Mullite matrix composite

Claim 2

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 40% by volume to about 80% by volume of said composite and a polycrystalline inorganic non-oxide filler phase ranging from about 20% by volume to about 60% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 3

The composite according to claim 1 wherein said filler is particulate in form.

Claim 4

The composite according to claim 1 wherein said filler is in the form of filaments.

Claim 5

The composite according to claim 1 wherein said filler is comprised of a mixture of particles and filaments.

Claim 6

The composite according to claim 1 wherein said mullite has an average grain size less than about 15 microns.

Claim 7

The composite according to claim 1 wherein said composite contains a glassy phase ranging from a detectable amount up to about 10% by volume of said composite.

Claim 8

The composite according to claim 1 wherein said porosity is less than about 1% by volume.

Claim 9

A process for producing a composite comprised of polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler ranging from about 0.1% by volume to about 80% by volume of the composite, said composite having a porosity of less than about 10% by volume, which consists essentially of forming a mixture of amorphous alumino-silicate glass powder, alumina powder and filler in amounts required to produce said composite, said glass powder consisting essentially of from about 15% by weight to about 40% by weight Al 2 O 3 balance SiO 2 and having a liquidus temperature below about 1800° C., said glass powder, alumina powder and filler being present in amounts required to produce said composite, said filler being a solid in said process and not significantly affected by said process, and hot pressing the mixture at a temperature ranging from about 1500° C. to about 1750° C. at which said glass is fluid but below its liquidus temperature under a pressure at least sufficient to force the fluid glass to encapsulate at least about 50% by volume of said filler and encapsulate and intermix with the balance of said filler forming a continuous interconnecting phase, said hot pressing of said mixture being carried out in a non-oxidizing atmosphere, said alumina dissolving in and reacting with said glass producing said composite.

Claim 10

A process for producing a composite comprised of polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler ranging from about 0.1% by volume to about 80% by volume of the composite, said composite having a porosity of less than about 10% by volume, which consists essentially of forming a mixture of amorphous alumino-silicate glass powder, alumina powder and filler in amounts required to produce said composite, said glass powder consisting essentially of from about 15% by weight to about 40% by weight Al 2 O 3 balance SiO 2 and having a liquidus temperature below about 1800° C., said glass powder, alumina powder and filler being present in amounts required to produce said composite, said filler being a solid in said process and not significantly affected by said process, and hot pressing the mixture at a temperature ranging from about 1500° C. to about 1750° C. at which said glass is fluid but below its liquidus temperature under a pressure at least sufficient to force the fluid glass to encapsulate at least about 50% by volume of said filler and encapsulate and intermix with the balance of said filler forming a continuous interconnecting phase, said hot pressing of said mixture being carried out in a non-oxidizing atmosphere, said alumina dissolving in and reacting with said glass producing said composite.

Claim 11

The process according to claim 8 wherein said filler is in the form of a powder.

Claim 12

The process according to claim 8 wherein said filler is in the form of filaments.

Claim 13

The process according to claim 8 wherein said filler is comprised of a mixture of powder and filaments.

Claim 14

The process according to claim 8 wherein said composite contains a glassy phase from a detectable amount up to about 20% by volume of said composite.

Claim 15

The process according to claim 8 wherein said composite contains a glassy phase ranging from a detectable amount up to about 20% by volume of said composite and wherein said composite is heated at a temperature ranging from about 1200° C. to about 1500° C. to convert said glassy phase to polycrystalline mullite.

Claim 16

A process for producing a composite comprised of polycrystalline mullite phase having an average grain size of less than about 15 microns ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of said composite, said composite having a porosity of less than about 10% by volume, which consists essentially of forming a mixture of amorphous alumino-silicate glass powder, alumina powder, polycrystalline mullite nucleating agent powder and filler, said glass powder consisting essentially of from about 15% by weight to about 40% by weight Al 2 O 3 balance SiO 2 and having a liquidus temperature below about 1800° C., said glass powder, alumina powder, nucleating agent and filler being present in amounts required to produce said composite, said nucleating agent having an average particle size of less than about 5 microns and ranging from about 0.1% by weight to about 10% by weight of the total weight of said glass and alumina, said filler being a solid in said process and not significantly affected by said process, and hot pressing the mixture at a temperature ranging from about 1500° C. to about 1750° C. at which said glass is fluid but below its liquidus temperature under a pressure at least sufficient to force the fluid glass to encapsulate at least about 50% by volume of said filler and encapsulate and intermix with the balance of said filler forming a continuous interconnecting phase, said hot pressing of said mixture being carried out in a non-oxidizing atmosphere, said alumina dissolving in and reacting with said glass producing said composite.

Claim 17

A process for producing a composite comprised of polycrystalline mullite phase having an average grain size of less than about 15 microns ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of said composite, said composite having a porosity of less than about 10% by volume, which consists essentially of forming a mixture of amorphous alumino-silicate glass powder, alumina powder, polycrystalline mullite nucleating agent powder and filler, said glass powder consisting essentially of from about 15% by weight to about 40% by weight Al 2 O 3 balance SiO 2 and having a liquidus temperature below about 1800° C., said glass powder, alumina powder, nucleating agent and filler being present in amounts required to produce said composite, said nucleating agent having an average particle size of less than about 5 microns and ranging from about 0.1% by weight to about 10% by weight of the total weight of said glass and alumina, said filler being a solid in said process and not significantly affected by said process, and hot pressing the mixture at a temperature ranging from about 1500° C. to about 1750° C. at which said glass is fluid but below its liquidus temperature under a pressure at least sufficient to force the fluid glass to encapsulate at least about 50% by volume of said filler and encapsulate and intermix with the balance of said filler forming a continuous interconnecting phase, said hot pressing of said mixture being carried out in a non-oxidizing atmosphere, said alumina dissolving in and reacting with said glass producing said composite.

Claim 18

The process according to claim 14 wherein said filler is in the form of a powder.

Claim 19

The process according to claim 14 wherein said filler is in the form of filaments.

Claim 20

The process according to claim 14 wherein said filler is comprised of a mixture of powder and filaments.

Claim 21

The process according to claim 14 wherein said nucleating agent is used in an amount of less than 1% by weight and has a particle size ranging between about 0.1 micron to about 0.5 micron and said polycrystalline mullite phase has an average grain size of about 1 micron.

Claim 22

The process according to claim 14 wherein said composite contains a glassy phase ranging from a detectable amount up to about 20% by volume of said composite and wherein said composite is heated at a temperature ranging from about 1200° C. to about 1500° C. to convert said glassy phase to mullite.

Claim 23

The composite according to claim 1 wherein said filler is a carbide of a member selected from the group consisting of boron, hafnium, niobium, silicon, tantalum, titanium, vanadium, zirconium and a mixture and solid solution thereof.

Claim 24

The composite according to claim 1 wherein said filler is a boride selected from the group consisting of HfB 2 , NB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 and a mixture and solid solution thereof.

Claim 25

The composite according to claim 1 wherein said filler is a ceramic nitride.

Claim 26

The composite according to claim 1 wherein the filler is a ceramic silicide.

Claim 27

The composite according to claim 1 wherein said filler is silicon nitride.

Claim 28

The composite according to claim 1 wherein said mullite phase encapsulates more than 90% by volume of said filler phase.

Claim 29

The process according to claim 14 wherein said filler is a carbide of a member selected from the group consisting of boron, hafnium, niobium, silicon, tantalum, titanium, vanadium, zirconium and a mixture and solid solution thereof.

Claim 30

The process according to claim 14 wherein said filler is a boride selected from the group consisting of HfB 2 , NbB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 , and a mixture and solid solution thereof.

Claim 31

The process according to claim 14 wherein said filler is a ceramic nitride.

Claim 32

The process according to claim 14 wherein said filler is a ceramic silicide.

Claim 33

A composite consisting essentially of a continuous interconnecting mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said filler phase being a carbide of a member selected from the group consisting of boron, hafnium, niobium, silicon, tantalum, titanium, vanadium, zirconium, and a mixture and solid solution thereof, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 34

A composite consisting essentially of a continuous interconnecting mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said filler phase being a carbide of a member selected from the group consisting of boron, hafnium, niobium, silicon, tantalum, titanium, vanadium, zirconium, and a mixture and solid solution thereof, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 35

The composite according to claim 30 wherein said filler is particulate in form.

Claim 36

The composite according to claim 30 wherein said filler is in the form of a filaments.

Claim 37

The composite according to claim 30 wherein said filler is comprised of a mixture of particles and filaments.

Claim 38

The composite according to claim 30 wherein said mullite has an average grain size less than about 15 microns.

Claim 39

The composite according to claim 30 wherein said composite contains a glassy phase ranging from a detectable amount up to about 10% by volume of said composite.

Claim 40

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said filler being a member selected from the group consisting of HfB 2 , NbB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 , and a mixture and solid solution thereof, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 41

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said filler being a member selected from the group consisting of HfB 2 , NbB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 , and a mixture and solid solution thereof, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 42

The composite according to claim 36 wherein said filler is particulate in form.

Claim 43

The composite according to claim 36 wherein said filler is in the form of filaments.

Claim 44

The composite according to claim 36 wherein said filler is comprised of a mixture of particles and filaments.

Claim 45

The composite according to claim 36 wherein said mullite has an average grain size less than about 15 microns.

Claim 46

The composite according to claim 36 wherein said composite contains a glassy phase ranging from a detectable amount up to about 10% by volume of said composite.

Claim 47

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and polycrystalline silicon nitride filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said silicon nitride filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 48

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and polycrystalline silicon nitride filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said silicon nitride filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 49

The composite according to claim 42 wherein said filler is particulate in form.

Claim 50

The composite according to claim 42 wherein said filler is in the form of filaments.

Claim 51

The composite according to claim 42 wherein said filler is comprised of a mixture of particles and filaments.

Claim 52

The composite according to claim 42 wherein said mullite has an average grain size less than about 15 microns.

Claim 53

The composite according to claim 42 wherein said composite contains a glassy phase ranging from a detectable amount up to about 10% by volume of said composite.

Claim 54

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and polycrystalline molybdenum disilicide filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 55

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and polycrystalline molybdenum disilicide filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 56

The composite according to claim 48 wherein said filler is particulate in form.

Claim 57

The composite according to claim 48 wherein said filler is in the form of filaments.

Claim 58

The composite according to claim 48 wherein said filler is comprised of a mixture of particles and filaments.

Claim 59

The composite according to claim 48 wherein said mullite has an average grain size less than about 15 microns.

Claim 60

The composite according to claim 48 wherein said composite contains a glassy phase ranging from a detectable amount up to about 10% by volume of said composite.

Claim 61

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being in the form of filaments and being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 62

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 20% by volume to about 99.9% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 0.1% by volume to about 80% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being in the form of filaments and being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 63

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 40% by volume to about 80% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 20% by volume to about 60% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being in the form of filaments and being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 64

A composite consisting essentially of a continuous interconnecting polycrystalline mullite phase ranging from about 40% by volume to about 80% by volume of said composite and a polycrystalline inorganic filler phase ranging from about 20% by volume to about 60% by volume of the composite, said mullite phase encapsulating at least about 50% by volume of said filler phase and encapsulating and being intermixed with the balance of said filler phase, said filler phase being in the form of filaments and being distributed at least significantly uniformly in said composite, said composite having a porosity of less than about 5% by volume of said composite.

Claim 65

The composite according to claim 55 wherein said filler is a carbide of a member selected from the group consisting of boron, hafnium, niobium, silicon, tantalum, titanium, vanadium, zirconium and a mixture and solid solution thereof.

Claim 66

The composite according to claim 55 wherein said filler is a boride selected from the group consisting of HfB 2 , NB, NbB 2 , TaB, TaB 2 , TiB 2 , VB, VB 2 , ZrB 2 and a mixture and solid solution thereof.

Claim 67

The composite according to claim 55 wherein said filler is a ceramic nitride.

Claim 68

The composite according to claim 55 wherein said filler is ceramic silicide.

Claim 69

The composite according to claim 55 wherein said composite contains a glassy phase ranging from a detectable amount up to about 10% by volume of said composite.