High temperature stabilized mullite-aluminum titanate
First Claim
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1. A method of producing a high temperature stabilized mullite-aluminum-titanate article, the article consisting essentially, expressed in weight percent based on the oxides, of 1.5-20%, SiO2, 5-25% Fe2 O3, 35-75% Al2 O3, and 10-40% TiO2, said method comprising the steps of:
- forming doped mullite by a process selected from;
(1) doping mullite with dopant selected from titania, titania precursors, hematite, and hematite precursors to form doped mullite; and
(2) pre-reacting mullite precursors with dopant selected from titania, titania precursors, hematite, and hematite precursors to form doped mullite precursors;
calcining and milling the doped mullite;
calcining and milling aluminum-titanate;
mixing the mullite and the aluminum-titanate with a binder to form a ceramic batch;
shaping the ceramic batch to form a green ceramic article; and
firing the green ceramic article at a temperature and for a duration of time sufficient to form the sintered ceramic article.
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Abstract
This invention relates to a sintered mullite-aluminum titanate article formed by doping the mullite with 1-5% titania and/or titania precursors, and 1-5% hematite and/or hematite precursors, pre-calcining the mullite and mixing with calcined aluminum titanate to form a mullite-aluminum titanate composition which may be formed into a high temperature stabilized ceramic article such as a honeycomb.
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Citations
9 Claims
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1. A method of producing a high temperature stabilized mullite-aluminum-titanate article, the article consisting essentially, expressed in weight percent based on the oxides, of 1.5-20%, SiO2, 5-25% Fe2 O3, 35-75% Al2 O3, and 10-40% TiO2, said method comprising the steps of:
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forming doped mullite by a process selected from;
(1) doping mullite with dopant selected from titania, titania precursors, hematite, and hematite precursors to form doped mullite; and
(2) pre-reacting mullite precursors with dopant selected from titania, titania precursors, hematite, and hematite precursors to form doped mullite precursors;calcining and milling the doped mullite; calcining and milling aluminum-titanate; mixing the mullite and the aluminum-titanate with a binder to form a ceramic batch; shaping the ceramic batch to form a green ceramic article; and firing the green ceramic article at a temperature and for a duration of time sufficient to form the sintered ceramic article. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of producing a sintered ceramic body consisting essentially of the composition expressed in terms of weight percent based on the oxides, of 1.5-20% SiO2, >
- 5-25% Fe2 O3, 35-75% Al2 O3. 10-40% TiO2, and 0.1-5% RE2 O3, the steps comprising;
(a) calcining a mixture of Fe2 O3, TiO2 and Al2 O3 to a single phase solid solution; (b) grinding the solid solution to a powder; (c) mixing mullite with the powder to from a homogeneous body; (d) combining rare earth metal oxides either to the mixture prior to the calcining step or to the powder in the mixing step; and (e) firing the body to form the sintered ceramic body;
the improvement being that prior to mixing the mullite with the powder to form a homogeneous body, the mullite is first (1) doped with dopant selected from titania, titania precursors, hematite, and hematite precursors to form doped mullite precursors, and (2) calcined.
- 5-25% Fe2 O3, 35-75% Al2 O3. 10-40% TiO2, and 0.1-5% RE2 O3, the steps comprising;
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8. A method of producing a sintered ceramic body consisting essentially of the composition expressed in terms of weight percent based on the oxides, of 1.5-20% SiO2, 5-25% Fe2 O3, 35-75% Al2 O3, and 10-40% TiO2, the steps comprising:
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(a) calcining a mixture of TiO2 and Al2 O3 to a single phase solid solution; (b) grinding the solid solution to a powder; (c) doping mullite with hematite; (d) calcining the doped mullite; (e) mixing the doped mullite with the powder to form a homogeneous body; and (f) firing the body to form the sintered ceramic body. - View Dependent Claims (9)
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Specification