Fiber reinforced composite having an aluminum phosphate bonded matrix
AssigneeAluminum Company of America
InventorsRobert A. Marra, Donald J. Bray, G. Edward Graddy, Jr., Siba P. Ray
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Abstract
A method of forming fiber reinforced aluminum phosphate bonded material having improved strength at elevated temperatures. The method comprises the steps of: (a) preparing a slurry by blending alumina and alumina phosphate solution, the slurry being substantially free of silica; (b) providing a fiber substrate; (c) infiltrating the solution into the fiber substrate; and (d) curing the infiltrated substrate to form a fiber reinforced aluminum phosphate bonded composite material. In a preferred embodiment of the present invention, the fiber substrate is made from SiC fibers.
Claims35
A method of forming fiber reinforced aluminum phosphate bonded refractory material, the method comprising the steps of:
- preparing a slurry by blending alumina having an average particle size of less than approximately 10 microns and aluminum phosphate solution, said slurry being substantially free of silica;
- infiltrating said slurry into a refractory fibrous substrate to form an infiltrated substrate;
- and
- curing without sintering said infiltrated substrate at a temperature of greater than approximately 200° C. to form a fiber reinforced aluminum phosphate bonded refractory material.
A method of forming fiber reinforced aluminum phosphate bonded refractory material having a high fracture resistance at temperatures in excess of 1200° C., the method comprising the steps of:
- providing refractory fiber;
- providing a solution of from about 30 to about 70 wt. % monoaluminum phosphate solution and from about 30 to about 70 wt. % H2O;
- preparing a slurry by blending approximately 10-70 wt. % alumina having an average particle size of less than approximately 10 microns and said aluminum phosphate solution, said slurry being substantially free of silica;
- impregnating said refractory fiber with said slurry to form a green matrix;
- at least partially drying said impregnated refractory fiber to remove some of the excess free water from said green matrix;
- and
- curing, without sintering said green matrix at a temperature of greater than approximately 200° C. to form said fiber reinforced aluminum phosphate bonded refractory material.
A fiber reinforced aluminum phosphate bonded refractory material comprising:
- a matrix formed from a slurry prepared by:
- blending approximately 10-70 wt. % alumina having an average particle size of less than approximately 10 microns and aluminum phosphate solution of from about 30 to about 70 wt. % monoaluminum phosphate solution and from about 30 to about 70 wt. % H2O, said slurry being substantially free of silica;
- and
- refractory fiber.
A fiber reinforced aluminum phosphate bonded refractory material comprising:
- refractory fiber;
- and
- a matrix formed from a slurry prepared by blending alumina and aluminum phosphate
- solution, said slurry being substantially free of silica;
- impregnating said refractory fiber with said slurry;
- drying said impregnated refractory fiber to form a green matrix;
- and
- curing, without sintering said green matrix to form said fiber reinforced aluminum phosphate bonded refractory material.
A refractory moldable composition consisting of:
- from about 30 to about 70 wt. % monoaluminum phosphate solution;
- from about 30 to about 70 wt. % H2O;
- and
- from about 10 to about 40 wt. % alumina having particle size of less than 10 microns;
- and a refractory fiber.
A fiber reinforced aluminum phosphate bonded refractory material comprising:
- (a) a matrix material of:
- 20-90 wt % alumina having a particle size less than about 10 microns
- 0-1 wt % silica
- 10-80 wt % aluminum phosphate solution;
- and
- (b) refractory fiber.
Dependencies are inferred from the claim text.