Production of metal carbide articles
AssigneeLanxide Technology Company, LP
InventorsAdam J. Gesing, Edward S. Luce, Narashima S. Raghavan, Danny R. White
Life of this patent
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Abstract
A method for manufacture of Group IVB metal carbide comprising a carbide of a metal selected from the group consisting of titanium, hafnium and zirconium ceramic composites is provided wherein a permeable mass of filler and carbon is contacted with a molten Group IVB metal. The molten metal is maintained in contact with the permeable mass for a sufficient period to infiltrate the permeable mass and to react the molten metal with the carbon source to form a Group IVB metal carbide composite. The permeable mass may comprise a Group IVB metal carbide, or other inert filler, or a combination of filler materials.
Claims20
A self-supporting ceramic composite comprising
- (a) at least one filler selected from the group consisting of (i) at least one carbide of a metal selected from the group consisting of titanium, hafnium and zirconium and (ii) a material which is substantially inert to molten parent metal and a reaction product described in step (b) below;
- and (b) a ceramic matrix embedding said filler, said ceramic matrix comprising at least one non-stoichiometric carbide of a metal selected from a group consisting of titanium, hafnium and zirconium and characterized as a carbon-deficient reaction product between at least one of said metals and a precursor carbon source which is provided in less than a stoichiometric amount.
A self-supporting ceramic composite comprising (a) at least one filler selected from the group consisting of (i) at least one carbide of a metal selected from the group consisting of titanium, hafnium, and zirconium and (ii) a material which is substantially inert to molten parent metal and a reaction product described in step (b) below;
- and (b) a ceramic matrix embedding said filler, said ceramic matrix consisting essentially of at least one stoichiometric carbide of a metal selected from the group consisting of titanium, hafnium, and zirconium, and characterized as the reaction product between at least one of said metals and a precursor carbon source which is provided in a stoichiometric amount.
A method for producing a self-supporting ceramic composite comprising a carbide, which method comprises:
- (a) establishing in a substantially inert atmosphere a body of molten parent metal comprising a metal selected from the group consisting of titanium, hafnium and zirconium in surface contact with a permeable mass comprising (i) at least one filler and (ii) a carbon source for reaction with said molten metal to form a carbide of the molten metal, the carbon moiety of said carbon source being present in no more than a stoichiometric amount, wherein at least two of said at least one filler and said carbon source comprise at least two different carbides of said parent metal;
- (b) maintaining said surface contact for a time sufficient to effect infiltration of molten parent metal into said permeable mass and to permit reaction of said molten parent metal with said carbon source to form a matrix comprising a parent metal carbide;
- and
- (c) continuing said infiltration and reaction for a time sufficient to at least substantially complete said reaction and to thereby produce said self-supporting ceramic composite.
A self-supporting ceramic composite comprising (a) at least one filler selected from the group consisting of (i) at least one carbide of a metal selected from the group consisting of titanium, hafnium and zirconium and (ii) a material which is substantially inert to (A) a parent metal in molten form and (B) a ceramic matrix described in (b) below;
- and (b) a ceramic matrix embedding Said filler, said ceramic matrix comprising at least one carbide of a parent metal selected from the group consisting of titanium, hafnium and zirconium, wherein said at least one filler and said ceramic matrix comprise at least two different carbides of said metal.
Dependencies are inferred from the claim text.