Aluminum Company of America

Raymond P Heilich

John E Marhanka

Thomas L Francis

James Chervenka, Jr

George Maczura

Frank J Rohr

A lightweight, porous, ceramic material is made by mixing a slurry containing a foaming agent until a constant volume of foam is achieved. The foam is then pumped or poured into a mold or form where it sets up into a cellular structure. The formed foam is then cured, dried and heated at elevated temperatures. The slurry used in making the foam is made from ceramic particles, water, foaming agent and bonding materials. The bonding materials function to provide an initial bond as the foam is generated to prevent foam collapse, a low temperature bond after the foam structure is set, cured and dried, and a final bond after heating to elevated temperatures. In a preferred embodiment, the ceramic particles used are alumina.

Noncollapsible ceramic foam

A high purity mortor suitable for bonding refractory brick is disclosed. The mortar, which is resistant to attack by molten aluminum, comprises 43 to 89 wt.% alumina aggregate, 10 to 45 wt.% calcium aluminate cement, 0.5 to 10 wt.% zinc borosilicate and 0.1 to 1.5 wt.% boric acid.

High purity mortar suitable for bonding refractory brick

A high early strength cement composition is disclosed which is capable of providing sufficient compressive strength within 2 to 24 hours to enable one to use it in highway or airport runway patching. The cement also exhibits satisfactory ultimate strength, that is, strength after 28 or more days of curing. The high early strength cement comprises a mixture of portland cement, calcium aluminate, and calcium sulfate in certain specified proportions.

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Mehlville, MO, United States of America

Raymond P Heilich