Process for preparing self-supporting bodies having controlled porosity and graded properties and products produced thereby

A method of producing a self-supporting body comprising:

• mixing at least one combustible material and particulate first parent metal with a boron carbide material to form a reaction mixture, said reaction mixture optionally containing at least one filler material;
• contacting said reaction mixture with a body of second parent metal to form a lay-up;
• heating said reaction mixture to a temperature which is sufficient to permit the combustion of said combustible material, said temperature being approximately equal to or less than the melting temperature of said particulate first parent metal and said second parent metal;
• heating said lay-up to a temperature which is above the melting point of said particulate first parent metal and said second parent metal to result in a reaction of the body of second parent metal with the boron carbide material and a reaction of the particulate first parent metal with the boron carbide material, thereby forming at least one boron-containing compound, and resulting in a self-supporting body having porosity.

A method of producing a self-supporting body comprising:

• mixing at least one combustible material with a bed or mass comprising a boron carbide material to form a mixture;
• and
• contacting said mixture with a body of parent metal to form a lay-up;
• heating said mixture to a temperature which is sufficient to permit the combustion of said combustible material, said temperature being approximately equal to or less than the melting temperature of said parent metal;
• heating said lay-up to a temperature which is above the melting point of said parent metal to result in a reaction of the body of parent metal with the boron carbide material, thereby forming at least one boron-containing compound, and resulting in a self-supporting body having porosity.