Method for making self-supporting composite bodies
First Claim
1. A method for forming a self-supporting body, comprising:
- providing a solid oxidant-containing material;
coating at least a portion of at least one surface of said solid oxidant-containing material with a material comprising at least one filler material and at least one solid oxidant to form a coated solid oxidant-containing material;
providing a source of parent metal in a spaced-apart relationship with respect to said coated solid oxidant-containing material;
communicating a vapor of said parent metal to said coated solid oxidant; and
causing said parent metal vapor to react with said solid oxidant of said coating layer to form at least one reaction product within said coating layer.
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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 (e.g., a parent metal vapor) is induced to react with at least one solid oxidant-containing material to result in the directed growth of a reaction product which is formed from a reaction between the parent metal and the solid oxidant-containing material. The inventive process can be utilized to form bodies having substantially homogeneous compositions, graded compositions, and macrocomposite bodies.
In a preferred embodiment, a substance comprising a filler material and a solid oxidant, preferably an admixture of particulates, is coated onto at least a portion of the solid oxidant-containing material. Such a technique is particularly advantageous for forming relatively thick reaction product layers which might not otherwise develop to the desired thickness using the original "directed growth" embodiment. In a particularly preferred embodiment, the solid oxidant and the solid oxidant-containing material have the same chemical composition, and the filler material and the reaction product have the same chemical composition.
97 Citations
16 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; coating at least a portion of at least one surface of said solid oxidant-containing material with a material comprising at least one filler material and at least one solid oxidant to form a coated solid oxidant-containing material; providing a source of parent metal in a spaced-apart relationship with respect to said coated solid oxidant-containing material; communicating a vapor of said parent metal to said coated solid oxidant; and causing said parent metal vapor to react with said solid oxidant of said coating layer to form at least one reaction product within said coating layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method for forming a self-supporting body, comprising:
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providing a solid oxidant-containing material; coating at least a portion of at least one surface of said solid oxidant-containing material with a material comprising at least one filler material and at least one solid oxidant but not a solid parent metal to form a coated solid oxidant-containing material; contacting said coated solid oxidant-containing material to at least one parent metal vapor; and causing said parent metal vapor to react with said solid oxidant of said coating layer to form at least one reacton product within said coating layer. - View Dependent Claims (16)
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Specification