of greater than 30 ?m, although the grains can also be smaller than 30 ?m. In a process for making a transparent polycrystalline ceramic in accordance with the present invention, ceramic nanoparticles can be coated with a sintering aid to minimize direct contact of adjacent ceramic powder particles and then baked at high temperatures to remove impurities from the coated particles. The thus-coated particles can then be densified by hot pressing into the final ceramic product. The invention further provides a transparent polycrystalline ceramic solid-state laser material and a laser using the hot pressed polycrystalline ceramic.

Abstract: A method of fabricating a composite powder includes forming a plurality of loose particles having discrete regions of a first material and discrete regions of a second material that is different than the first material. At least one of the first material and the second material includes a chemical precursor to a third, different material.

Abstract: A composite powder includes a plurality of loose particles having discrete regions of a first material and discrete regions of a second material that is different than the first material. At least one of the first material and the second material is a chemical precursor to a third material.