Ceramic composite

A braze-bonded ceramic composite structure comprising:

• a ceramic body and a substrate;
• said substrate having a top major surface and consisting essentially of a single pure metal;
• said ceramic body having a bottom surface overlying the top major surface of said substrate;
• a braze-bonding layer including a bonding metal which forms a chemical compound of said bonding metal in said braze-bonding layer;
• said braze-bonding layer being microscopically pore-free so that substantially no pores are visible in said bonding layer at magnification of up to 1000.times. and directly and continuously bonding the top major surface of said substrate to the bottom surface of said ceramic body.

A ceramic composite structure comprising:

• a ceramic body and a substrate;
• said substrate having a top surface which includes a portion and consisting essentially of a material selected from the group consisting of a metal and a ceramic;
• said ceramic body having a bottom surface overlying the portion of the top surface of the substrate for establishing a contact area therewith;
• said contact area defining a continuous bonding layer comprising a bonding metal between the top surface of said substrate and the bottom surface of said ceramic body;
• said bonding layer being substantially free of pores visible at magnification up to 1000.times.;
• said bonding layer bonding together the portion of the top surface of said substrate to the bottom surface of said ceramic body and having a thickness to an accuracy of 100 Angstroms.

A diamond composite structure comprising:

• a plurality of diamond bodies chemically bonded into a laterally extending diamond layer of at least 1.5 mm on a length thereof;
• each of said diamond bodies having side surfaces, and neighboring diamond bodies having their side surfaces opposite to and intimately contacting each other at a respective contact area;
• a first continuous and void-free bonding layer comprising a first bonding composition and produced by a first chemical reaction of said first bonding matter with said diamond bodies;
• said first bonding layer bonding said diamond bodies together over the respective entire contact area directly, continuously and substantially free of voids visible at magnification of up to 1000.times..

A ceramic composite structure comprising:

• a substrate;
• a ceramic body having a bottom surface overlying said substrate;
• and
• a bonding composition chemically bonding said bottom surface of said ceramic body onto said substrate;
• said bonding composition being substantially free of pores visible at magnification up to 1000.times. and being interposed between said ceramic body and said substrate for defining an interfacial bonding layer having a maximum thickness of 3.5 mm.

A ceramic composite structure for practical operation above 630.degree. C. comprising:

• a substrate;
• a ceramic body having a bottom surface overlying a portion of a top surface of said substrate for establishing a contact area therewith;
• and
• a bonding composition bonding said ceramic body onto said substrate at said portion;
• said bonding composition being interposed, continuously and substantially free of pores visible at magnification up to 1000.times. between said ceramic body and said substrate for defining a continuous interfacial bonding layer;
• said bonding layer having a maximum thickness of 1 micron.

A chemically bonded ceramic composite structure comprising:

• a first solid body of a first solid material consisting essentially of a first ceramic material and having a first surface;
• a second solid body of a second solid material having a second surface contacting the first surface of said first solid body to define a contact area;
• and
• a chemically bonding layer at said contact area to directly bond the first surface of said first solid body to the second surface of the second solid body;
• said bonding layer being sufficiently free of bonding defects to retain bond integrity after at least one thermal shock by quenching in water from a temperature of at least 630.degree. C.

A heat-resistant ceramic bonded article of manufacture for practical use above 630.degree. C., comprising:

• a first solid material having a first exposed surface thereon;
• a second solid material having a second exposed surface thereon;
• at least one of said first and second solid materials consisting essentially of a ceramic;
• said article having components including said first and second solid materials and all said components being independently operable for said practical use;
• said first exposed surface on said first solid material being sufficiently adjacent to at least a portion of said second exposed surface on said second solid material to thereby form therebetween a contact interface having a dimension of at least 1.5 mm;
• and
• a ceramic bonding layer positioned at said contact interface for chemically and physically bonding together said first and second solid materials;
• and
• said ceramic bonding layer being no more than 3.5 mm thick and microscopically sufficiently free of voids visible at a magnification of 1,000 times to withstand said practical use without failure, whereby said article is made heat-resistant for said practical use.