Ceramic products and methods of making thereof

Patent metadata

Field	Value
Publication number	US-2018009717-A1
Application number	US-201715643149-A
Country	US
Kind code	A1
Filing date	Jul 6, 2017
Priority date	Jul 6, 2016
Publication date	Jan 11, 2018
Grant date	—

Abstract

In some embodiments, a ceramic armor product includes: a ceramic powder; an at least one metal-based additive; and a density of 4.3-4.7 g/cc, wherein the ceramic armor product is substantially lacking grain orientation. In some embodiments, a ceramic armor product, includes: a ceramic powder, wherein the ceramic powder is titanium diboride (TiB2); an at least one metal-based additive, wherein the at least one metal based additive comprises elements ranging from atomic numbers 21 through 30, 39 through 51, and 57 through 77; and a density of 4.3-4.7 g/cc, wherein the ceramic armor product is substantially lacking grain orientation.

First claim

We claim:

1 . A ceramic armor product, comprising:
a ceramic powder; an at least one metal-based additive; and a density of 4.3-4.7 g/cc, wherein the ceramic armor product is substantially lacking grain orientation.

2 . The product of claim 1 , wherein the at least one metal based additive is selected from the group consisting of Fe, Ni, Co, W, Cr, Mn, MO, Pt, and Pd and combinations thereof.

3 . The product of claim 1 , wherein the at least one metal based additive comprises elements ranging from atomic numbers 21 through 30, 39 through 51, and 57 through 77.

4 . The product of claim 1 , wherein the ceramic armor product comprises 0.1-1 wt % of the at least one metal based additive.

5 . The product of claim 1 , wherein the ceramic powder is titanium diboride (TiB2).

6 . The product of claim 5 , wherein the titanium diboride (TiB 2 ) powder has a surface area of 1.5-4 m 2 /g.

7 . A ceramic armor product, comprising:
a ceramic powder, wherein the ceramic powder is titanium diboride (TiB2); an at least one metal-based additive, wherein the at least one metal based additive comprises elements ranging from atomic numbers 21 through 30, 39 through 51, and 57 through 77; and a density of 4.3-4.7 g/cc, wherein the ceramic armor product is substantially lacking grain orientation.

8 . The product of claim 7 , wherein the at least one metal based additive is selected from the group consisting of Fe, Ni, Co, W, Cr, Mn, MO, Pt, and Pd and combinations thereof.

9 . The product of claim 7 , wherein the ceramic armor product comprises 0.1-1 wt % of the at least one metal based additive.

10 . The product of claim 7 , wherein the titanium diboride (TiB 2 ) powder has a surface area of 1.5-4 m 2 /g.

11 . A method of forming a ceramic armor product, comprising:
(a) mixing incoming materials (“precursors”); (b) drying the mixed precursors; (c) exposing the mixed precursors to a reactor to synthesize TiB2; (d) milling the TiB2; (e) adding metal-based additives to the TiB2 to form a first mixture; (f) drying the first mixture by a spray dry process; (g) pressing the first mixture by use of at least one of a uniaxial dry press or a cold isostatic press; (h) one of sintering or hot isostatic pressing (HIP) the first mixture; (i) following sintering or HIP, processing the first mixture using at least one of an electrical discharge machine or grinder; and (j) forming the ceramic armor product.

12 . The method of claim 11 , wherein sintering is performed at a temperature of 1650-2000° C.

13 . The method of claim 12 , wherein sintering is performed for 2-12 hours.

14 . The method of claim 11 , wherein HIP is performed at a temperature of 1400-2000° C.

15 . The method of claim 14 , wherein HIP is performed for 1-6 hours.

16 . The method of claim 11 , wherein HIP is performed in an argon gas atmosphere at 1500 psi for 4 hours.

Assignees

• Alcoa Usa Corp

Inventors

• Mosser Benjamin D
• Mcmillen James C
• Wolf William
• Sworts Lance M
• Steere Artemas

Classifications

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title

• C04B2235/3813

  Refractory metal borides · CPC title

• C04B2235/405

  Iron group metals · CPC title

• C04B2235/96

  Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance · CPC title

• C04B35/6455

  Hot isostatic pressing · CPC title