Low creep refractory ceramic and method of making
AssigneeCorning Incorporated
InventorYanxia Lu
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Abstract
A method is disclosed for manufacturing a zircon composition, the method comprising contacting a zircon powder with a sintering aid, wherein the sintering aid is in the form of a liquid, a sol, or a combination thereof. Also disclosed are methods for forming the zircon composition into a desired shape and for firing a composition to produce a ceramic body. The zircon composition and ceramic body produced by the described methods are also disclosed.
Claims30
A method of making a ceramic composition for use in producing a sintered ceramic body, the method comprising contacting a zircon powder with a sintering aid, wherein:
- (a) the sintering aid comprises a sol comprising a plurality of suspended TiO2 nanoparticles, and
- (b) the zircon powder has an average particle size of from about 3 μm to about 10 μm.
A method of making a ceramic composition for use in producing a sintered ceramic body, the method comprising contacting a zircon powder with a sintering aid, wherein:
- (a) the sintering aid comprises titanium isopropoxide in isopropyl alcohol, and
- (b) the zircon powder has an average particle size of from about 3 μm to about 10 μm.
A method for making a ceramic body comprising:
- (a) forming a ceramic composition into a desired shape, and
- (b) firing the desired shape at a time and temperature sufficient to form a ceramic body, wherein:
- (i) the ceramic composition comprises a zircon powder which has an average particle size of from about 3 μm to about 10 μm,
- (ii) the zircon powder is coated with a sintering aid which at the time of the coating comprises a sol comprising a plurality of suspended TiO2 nanoparticles, and
- (iii) the ceramic body has a creep rate of less than 1×10−6/hr at 1,180° C. and 1000 psi.
A method for making a ceramic body comprising:
- (a) forming a ceramic composition into a desired shape, and
- (b) firing the desired shape at a time and temperature sufficient to form a ceramic body, wherein:
- (i) the ceramic composition comprises a zircon powder which has an average particle size of from about 3 μm to about 10 μm,
- (ii) the zircon powder is coated with a sintering aid which at the time of the coating comprises titanium isopropoxide in isopropyl alcohol, and
- (iii) the ceramic body has a creep rate of less than 1×10−6/hr at 1,180° C. and 1000 psi.
Dependencies are inferred from the claim text.