Superior Graphite Company

The Dow Chemical Company

Exxon Research and Engineering Company

Battelle Memorial Institute

Battelle Development Corporation

Inland Steel Company

Silag, Inc.

Superior Graphite

William M Goldberger

Bhupendra K Parekh

Bobby P Faulkner

Harold M Epstein

Daniel Boss

Kenneth F Lowrance, Ii

A K Reed

Doreen Edwards

Allan Reed

Eric C Knorr

Allen K Reed

A method of manufacturing a shaped article from a powdered precursor, wherein the components of the powdered precursor are subjected to a self-propagating high-temperature synthesis (SHS) reaction and are consolidated essentially simultaneously. The shaped article requires essentially no machining after manufacture.

Method of manufacturing a shaped article from a powdered precursor

A method of consolidating particulate materials or combinations of such materials into shaped products of very low porosity. High compaction pressures are applied at temperatures in the range of sintering temperature of the materials being consolidated to achieve essentially complete densification at extremely rapid processing rates. Electrothermal heating is utilized to accomplish these results. Difficult materials such as silicon carbide, boron carbide and other very high melting point materials may be densified by these techniques.

Method for electroconsolidation of a preformed particulate workpiece

The present invention comprises an improved method of controlling resistivity in a process for consolidating particular materials or combinations of such materials into shaped products of very low porosity. High compaction pressures are applied at temperatures in the range of sintering temperature of the materials being consolidated to achieve essentially complete densification at extremely rapid processing rates. Electrothermal heating of a medium having controlled resistivity is utilized to accomplish these results. Various difficult materials, such as silicon carbide, boron carbide and other very high melting point materials, may be densified by these techniques.

Method for control of resistivity in electroconsolidation of a preformed

The present invention is directed generally to apparatus for and improvements in powdered metal consolidation processes, some of which referred to as 'electroconsolidation' processes, and more particularly to processes employing specially shaped rams or electrodes and/or other press elements for imparting uniformity of electrical flux and/or pressure to a workpiece. Some embodiments of the improved process of the present invention contemplate controlling the degree of compaction by providing rams which generally conform to the shape of the preform. Such projections may be provided on the rams to selectively develop at least one zone of relatively high compaction within the die chamber, which results in certain embodiments associated with the electroconsolidation process in release of the major portion of the electrical energy within the zone having a relatively high degree of compaction. Moreover, at least one member of a selected shape may be inserted within the die chamber for modifying the electrical resistivity pattern thereof.

Process and apparatus for electroconsolidation

This invention relates to the production of a unique class of granular graphitic carbon materials containing metallic elements dispersed throughout the graphitic structure. More specifically, the unique class of products contain elements that enhance the controlled nucleation of dissolved carbon during the solidification of molten cast irons and are of particular value in the manufacture of quality iron castings. Moreover, the chemical form of the selected metallic elements and their high degree of dissemination within and throughout a graphitic carbon structure has been shown to provide special properties that increase the controlled nucleating or 'inoculating' ability of the products of this invention over that obtained by use of the components added individually or in a simple mixture to molten cast iron.

Metal bearing graphitic carbons

The present invention is directed to a reaction product of silica sand and of particulate carbonaceous material to form, silicon carbide on the surface of the carbonaceous particles and within the pores thereof, with the silicon carbide ultra-microcrystallites having a diameter of approximately 500 Angstroms and the composition comprising approximately 60% silicon carbide. The present invention is further directed to the process by which the ultra-microcrystallite silicon carbide product is made. In other preferred embodiments the ultra-microcrystallites of silicon carbide may be separated from the carbonaceous material by heat or physical methods to form a substantially pure ultra-microcrystallite silicon carbide product.

Ultra-microcrystallite silicon carbide product

One aspect of the present invention relates to methods for the continuous production of silicon carbide and other carbide and refractory products by fluidized bed techniques, the apparatus for such continuous production, and the carbide products produced therefrom being further aspects of the present invention.

Method for the continuous production of carbides

Method of making ultra-microcrystallite silicon carbide product

One aspect of the present invention concerns an improved process for the electrolytic reduction of a metal from a metal compound and comprises the steps of providing a carbon cathode within a container, dissolving the metal compound in a molten salt electrolyte solvent bath which is disposed within the container, the molten electrolyte bath having a higher decomposition potential than the metal compound and having a lesser density than the reduced molten metal, and continuously providing a particulate, free-flowing, high purity, and highly conductive carbon material to the molten bath to serve as the anode, the particulate carbon material having a lesser density than the molten bath, placing an electrical connection in contact with the particulate carbon anode material and applying an electric current thereto, and collecting reduced metal at the cathode. In another aspect of the present invention, a high purity and highly conductive, free-flowing particulate carbon material having a density lower than that of an electrolytic bath and floating thereon is provided to form the cell anode and in preferred embodiments is continuously provided to the cell as the particulate carbonaceous anode material is consumed.

Process for the electrolytic reduction of metals and an improved

A two-step method for separating mineral grains from their ores is practised by first applying a shock discharge directly through the ore sample producing shock waves emanating from along the discharge path and reflected shock waves (tension waves) from grain boundaries and other discontinuities in the ore, such tension waves resulting in tensile stresses in the ore greater than the strength of the boundary or discontinuity whereby to gross spall the sample generally along the discharge path and to microfracture the region near the discharge path. The second step comprises comminuting the microfractured ore by impact or non-impact means to further reduce the ore generally along microfractures wherein considerably less energy is expended in the second step than would be required to reduce the ore to the same condition without the first step. A second non-impact step is preferably the application of acoustic energy to the microfractured region of the ore resulting in enlargement of microfractures and subsequent spalling of these microfractured regions.

Two stage comminution

The present invention is directed to silicon carbide whisker recovery from a mixture of silicon carbide whiskers and carbonaceous silicon carbide particles. The invention involves shredding the mixture down to a specified particle size, dispersing the mixture in water to form an aqueous mixture, agitating the aqueous mixture, adding surface active reagents to the aqueous mixture, agitating the resulting water-reagent mixture, subjecting the water-reagent mixture to froth flotation having at least three stages, removing tailings therefrom containing water and silicon carbide whiskers and removing float therefrom containing reagents and carbonaceous silicon carbide particles, performing a solid-liquid separation on the tailings and the float, thereby obtaining from the aqueous solution the desired silicon carbide whiskers and obtaining from the reagent solution a carbonaceous silicon carbide particle product.

Recovery of silicon carbide whiskers from coked, converted rice hulls by

The present invention is directed to silicon carbide whisker recovery from a mixture of silicon carbide whiskers and carbonaceous silicon carbide particles. The invention involves shredding the mixture down to a specified size, dispersing the mixture in water to form an aqueous mixture, agitating the aqueous mixture, mixing the aqueous mixture with an immiscible organic solvent which is lighter than water, agitating the resulting water-organic solvent mixture, allowing the organic solvent and its contents to rise above the water and its contents, separating the two liquid phases into an organic solvent phase and an aqueous phase and, lastly, performing a solid-liquid separation on each of the two phases, thereby obtaining from the aqueous solution the desired silicon carbide whiskers and obtaining from the organic solvent solution a carbonaceous silicon carbide particle product.

Metal beads, e.g., magnesium beads, or Mg alloy beads, having a high degree of rotundity, and having a thin coating of sludge or slag ingredients, are recovered from entrapment in a friable contiguous material of sludge or slag material by (a) a primary milling of the friable matrix in a hammer mill or impact mill, (b) screening the material to collect the desired particle sizes, (c) attriting the material in a secondary milling operation to further, and gently, grind sludge material from around the beads, and (d) separating the rotund beads from the pulverized matrix material by using a shape-classifier, such as a slanted shaker table. The material may be treated beforehand by melting the metal-containing sludge or slag, adding a flux or emulsifier material with stirring to cause dispersion of the metal into a relatively narrow particle size range and then freezing the molten mixture. The invention is especially useful in the case of Mg beads, since Mg beads are malleable and pyrophoric.

Recovery of round metal granules from process sludge

Methods of treating an oil derived by liquefaction of coal particles to separate unreacted solid matter therefrom and collect it in water or other aqueous medium, which comprise controlling the specific gravity of the oil to provide an oleaginous fluid having a substantially lower specific gravity than the aqueous medium, as by mixing the oil with a liquid that is miscible therewith and has a lower specific gravity, or by controlling the temperature of the oil, or both; contacting the fluid with the aqueous medium; moving the fluid in such a manner as to provide a substantial acceleration thereto in a direction to drive most of the solid matter away from the fluid and into the aqueous medium as by moving the fluid in a swirling path around an axis while maintaining a portion of the aqueous medium around at least a portion of the periphery of the path; and separating the aqueous medium with the solid matter contained therein from the fluid. Typically a layer of the aqueous medium is formed with a layer of the fluid contiguous thereto, and the fluid layer is accelerated (as by centrifuging) to generate a force which acts to drive the particles from the fluid layer toward the aqueous layer; or the layers may be formed by injecting the fluid and the aqueous medium through separate, adjacent passageways into a cyclone separator whereby the layers are accelerated.

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Columbus, OH, United States of America

William M Goldberger