Abstract: The present invention is a composite material, a process and a product formed by the process. The composite is formed by a process that includes forming a fibrous structure comprising fibers into a preform, coating the fibers of the fibrous structure preform with elemental carbon to impregnate that preform, infiltrating the preform with boron carbide to form an impregnated green body. The impregnated green body is infiltrated with liquid naphthalene or other carbon precursor, which is thereafter pyrolyzed to form a carbon char. Then, the char infiltrated green body is infiltrated with molten silicon to form a continuous matrix throughout the composite. The silicon in the continuous matrix is reacted with the carbon char to form silicon carbide.

Abstract: High-density composites of ceramic materials, notably alumina or metal oxides in general, are formed by the incorporation of metal particles, of which niobium is a preferred example, and single-wall carbon nanotubes. The composites demonstrate an unusually high fracture toughness compared to the ceramic alone, and also when compared to composites that contain either the metal alone or single-wall carbon nanotubes alone. The two additives thus demonstrate a synergistic effect in improving the toughness of the ceramic.

Abstract: A composite material includes a plurality of continuous graphite fiber strands, bundles, or other such fiber configurations disposed within a hardened ceramic matrix. The continuous graphite fiber strands are preferably covered or “pegged” with a ceramic slurry (e.g., a porcelain ceramic slurry), attached to a pre-formed foundation, then fired to produce a fiber-enhanced ceramic structure. In this way, a may be efficiently fabricated for use in applications requiring high-strength materials capable of withstanding temperature extremes.

Abstract: Composites of ceramic materials, notably alumina or metal oxides in general, with single-wall carbon nanotubes are consolidated by electric field-assisted sintering to achieve a fully dense material that has an unusually high fracture toughness compared to the ceramic alone, and also when compared to composites that contain multi-wall rather than single-wall carbon nanotubes, and when compared to composites that are sintered by methods that do not include exposure to an electric field.

Abstract: A ceramic article resulting from a chemical interaction between a particulate ceramic material and a ceramic matrix material is described. The ceramic matrix results from at least partial chemical transformation of a precursor material. A chemical bond between the ceramic matrix and the particulate ceramic material is developed during manufacture. The configuration of the ceramic article is developed through use of a rapid prototyping process. A ceramic article comprising different compositions in two or more regions of the article is described. A manufacturing process comprising the steps employed to produce such a ceramic article is also described.

Abstract: A transition metal-containing ceramic made by the process comprising the step of pyrolyzing an organometallic linear polymer containing at least one metallocenylene unit, at least one silyl or siloxyl unit, and at least one acetylene unit to form a ceramic; where the ceramic has a ceramic yield of at least about 75% by weight. A transition metal-containing ceramic made by the process comprising the steps of: forming an organometallic linear polymer containing at least one metallocenylene, at least one silyl or siloxyl unit, and at least one acetylene unit; crosslinking said linear polymer through the acetylene units, thereby forming a thermoset; and pyrolyzing said thermoset to form a ceramic; where the ceramic has a ceramic yield of at least about 75% by weight.

Abstract: A hybrid insulation material comprises of porous ceramic substrate material impregnated with nanoporous material and method of making the same is the topic of this invention. The porous substrate material has bulk density ranging from 6 to 20 lb/ft3 and is composed of about 60 to 80 wt % silica (SiO2) 20 to 40 wt % alumina (Al2O3) fibers, and with about 0.1 to 1.0 wt % boron-containing constituent as the sintering agent. The nanoporous material has density ranging from 1.0 to 10 lb/ft3 and is either fully or partially impregnated into the substrate to block the pores, resulting in substantial reduction in conduction via radiation and convention. The nanoporous material used to impregnate the fiber substrate is preferably formed from a precursor of alkoxysilane, alcohol, water, and an acid or base catalyst for silica aerogels, and from a precursor of aluminum alkoxide, alcohol, water, and an acid or base catalyst for alumina aerogels.

Abstract: A silica-based photocatalyst fiber having visible-light activity, which fiber comprises a composite oxide phase comprising an oxide phase (first phase) mainly made of a silica component and a titania phase (second phase), wherein the second phase contains a metal element other than titanium and the existent ratio of the second phase slopingly increases towards the surface of the fiber, and a process for the production thereof.

Abstract: Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400° F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.

Abstract: A porous ceramic fiber insulating material and method of making a material having a combination of silica (SiO2) and alumina (Al2O3) fibers, and boron-containing powders is the topic of the new invention. The insulative material is composed of about 60 wt % to about 80 wt % silica fibers, about 20 wt % to about 40 wt % alumina fibers, and about 0.1 wt % to about 1.0 wt % boron-containing powders. A specific boron-containing powder used for this invention is boron carbide powder which provide boron-containing by-products, which aid in fusion and sintering of the silica and alumina fibers. The material is produced by forming an aqueous slurry, blending and chopping the fibers via a shear mixer, orienting the fibers in the in-plane direction, draining water from the fibers, pressing the fibers into a billet, heating the fibers to remove residual water, and firing the billet to fuse the fibers of the material. After sintering, bulk density of the new insulation material ranges from 6 to 20 lb/ft3.

Abstract: A method for producing composite ceramic material is provided wherein a core ceramic structure is produced and simultaneously enveloped with a sleeve of similar material.

Abstract: A titanium based composite which includes a Ti(Al,O) base matrix, discrete ceramic particles, and an oxide layer on the surface of the composite. The discrete ceramic particles are integrally associated with the Ti(Al,O) base matrix and the oxide layer, so that at a temperature of above about 600° C., the composite is substantially resistant to oxidation and spallation.

Abstract: A temperature resistant material, comprising a temperature resistant matrix and a set of short metal fibers, which characterized in that the set of short metal fibers represents at least 0.5% by weight of the temperature resistant material. The set of short metal fibers has an equivalent diameter D in the range of 1 to 150&mgr;, and comprising curved fibers and entangled fibers. The curved fibers have an average length L in the range of 10 to 2000&mgr;.

Abstract: Production processes of an inorganic fiber-bonded ceramic component comprising inorganic fibers mainly comprising Si, M, C and O, an inorganic substance mainly comprising Si and O and boundary layers comprising carbon as a main component; and an inorganic fiber-bonded ceramic component comprising inorganic fibers which are composed mainly of a sintered structure of SiC and contain specific metal atoms and boundary layers composed mainly of carbon, wherein a preliminary shaped material is set in a carbon die, covered with a carbon powder and then hot-pressed to load a pseudo-isotropic pressure on the preliminary shaped material; and a highly heat-resistant inorganic fiber-bonded ceramic component almost free from the occurrence of peelings of surface fibers or delamination, wherein fibers are aligned in a surface shape.

Abstract: The present invention is directed towards a ceramic nanocomposite comprising a nanostructured carbon component inside a ceramic host. The ceramic nanocomposite may further comprise vapor grown carbon fibers. Such nanostructured carbon materials impart both structural and thermal barrier enhancements to the ceramic host. The present invention is also directed towards a method of making these ceramic nanocomposites and for methods of using them in various applications.

Abstract: The subject of the invention is ceramic fibers for the reinforcement of refractory materials, being constituted by sintered bauxite fibers with a length/diameter greater than 10. Preferably, they have a cylindrical or prismatic shape truncated by two surfaces, for example, substantially planar surfaces perpendicular to the axis of the prism. They enable the mechanical strength and the lifetime of the refractory products to be significantly increased.

Abstract: The present invention relates to shaped bodies made of fiber-reinforced ceramic composites and comprising a core zone and at least one covering layer which has a coefficient of thermal expansion which is higher than that of the core zone. The covering layer is an SiC-rich covering layer and is divided into segments which are separated from the adjacent segments by gaps or bridging zones of a material which is different from the material of the segments. The invention also relates to a process for producing such shaped bodies by infiltration of an intermediate body with molten silicon and their use for friction disks, in vehicle construction or as protective plates.

Abstract: The present invention discloses an oxide ceramic fiber/oxide ceramic composite material comprising primary composite materials each consisting of (a) an assembly of ceramic fibers composed mainly of a metal oxide and (b) a metal oxide ceramic which includes the ceramic fiber assembly (a) therein, the metal oxide of the ceramic (b) being different from the main component metal oxide of the ceramic fiber assembly (a) and the amount of the metal oxide ceramic (b) being 1 to 85% by weight relative to the weight of the ceramic fiber assembly (a), and a metal oxide ceramic which is a matrix for the primary composite materials and which includes the primary composite materials therein, the metal oxide of the ceramic being the same as or different from the main component metal oxide of the ceramic fiber assembly (a); and a process for producing thereof.

Abstract: Material from a fibre composite ceramic, constructed from

Abstract: Ultra hard materials and ceramics reinforced with elongate ultra hard material particles and methods of forming the same are provided. These materials have improved toughness and damage tolerance and can be used on, or to form, tools such as cutting tools and various work pieces and parts.

Abstract: The present invention relates to high temperature composite materials formed from nano-sized powders suitable for use in the manufacture of jet engine components. The composite materials consist essentially of a matrix formed from a powdered material having a particle size in the range of from about 1 to about 100 nanometers and a plurality of reinforcing fibers embedded within the matrix and comprising from about 20% to about 40% by volume of the composite material. The method of manufacturing the composite materials broadly comprises the steps of mixing the powdered material with the reinforcing fibers and consolidating the mixture to form the composite material.

Abstract: SiC fiber-reinforced SiC-matrix composite has the structure that SiC filaments are inserted into SiC matrix formed as a pyrolysis product of polyvinyl-silane (PVS) infiltrated into openings of said SiC filaments. PVS as a polymeric SiC precursor has structural units (a) and (b) at an a/b ratio of 1. A SiC fiber preform is impregnated with PVS slurry in an open or vacuum atmosphere, preheated at 300-400° C. in an inert gas atmosphere to moderate PVS to a viscous or semi-cured state, and then pyrolyzed in an argon atmosphere under application of a unidirectional pressure. A product is SiC fiber-reinforced SiC-matrix composite excellent in mechanical strength and high-temperature property with high density. The SiC composite is further densified by infiltration of PVS slurry suspending fine SiC particles therein or by repetition of impregnation with sole PVS and pressure-less pyrolysis after the pressurized pyrolysis.

Abstract: Rare-earth alloy is cast into a sheet (6) or the like by using a tundish (3, 13). The refractory material of the tundish used for casting does not necessitate preheating for improving the flowability of the melt (2). The refractory material used essentially consists of 70 wt % or more of Al2O3 and 30 wt % or less of SiO2, or 70 wt % or more of ZrO2 and 30 wt % or less of one or more of Y2O3, Ce2O3, CaO, MgO, Al2O3, TiO2 and SiO2. The refractory material has 1 g/cm3 or less of bulk density, has 0.5 kca/(mh° C.) or less of thermal conductivity in the temperature range of from 1200 to 1400° C., and has 0.5 wt % or less of ratio of ignition weight-loss under the heating condition of 1400° C. for 1 hour.

Abstract: A composite ceramic-metal material has an Al2O3 matrix interpenetrated by a network of a ductile metal phase with a higher meltin temperature than aluminum and which makes up 15 to 80 vol. % of its total volume. The Al2O3 matrix forms a coherent network that makes up 20 to 85 vol. %, and the material contains 0.1 to 20 atom % aluminide. To produce this composite material, a green body shaped by powder metallurgy and which contains a finely divided powdery mixture of Al2O3 and optionally other ceramic substances, as well as one or several metals or metal alloys different from aluminum and to which 0.1 to 20 atom % aluminum are added, in relation to the metal proportion, is sintered. The composition is selected in such a way that maximum 15 vol. % aluminide phase can be formed in the finished sintered body.

Abstract: Compositions for use as thermal insulation or barriers in articles that are required to function under transient elevated temperature conditions, such as are experienced during a fire. Articles in which compositions according to the invention may be used include electrical and optical cables which have fire resistant properties, electrical fittings such as terminals and cable clips, and void-filling compounds which are required to act as fire barriers. The invention provides a composition that is ductile or flexible at the elevated temperatures experienced during a fire and retains integrity so as to stay in place throughout the fire enabling it to continue to function as a thermal barrier.

Abstract: A new method for combining magnesium oxide, MgO, and magnesium dihydrogen phosphate to form an inexpensive compactible ceramic to stabilize very low solubility metal oxides, ashes, swarfs, and other iron or metal-based additives, to create products and waste forms which can be poured or dye cast, and to reinforce and strengthen the ceramics formed by the addition of fibers to the initial ceramic mixture.

Abstract: A sensor material for measuring physical parameters capable of configuring a sensor capable of directly measuring a high value of physical parameters such as high stress or high pressure without employing a pressure resistance container. The sensor material for measuring static and dynamic physical parameters includes a matrix made of an electrically insulating ceramic material, and piezoresistance materials which are dispersed in the matrix so as to be electrically continuous to each other.

Abstract: Monazite or xenotime-based blanket coatings that stiffen ceramic fabrics without causing embrittlement at temperatures of at least as high as 2400° F. are provided. Methods for making the coatings are also provided. The methods comprise the synthesis of high purity, monazite and xenotime powders with the stoichiometric ratio of metal to phosphorous of about 1:1.

Abstract: Acicular bodies of a metal compound are produced by slowly precipitating an organic salt of the metal from a solution of an ester of a dicarboxylic acid having 1-5 carbon atoms and firing the precipitate in an oxidizing atmosphere. These acicular bodies have a cross-sectional dimension less than about 20 &mgr;m and are useful for providing reinforcement of a larger ceramic body. Acicular bodies of rare-earth metal oxides also are useful in reinforcing x-ray scintillator bodies without diminishing their luminescent capacity.

Abstract: A method for preparing a metal reinforced refractory body comprising the steps of providing a mold for containing a slurry of refractory material. A body of metal fibers is inserted into the mold, the metal fibers having a coefficient of thermal expansion of less than 10×10−6 in/in/° F. and a yield strength of greater than 35 KSI at 1200° F. The slurry of refractory material is introduced to the mold to provide the slurry in intimate contact with the metal fibers, the refractory material in the hardened condition having a coefficient of thermal expansion of less than 10×10−6 in/in/° F. The refractory material is hardened to provide a metal reinforced composite refractory body comprised of a reinforcing component and a refractory component having a coefficient of thermal expansion of less than 10×10−6 in/in/° F. to minimize cracking of the refractory body.

Abstract: The present invention relates to a high strength light-weight ceramic insulator and a method for manufacture thereof wherein the light-weight ceramic insulator may be used at a high temperature by using a heat-resisting ceramic fiber. A colloidal silica or colloidal alumina which is an inorganic binder, and a methyl cellulose or a liquid-phase organic polymer which is an organic binder are added to an alumina-silica-based fiber containing zirconia, a concentration thereof is adjusted, a slurry is vacuum-molded, and drying and heating are carried out, thereby fabricating the ceramic insulator. Here, it is possible to fabricate the high strength light-weight ceramic insulator by artificially selectively positioning the inorganic binder to a contact point of the fibers.

Abstract: A ceramic matrix nanocomposite having enhanced mechanical behavior is made up of a nanotube filler composed of at least one nanotube material, and a ceramic matrix composed of a nanocrystalline ceramic oxide. A method for producing ceramic articles having improved fracture toughness includes combining of a nanotube filler made up of a nanotube material and a ceramic matrix made up of a nanocrystalline ceramic oxide, forming an article therefrom, and sintering the article under elevated pressure at elevated temperature.

Abstract: Ceramic oxide pre-forms comprising substantially continuous, alpha alumina fibers, and methods for making the same. The ceramic oxide pre-forms are useful, for example, as in making metal matrix composites reinforced with substantially continuous, alpha alumina fibers.

Abstract: A preform for metal matrix composite material comprising: inorganic particles, small-diameter inorganic fibers, and large-diameter inorganic fibers. An average particle diameter of the inorganic particles is 1 to 50 &mgr;m. An average fiber diameter of the small-diameter inorganic fibers is 2 to 5 &mgr;m, and an average fiber length of the small-diameter inorganic fibers is 10 to 200 &mgr;m. An average fiber diameter of the large-diameter inorganic fibers is 4 to 20 &mgr;m, and an average fiber length of the large-diameter inorganic fibers is 10 to 200 &mgr;m. The small-diameter inorganic fibers catch and disperse the inorganic particles in a process of forming a formed body, and the large-diameter inorganic fibers create voids in cooperation with the small-diameter inorganic fibers in the process of forming the formed body.

Abstract: The present invention relates to a sintered ceramic composite implant material and a fabrication method thereof. A sintered ceramic composite implant material includes an apatite matrix phase, a ceramic secondary phase located in the apatite matrix phase, a barrier layer coating the ceramic secondary phase. The secondary phase compensates for and improves the mechanical properties of the apatite matrix phase and the barrier layer restrains an interfacial reaction between the apatite matrix phase and the secondary phase.

Abstract: This invention pertains to ceramic matrix composites that comprise the coated ceramic fibers wherein the coating comprises at least one binary coating of boron nitride (BN) and silicon nitride (Si3N4) within ceramic matrices derived from curable preceramic polymers. The composites can be formed into complex shapes which have good oxidation resistance at high temperature, good resistance to moisture high flexural strength and are resistant to moisture.

Abstract: This invention pertains to ceramic matrix composites that comprise the coated ceramic fibers wherein the coating comprises at least one binary coating of boron nitride (BN) and silicon nitride (Si3N4) within ceramic matrices derived from curable preceramic polymers. The composites can be formed into complex shapes which have good oxidation resistance at high temperature, good resistance to moisture high flexural strength and are resistant to moisture.

Abstract: The composite includes inorganic fiber for reinforcement and a matrix of 40 to 95% by weight of silicon carbide ceramic and 5 to 60% by weight of an oxide phase dispersed in the silicon carbide ceramic. The oxide phase forms a continuous network structure in the matrix and includes ZrSiO4, BaO—MgO—Al2O3—SiO2 glass ceramic or Sro—Al2O3—SiO2 glass ceramic. The matrix surrounds and fills voids between the inorganic fiber.

Abstract: A method of internal molding and decreased supercritical fluid drying times for aerogels and exergels by means of using gas porous molding features that are compatible with the prestressed fiber reinforcing system.

Abstract: A ceramic-matrix composite having a multilayered interfacial coating adapted to protect the reinforcing fibers from long-term oxidation, while allowing these to bridge the wake of advancing cracks in the matrix, is provided by selectively mismatching materials within adjacent layers of the interfacial coating, the materials having different coefficients of thermal expansion so that a low toughness interface region is created to promote crack deflection either within an interior layer of the mismatched interfacial coating or between adjacent layers of the mismatched interfacial coating.

Abstract: A method of forming fiber reinforced aluminum phosphate bonded material having improved strength at elevated temperatures. The method comprises the steps of: (a) preparing a slurry by blending alumina and alumina phosphate solution, the slurry being substantially free of silica; (b) providing a fiber substrate; (c) infiltrating the solution into the fiber substrate; and (d) curing the infiltrated substrate to form a fiber reinforced aluminum phosphate bonded composite material. In a preferred embodiment of the present invention, the fiber substrate is made from SiC fibers.

Abstract: A MoSi2 pest resistant material includes in-situ grown &bgr;-Si3N4 whiskers. In addition to excellent pest resistance, the material provides a lower coefficient of thermal expansion for better match with continuous reinforcing fibers such as SiC fibers. A two stage heating and pressing production technique enables lower temperature processing with substantially full densification.

Abstract: A filter media system, which is capable of operating in the microfiltration regime, offers: low cost, durability, high temperature and chemical resistance, no particulation, mechanical strength, separation efficiency, and biocompatibility. A filter media system is comprised of a carbon or ceramic composite substrate which contains a carbon or ceramic matrix reinforced with carbon or ceramic fibers. The composite has an array of carbon or ceramic fiber whiskers grown onto its surface or in its bulk. A process is provided for manufacturing the filter media system wherein a carbon fiber is disposed in a matrix deposited by a CVI or LPI process, at temperatures of about 900 to about 1200° C. to achieve a weight gain of about 10 to 200% (the ceramic matrix is deposited by a CVI process from an aqueous slurry or by use of a preceramic polymer). This composite is treated with an aqueous solution of metal catalyst salt and is then heated in hydrogen at elevated temperatures to reduce the metal salt to metal.

Abstract: A matrix for high-performance ceramic matrix composite containing inorganic fiber for reinforcement, which comprises silicon carbide ceramic and an oxide phase having dispersed in the solicon carbide ceramic.

Abstract: The invention provides a fiber-reinforced composite ceramic containing high-temperature-resistant fibers, in particular fibres based on Si/C/B/N, which are reaction-bonded to a matrix based on Si, which is produced by impregnating fiber bundles of Si/C/B/N fibers with a binder suitable for pyrolysis and solidifying the binder, if desired subsequently conditioning the fiber bundles with an antisilicization layer suitable for pyrolysis, for example phenolic resin or polycarbosilane, subsequently preparing a mixture of fiber bundles, fillers such as SiC and carbon in the form of graphite or carbon black and binders, pressing the mixture to produce a green body and subsequently pyrolysing the latter under reduced pressure or protective gas to produce a porous shaped body which is then infiltrated, preferably under reduced pressure, with a silicon melt.

Abstract: A thermal gradient resistant fiber-reinforced composite structure which has a hot operating side and an opposite cool operating side and a thickness &tgr; therebetween. In one embodiment, the composite has two regions: hot and cool. The hot region consists essentially of a fiber having a first coefficient of thermal expansion and a matrix material and the cool region consists essentially of a fiber having a second coefficient of thermal expansion and a matrix material. In this embodiment, the hot region has a thickness &tgr;H of about 10 to 90 percent of the total thickness &tgr; between the hot side and the cool side, and the cool region has a thickness &tgr;C of about 90 to 10 percent of the total thickness &tgr;. In a second embodiment, the composite has a hot operating side and an opposite cool operating side and a thickness &tgr;′ therebetween. In this embodiment, the composite has three regions: hot, intermediate and cool.

Abstract: Wire comprising polycrystalline &agr;-Al2O3 fibers within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper.

Abstract: The invention relates to a porous ceramic used for producing alkali ion water. The ceramic of the invention includes finely particulate zeolite having an average particle size of 0.1 to 40 &mgr;m and an alkali ion producing material as components. Besides the above components, the invention preferably comprises a fibrous mineral and/or a clay mineral. To produce the ceramic of the invention, a slurry obtained by grinding zeolite by a wet process, a slurry obtained by grinding the alkali ion producing material and the clay mineral by a wet process and a slurry obtained by grinding the fibrous mineral are first mixed and stirred to prepare a mixed slurry. This mixed slurry is then dried and fired to obtain a sintered body.

Abstract: The ceramic matrix composite is constructed by a ceramic matrix containing SiC formed by a reaction sintering as a main phase and ceramic fibers comprising SiC compounded in this matrix. A coat layer that has been previously coated on the fibers is disposed between the fiber and the matrix. The layer is provided with a BN layer with a preset thickness covering on the surface of the fiber, a C layer with a preset thickness covering the BN layer, and a SiC layer with a preset thickness covering the C layer.

Abstract: High-temperature, lightweight, ceramic carbon insulation is prepared by coating or impregnating a porous carbon substrate with a siloxane gel derived from the reaction of an organodialkoxy silane and an organotrialkoxy silane in an acid or base medium in the presence of the carbon substrate. The siloxane gel is subsequently dried on the carbon substrate to form a ceramic carbon precursor. The carbon precursor is pyrolyzed, in an inert atmosphere, to form the ceramic insulation containing carbon, silicon, and oxygen. The carbon insulation is characterized as a porous, fibrous, carbon ceramic tile which is particularly useful as lightweight tiles for spacecraft.