Methods for making self-supporting composite bodies and articles produced thereby
First Claim
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1. A method for forming a self-supporting body comprising:
- providing a solid oxidant-containing material;
providing at least one filler on at least a portion of said solid oxidant-containing material;
contacting at least one vapor-phase parent metal with at least a portion of said solid oxidant-containing material; and
causing said at least one vapor-phase parent metal and at least a portion of said solid oxidant-containing material to form at least one reaction product on at least a portion of at least one surface of said solid oxidant-containing material, wherein said at least one reaction product embeds at least a portion of said at least one filler.
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Abstract
This invention relates generally to a novel directed metal oxidation process which is utilized to produce self-supporting bodies. In some of the more specific aspects of the invention, a parent metal vapor is induced to react with a solid oxidant to result in the directed growth of a reaction product which is formed from a reaction between the parent metal vapor and the solid oxidant. The inventive process can be utilized to form bodies having substantially homogeneous compositions, graded compositions, and macrocomposite bodies.
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Citations
27 Claims
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1. A method for forming a self-supporting body comprising:
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providing a solid oxidant-containing material; providing at least one filler on at least a portion of said solid oxidant-containing material; contacting at least one vapor-phase parent metal with at least a portion of said solid oxidant-containing material; and causing said at least one vapor-phase parent metal and at least a portion of said solid oxidant-containing material to form at least one reaction product on at least a portion of at least one surface of said solid oxidant-containing material, wherein said at least one reaction product embeds at least a portion of said at least one filler. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 20, 21)
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13. A method for forming a self-supporting body comprising:
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providing a first solid oxidant-containing material; placing at least one different solid oxidant-containing material on at least a portion of said first solid oxidant-containing material; contacting at least one vapor-phase parent metal with at least a portion of said first solid oxidant-containing material and said different solid oxidant-containing material; and causing said at least one vapor-phase parent metal and at least said first solid oxidant-containing material to form at least one reaction product on at least a portion of at least one surface of at least said first solid oxidant-containing material, wherein said at least one reaction product includes at least a portion of said at least one different solid oxidant-containing material or at least one different reaction product formed from said at least one different solid oxidant-containing material. - View Dependent Claims (14, 15, 16, 17, 18, 19, 22)
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23. A method for forming a self-supporting body comprising:
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providing a first solid oxidant-containing material; coating at least a portion of said first solid oxidant-containing material with at least one material selected from the group consisting of at least one parent metal powder and at least one different solid oxidant-containing material; contacting at least a portion of said coated first said solid oxidant-containing material with a parent metal vapor; and causing said parent metal vapor to react to form at least one reaction product on at least a portion of at least one surface of said first solid oxidant-containing material, wherein said at least one reaction product includes at least a portion of at least one material selected from the group consisting of said at least one powdered parent metal, said at least one different solid oxidant-containing material and at least one different oxidation reaction product formed from said at least one powdered parent metal or said at least one different solid oxidant-containing material. - View Dependent Claims (24, 25, 26, 27)
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Specification