Forming a ceramic by flocculation and centrifugal casting
First Claim
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1. A method of fabricating a structural ceramic comprising the steps of:
- dispersing ceramic particles in a liquid;
sedimenting the disposed particles to remove large particles and agglomerates;
flocculating the dispersed ceramic particles;
removing the clear supernate from the flocced ceramic particles;
centrifuging said flocced ceramic particles to produce a consolidated mass capable of retaining its shape; and
sintering the centrifuged ceramic particles.
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Abstract
A ceramic is fabricated by dispersing ceramic particles in a liquid, sedimenting the dispersion to remove large particles, and then changing its pH to flocculate the dispersed particles. The size distribution of the particles in each individual floc is similar to the size distribution of particles throughout the dispersion. The supernate is removed and the flocs are cast by centrifuging them into a mold. The cast flocs are dried and sintered to form the ceramic. To provide a multiphase ceramic, particles of two or more ceramics can be mixed together and flocced prior to centrifuging.
22 Citations
12 Claims
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1. A method of fabricating a structural ceramic comprising the steps of:
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dispersing ceramic particles in a liquid; sedimenting the disposed particles to remove large particles and agglomerates; flocculating the dispersed ceramic particles; removing the clear supernate from the flocced ceramic particles; centrifuging said flocced ceramic particles to produce a consolidated mass capable of retaining its shape; and sintering the centrifuged ceramic particles. - View Dependent Claims (2, 3, 4)
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5. A method of fabricating a structural ceramic comprising the steps of:
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dispersing ceramic particles in a liquid; sedimenting said dispersed particles to remove large particles and agglomerates; flocculating said dispersed particles by changing the pH of said liquid; removing supernate from said flocced particles; centrifugally casting said flocced particles into a mold to produce a consolidated mass capable of retaining its shape; drying said cast particles; and sintering said dried particles.
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6. A method of fabricating a multiphase structural ceramic comprising the steps of:
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dispersing particles of a first ceramic in a first liquid; sedimenting said dispersed particles of a first ceramic to remove large particles and agglomerates; flocculating the dispersed particles of said first ceramic; dispersing particles of a second ceramic in a second liquid; sedimenting said dispersed particles of a second ceramic to remove large particles and agglomerates; flocculating the dispersed particles of said second ceramic; removing clear supernate and mixing the flocced particles of said first and said second ceramics; centrifuging the mixture of said first and said second ceramics to produce a consolidated mass capable of retaining its shape; and sintering the centrifuged mixture. - View Dependent Claims (7, 8, 9)
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10. A method of fabricating a multiphase structural ceramic comprising the steps of:
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dispersing particles of a first ceramic in a first liquid; sedimenting said dispersed particles of a first ceramic to remove large particles and agglomerates; dispersing particles of a second ceramic in a second liquid; sedimenting said dispersed particles of a second ceramic to remove large particles and agglomerates; mixing the dispersed particles of said first and second ceramics; flocculating the particles of said first and second ceramics; removing clear supernate from said flocced particles; centrifuging the flocced particles of said first and second ceramics to produce a consolidated mass capable of retaining its shape; and sintering the centrifuged particles of said first and second ceramics. - View Dependent Claims (11, 12)
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Specification