Alliedsignal Inc.

Allied Corporation

Honeywell International Inc.

Gary B Marsh

Anthony J Fanelli

John N Armor

Joan V Burlew

Clifford P Ballard

Patrick M Zambri

Jean Yamanis

James F Stevenson

Jerry C LaSalle

Mohammad Behi

Stephen Haig

Beili Li

William S Frei

A process for adjusting the level of water or water soluble additives in aqueous-based powder injection molding compounds for the purpose of recycling scrap material, controlling shrinkage or rehydrating dry feedstock. Depending on the objective, the process may require material granulation equipment, equipment for the addition or removal of water and mixing equipment. The molding compounds may be comprised of either recycled scrap material before being heat-treated or dry, virgin feedstock material.

Recycle methods for water based powder injection molding compounds

A process for shaping parts from ceramic powder that comprises the steps of (1) forming a concentrated mixture in excess of 40% ceramic solids by volume, the mixture comprising ceramic powder, a gel forming material chosen from the class of polysaccharides known as 'agaroids', and a gel forming material solvent and being formed in a blender that provides a shearing action and is heated to raise the temperature of the mixture to about 70.degree. C. to 100.degree. C.; and (2) molding the mixture at a temperature sufficient to produce a self-supporting structure comprising the powder and gel. The parts exhibit excellent green strength and are rapidly fired without cracking, distortion or shrinkage problems.

Aqueous process for injection molding ceramic powders at high solids

A ceramic element of a zirconia oxygen sensor is shaped from a powder mixture. The mixture, comprising a ceramic powder having an average particle size less than or equal to 1 micrometer, a gel-forming material and a gel forming material solvent, is molded at a temperature and pressure sufficient to produce the ceramic element having a density of at least 5.5 g/cm.sup.3.

Injection molding of zirconia oxygen sensor thimbles by an aqueous

Zirconia toughened alumina (ZTA) is produced from precursor salts. The precursor salts are coprecipitated from solution to yield a gel in a liquid phase. The gel in excess of the critical temperature and pressure is dried at a temperature and pressure in excess of the critical temperature and pressure of the liquid phase to thereby convert the liquid phase to a gas. The solid particles, when separated from the gas, form a fine particulate ZTA which, upon consolidation yields near theoretical density toughened ceramics.

Process for making zirconia-alumina

Inorganic metal oxides having high surface area and pore volume are prepared by spray drying. The admixture which is spray dried to yield the metal oxides is produced from reactants comprising at least one hydrolyzable metal compound, a sufficient amount of water to at least partially hydrolyze the metal compound and an organic solvent. The admixture is supplied as a plurality of droplets to a reaction zone operated under conditions of temperature and pressure below the critical temperature and pressure of the reactants but sufficient to produce a product comprising metal oxide powders and a gas comprising organic solvent vapors. The powders are separated from the gas in a known fashion and collected. Spray drying of non-aqueous systems unexpectedly produces metal oxides having properties generally intermediate conventionally produced oxides and aerogels.

Spray-dried inorganic oxides from non-aqueous gels or solutions

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Pittstown, NJ, United States of America

Gary B Marsh