Uniformly-coated ceramic particles
AssigneeNorton Company
InventorParam H. Tewari
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AssigneeNorton Company
InventorParam H. Tewari
Estimating the term…
Solids that are subject to a deleterious reaction with a dispersion medium in which they are suspended can be safely comminuted in that dispersion medium by providing therein a surfactant capable of reacting with the solid at a faster rate than the dispersion medium can so react to thereby suppress the deleterious reaction. In particular, unsintered silicon nitride or silicon carbide which when contacted with water would decompose to form silica on their surfaces can be milled in water, without producing excessive amounts of silica. The dispersions produced are sufficiently stable to be filtered through openings of 2 microns with loss of no more than 5% of the silicon nitride or carbide. Stable dispersions of solids in liquids can be coated with a different solid by surface precipitation under conditions which preclude the formation of a bulk precipitate. Thus, ceramic nitride or carbide particles are coated with densification aids, such as yttria, by the surface precipitation of the corresponding hydroxides on the ceramic particles in water. Ceramic powders prepared in this way densify to give products with moduli of rupture and fracture toughnesses at least as high as those made from powders conventionally milled in alcohol with lower amounts of densification aid.
A method of preparing an aqueous dispersion of ceramic particles comprising an inorganic nitride or carbide having an average diameter less than about 2 microns and having deposited thereon a substantially uniform surface layer coating of a metal compound selected from metal hydroxides and metal oxides in the substantial absence of free particles of metal hydroxide and metal oxide which comprises (i) placing nitride or carbide particles having average diameters less than about 2 microns into a solution comprising water and a surfactant which reacts with the nitride or carbide particles at a faster rate than the water, (ii) adding thereto an aqueous solution which comprises ions of the metal, which will form the metal compound, and (iii) increasing the pH of the solution of the metal ions and the nitride or carbide to deposit the metal hydroxide on the surface of the ceramic nitride or carbide particles, wherein the pH of the nitride or carbide solution is increased to no higher than about 1.5 pH units below the hydrolysis constant of the metal ion until at least about 90 weight percent of the metal ions have been deposited upon the nitride or carbide particles.
A process for the preparation of suspensions of finely divided particles of a first solid which is predominantly an inorganic nitride or carbide in a fluid suspension medium which is predominantly water and with which surfaces of said first solid are chemically reactive, comprising the steps of:
A process for depositing a first solid material upon the surface of a particle of a second solid material suspended in a dispersion medium while substantially avoiding the generation of free particles of said first solid material, comprising the steps of:
A process for the preparation of suspensions of finely divided particles of a first solid which is predominantly an inorganic nitride or carbide in a fluid suspension medium which is predominantly water and with which surfaces of said first solid are chemically reactive, comprising the steps of
Dependencies are inferred from the claim text.