Process for preparing self-supporting ceramic composite bodies and bodies produced thereby
AssigneeLanxide Technology Company, LP
InventorPaul V. Kelsey
Life of this patent
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Abstract
This invention relates generally to a novel method of preparing self-supporting bodies, and to novel products made thereby. In its more specific aspects, this invention relates to a method of producing self-supporting bodies comprising one or more boron-containing compounds, e.g., a boride or a boride and a carbide, by reactive infiltration of a molten parent metal actinide into (1) a bed or mass containing boron carbide and, optionally, (2) at least one of a boron donor material (i.e., a boron-containing material) and a carbon donor material (i.e., a carbon-containing material), (3) a bed or mass comprising a mixture of a boron donor material and a carbon donor material and, optionally, (4) one or more inert fillers in any of the above masses, to form the body.
Claims22
A method for producing a self-supporting body, comprising:
- selecting a parent metal comprising at least one metal selected from the group consisting of the actinide series of metals;
- heating said parent metal in a substantially inert atmosphere to a temperature above its melting point to form a body of molten parent metal;
- contacting said body of molten parent metal with a permeable mass comprising at least one material selected from the group consisting of (1) boron carbide, (2) a mixture of a boron donor material , (4) a mixture of boron carbide and a carbon donor material, and (5) a mixture of boron carbide and a boron donor material and a carbon donor material;
- maintaining said temperature for a time sufficient to permit infiltration of molten parent metal into said permeable mass and to permit reaction of said molten parent metal with at least a portion of said at least one material to form at least one compound selected from the group consisting of a parent metal boride, a parent metal boro compound and a parent metal carbide;
- controlling at least one condition of said infiltration and said reaction, said controlling comprising at least one step selected from the group of steps consisting of controlling said temperature, controlling said time and controlling a particle size of said at least one material, whereby said controlling, upon conclusion of said infiltration and reaction, results in at least a portion of said at least one material remaining unreacted with said parent metal;
- continuing said infiltration and reaction for a time sufficient to produce said self-supporting body comprising residual parent metal and said at least one material embedded by a matrix comprising said at least one compound;
- and
- cooling said formed self-supporting body.
A self-supporting composite body comprising at least one material selected from the group consisting of (1) boron carbide, (2) a mixture of a boron donor material and a carbon donor material, (3) a mixture of boron carbide and a boron donor material, (4) a mixture of boron carbide and a carbon donor material and (5) a mixture of boron carbide and a boron donor material and a carbon donor material embedded in a three-dimensionally interconnected ceramic phase extending to the boundaries of said composite body, said ceramic phase comprising at least one carbide selected from the group consisting of a carbide of uranium and a carbide of thorium, and said composite body further comprising a boride of the metal corresponding to said carbide, said boride having a platelet-like structure.
A self-supporting composite body comprising at least one metal phase selected from the group consisting of uranium and thorium, and a three-dimensionally interconnected ceramic phase extending to the boundaries of said composite body, said ceramic phase comprising at least one boride selected from the group consisting of a boride of uranium and a boride of thorium, said boride having a platelet-like structure, and said composite body further comprising a carbide of the metal corresponding to said boride.
Dependencies are inferred from the claim text.