Ford Motor Company Limited

Hiroshi Sato

Leslie L Terner

Jack E Noakes

A method of forming a silicon carbide article is disclosd. Selected weight percentages of silicon carbide particles, graphite particles, if desired, and a thermosetting binder are mixed together and molded into an article by molding techniques which operate on the basis that the thermosetting binder forms a continuous medium about all the particles supported therein. The molded article is heated in the absence of oxygen and the thermosetting binder breaks down to form a low density, vitreous carbon phase. The article is heated in the absence of oxygen to a selected temperature at which the article is maintained for a period of time in a gaseous environment consisting of nitrogen preferably with a small amount of hydrogen therein. The hydrogen-nitrogen treatment is effective to cleanse the article and insure that there is an adequate pore structure through the article for a later siliciding operation to be carried out thereon. The article is silicided at an elevated temperature by penetration of the article through its pore structure with a reactable form of silicon.

Method of forming a silicon carbide article

A method of forming a silicon carbide article is disclosed. Selected weight percentages of silicon carbide particles, graphite particles, if desired, and a thermosetting binder are mixed together and molded into an article by molding techniques which operates on the basis that the thermosetting binder forms a continuous medium about all the particles supported therein. The molded article is heated in the absence of oxygen and the thermosetting binder breaks down to form a low density, vitreous carbon phase. The article is heated in an oxygen containing environment to remove excess surface carbon. The article is silicided at an elevated temperature by penetration of the article through its pore structure with a reactable form of silicon.

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West Lafayette, IN, United States of America

Hiroshi Sato