The Dow Chemical Company

Jack J Ott

Aleksander Jozef Pyzik

Uday V Deshmukh

Harold E Rossow

Stephen D Dunmead

Arthur Richard Prunier, Jr

Timothy L Allen

Tim L Allen

Dniel F Carroll

Scott J Jankowski

A method of coating a fluidizable material onto a surface of a substrate, wherein the substrate is not wettable by the fluidizable material includes depositing a layer of powder particles on the surface of the substrate, the powder particles being wettable by the fluidizable material; contacting the fluidizable material to the layer of powder particles; and allowing the fluidizable material to wick between the powder particles and to contact the surface of the substrate. The method of the invention provides a method which requires little or no binders or organic solvents, is applicable to many different ceramic-metal formulations, allows easy control of the thickness of the tape, forms fairly dense tapes so that little or no shrinkage occurs upon densification at elevated temperatures, and does not require undesirably high processing temperatures.

Method for coating a non-wetting fluidizable and material onto a

Subject boron carbide to a passivation treatment at a temperature within a range of 1350.degree. C. to less than 1800.degree. C. prior to infiltration with a molten metal such as aluminum. This method allows control of kinetics of metal infiltration and chemical reactions, size of reaction products and connectivity of B.sub.4 C grains and results in cermets having desired mechanical properties.

Light weight boron carbide/aluminum cermets

A method to at least partially impregnate a porous ceramic body with a metal comprising positioning a sacrificial porous ceramic transport means in physical contact with the metal and between the porous ceramic body to be impregnated and the metal; interposing a sufficient amount of a ceramic powder in contacting relationship between the ceramic body and the transport means to enable the metal to flow from the ceramic transport means to the ceramic body and insufficient to permit metal bonding between the transport means and the ceramic body, at least one constituent of the powder being wettable by, and chemically reactive with the metal; and maintaining at least the ceramic body and metal transport means at a temperature, and for a time, sufficient for at least a portion of the metal to flow through the transport means and into the ceramic body to impregnate the ceramic body a predetermined amount to form a metal impregnated ceramic body of near net shape.

Shaped ceramic-metal composites

The invention relates to subjecting boron carbide to a heat treatment at a temperature within a range of 1250.degree. C. to less than 1800.degree. C. prior to infiltration with a molten metal such as aluminum. This method allows control of kinetics of metal infiltration and chemical reactions, size of reaction products and connectivity of B.sub.4 C grains and results in cermets having desired mechanical properties.

Method of preparing boron carbie/aluminum cermets having a controlled

A method of infiltrating a porous ceramic compact with a molten metal to form a cermet is disclosed. A solid-phase metal is disposed on a surface of a porous ceramic compact. The surface of the porous ceramic compact is at an angle to the horizontal which is sufficient to allow molten metal formed from the solid-phase metal to rupture an oxide layer at least partially supporting the molten metal. The solid-phase metal is heated to a temperature sufficient to melt the solid-phase metal and to allow the molten metal formed to rupture the oxide layer. The molten metal flows through an opening in the metal oxide layer formed by the rupture and infiltrates the porous ceramic compact. The porous ceramic compact, containing the molten metal, is then cooled to a temperature whereby the molten metal solidifies, thereby forming a cermet.

Method for forming a cermet porous ceramic compact and heating the metal

The present invention employs poly(ethyloxazoline) as a temporary binder and lubricant during the preparation of greenware articles. According to the present invention, molten poly(ethyloxazoline) promotes the compressibility of the powder used to form the greenware article, thus improving the density and strength of both the greenware and the abrasive article. The molten poly(ethyloxazoline) acts as a lubricant to permit a more efficient grain rearrangement under applied pressure and thereby increases the average density of the greenware article by 6 to 8 percent as compared to standard cold pressing.

Method for making machinable abrasive greenware

A process is described for making a composite article without shrinkage, particularly of ceramic and metal wherein the article includes complex internal surfaces or cavities. The process requires forming an insert body that includes an external surface that corresponds to an internal cavity of the article. The insert body consists of a material having a melting temperature less than that of the article. The process further requires forming a porous compact about the insert body wherein the compact is formed into the substantially the net shape of the article. The compact is made of a material that is wetted by liquid insert material and has a sintering temperature greater than the wetting temperature of the insert material. The process further requires heating the article to a temperature such that the inserts substantially melts and infiltrates the porous compact forming the finished composite article. The process produces products including complex internal surfaces without the necessity of costly and sometimes technically difficult internal machining operations.

Method for making composite articles that include complex internal

An agent suitable to treat metals to, for example, desulfurize steel is disclosed. The treating agent is produced by coating a porous body with molten magnesium, oxidizing the magnesium coating and then impregnating the oxide coated porous body with magnesium.

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Hemlock, MI, United States of America

Jack J Ott