Molten metal-resistant ceramic fiber-containing composition
AssigneeStemcor Corporation
InventorsSteven J. Waisala, Ajit Y. Sane
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Abstract
A method of manufacturing a molten metal-resisting ceramic fiber composition includes mixing ceramic fibers, a frit, ceramic additives, a low temperature binder, and water. The mixture is formed into a desired shape, preferably by being extruded through a die. The shaped mixture is baked at low temperature, and then is fired at high temperature. During firing, the low temperature binder is oxidized and the frit is melted so as to substantially coat the fibers and fuse them into a porous matrix.
Claims24
A molten metal-resistant ceramic fiber containing composition of a density less than or equal to about 45 lb/ft.sup.3 produced by the steps of:
- providing a frit of CaQ, Al.sub.2 O.sub.3, and B.sub.2 O.sub.3
- providing a low temperature organic binder;
- mixing the low temperature organic binder with the frit;
- providing alumino-silicate ceramic fibers;
- mixing the binder-frit mixture with the fibers;
- adding water to the binder-frit-fiber mixture;
- forming the binder-frit-fiber mixture into a shape;
- drying the binder-frit-fiber mixture;
- and
- firing the binder-frit-fiber mixture to oxidize the binder and melt the frit.
A molten metal-resistant ceramic fiber-containing composition of a density less than or equal to about 45 lb/ft.sup.3 produced by the steps of:
- providing a frit of CaO, Al.sub.2 O.sub.3 and B.sub.2 O.sub.3, the frit constituting about 6-16 percent by weight of the initial mixture;
- providing a low temperature organic binder, the low temperature organic binder constituting about 3-5 percent by weight of the initial mixture;
- mixing the low temperature organic binder with the frit;
- providing alumino-silicate fibers, the fibers constituting about 17-24 percent by weight of the initial mixture;
- mixing the binder-frit mixture with the fibers;
- adding water to the binder-frit-fiber mixture, the water constituting about 55-72 percent by weight of the initial mixture;
- forming the binder-frit-fiber mixture into a shape;
- drying the binder-frit-fiber mixture at about 100.degree.-120.degree. C. for about 12 hours;
- firing the binder-frit-fiber mixture by heating the mixture to about 1050.degree. C. over a period of about ten hours, and holding the temperature at about 1050.degree. C. for about two hours;
- and
- cooling the binder-frit-fiber mixture from about 1050.degree. C. to about 25.degree. C. over a period of about six hours.
Dependencies are inferred from the claim text.