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Silicon nitride-alumina composites and their method of manufacture
titanium oxide and a member selected from the group consisting of tantalum oxide and niobium oxide and a calcium phosphate layer on the oxide.
Ethylene eopolymers reacted with metal oxides Neill, P.L., Lancaster, G.M. and Bryce, K.L. (The Dow Chemical Co., Midland, MI, USA) US Pat 4 847164 (11 July 1989) A substrate has a melt-reacted blend injection moulded onto its surface. The blend is a mix of ethylene/carboxylic acid copolymer with a minor addition of masterbatch comprising a metal oxide/ethylene polymer blend. The melt-reacted blend is caused to be substantially homogeneous by virtue of having had the metal oxide in the masterbatch uniformly mixed with the ethylene/ copolymer. Fibre-reinforced metallic composite material Maeda, H., Minato, S. and Nishio, K-I. (Sumitomo Chemical Co. Ltd., Osaka, Japan) US Pat 4 847167 (11 July 1989) The composite comprises a chemically inactive metal alloy matrix with a lower melting point than magnesium and reinforcing inorganic fibres of 15-70 volume %.
COMPONENTS Armour plate composite with ceramic impact layer Vogelesang, L.B., Verbruggen, M. and Paalvast, C. (Akzo nv., Arnhem, Netherlands) US Pat 4 836 084 (6 June 1989) The composite armour plating is based on a hard impact layer of ceramic material and an energy absorbing sub-layer containing fibres impregnated with a bonding aluminium alloy. Two piece metallic and composite golf shaft Pompa, J. (Palm Harbor, FL, USA) US Pat 4 836 545 (6June 1989) A hollow, circular cross section, two piece golf shaft is made of a lower metal tip and an upper composite section with a sliding fit into the metal section. Composite sliding surface bearing Baureis, H-P., Bickle, W. and Lankreijer, W. (Kolbenschmidt Aktiengesellschaft, Neckarsulm, FRG) US Pat 4 836 695 (6 June 1989) The bearing for use in highly-loaded internal combustion engines comprises a backing layer of steel, a bearing aluminium alloy layer and a surface layer composed of zinc phosphate deposited on a layer of the aluminium alloy. Composite long rod penetrator Jackson, R.P. (US Army, Washington DC, USA) US Pat4841 868 (27June 1989) The metal matrix fibre-reinforced rod has a forward ogive end and an aft end with a larger volume of fibres in the aft end conferring a hardness gradient increasing toward the aft. Composite refractory member Klcinevoss, A. and Kopia, J. (Didier-Werke AG, Wiesbaden FRG) US Pat 4 842 172 (27 June 1989) The refractory gate for allowing passage of molten metal has two parts: one of oxide ceramic, one of chemically setting refractory concrete including low iron sintered magnesia.
Composites with improved fibre-resin interfacial adhesion Cizmecioglu, M. (CIT, Pasadena, CA, USA) US Pat 4 842 933 (27June 1989) The composite is made of a dispersion of 10-80 weight % graphite fibres containing a precoated layer from a monolayer to 1000 ,~ thick of the thermoplastic matrix resin. Fibres for reinforcing plastic composites and reinforced plastic composites made from them Cordova, D.S., Coffin, D.R., Lazarus, S.D., Rowan, H. and Marshall, R. (Allied-Signal Inc., Morristown, N J, USA) US Pat 4 842 934 (27June 1989) The fibre-reinforced composite has a cured resin matrix reinforced with a high tenacity polyester fibre that is treated to enhance adhesion with the matrix. Composite tread for track laying vehicle Ranner, D. (Bombardier-Rotax-Wien Productions, Vienna, Austria) US Pat 4 844 562 (4 July 1989) The composite tread member comprises a metal support member embedded in a monofilament reinforced polymer which defines the wear surface of the tread member. Lightweight durable plumbing fixture fabricated from a delamination-resistant multilayer polymeric composite Grafe, P. and Kuszaj, K. (American Standard Inc., NY, USA) US Pat 4 844 944 (4 July 1989) The fixture is made of a thin polymer cosmetic layer and a suhstrate layer including a thick reinforced thermosetting mixture of polyester and polyether dense foam resin. Ceramic composite material lining for metallurgical smelting furnaces Hon, P.O. and Sonju, O. (Elkem a/s, Trondheim, Norway) US Pat 4 846 680 (11 July 1989) The furnace wall lining comprises a network of metal fibres bonded metallically to the wall and extending from the wall into the furnace. A ceramic material forms a cohesive mass around and between the fibres and forms the furnace first wall. The fibres occupy about 60-95% of the surface area of the first wall. The second interior wall is comprised solely of the ceramic material. Hollow composite body having an axis of symmetry Smith, J.B. (Fiber Materials Inc., Biddeford, ME, USA) US Pat 4 847 063 (11 July 1989) The body is a carbon-carbon composite made by shaping the surface of a refractory mandrel and covering with one or more plies of carbon filaments. The plies are impregnated with a carbonizable impregnant while on the mandrel which is then heat treated to carbonize the impregnant.
PROCESSES Method of testing composite materials for structural damage Martin, D.A. (Lockheed Corporation, Calabasas, CA, USA) US Pat 4 836 030 (6 June 1989) A method of detecting non-moulded defects
or damage in composite structural components. The technique involves embedding an optical fibre within the component during manufacture and comparing the intensity of radiation passed through the fibre to an undamaged reference.
Manufacture of composite structures Bell, J., Eerkes, T., Diaz, C. and Mankins, W.L. (Inco Ltd., Toronto, Canada) US Pat 4 836 979 (6 June 1989) The process produces a low expansion, high electrical and heat conductive material. The low expansion component is a nickel-iron alloy and the high electric and heat conductive material is selected from a group consisting of copper, silver and copper-silver alloys. A green compact is formed from powders of both materials and heated for 2-60 min at 550-750°C in a protective atmosphere to give a composite of at least 95% density. Rapid solidification of metal-second phase composites Brupbacher, J.M., Christodoulou, L. and Nagle, D.M. (Martin Marietta Corpn., Bethesda, MD, USA) US Pat 4 836 982 (6 June 1989) The method comprises precipitating at least one second phase in a metal matrix by contacting reactive, second-phase forming constituents in the presence of a non-reactive solvent matrix metal. Method of making a wear-resistant film Freller, H. and Schack, P. (Siemens, Munich, FRG) US Pat 4 842 710 (27June 1989) The method produces a mixed nitride film of at least two metals by reactively electric arc depositing a compound film on a substrate. Process of making ceramic composites with improved thermal shock resistance Smyth, R.M. and Henslee, W.W. (The Dow Chemical Co., Midland, MI, USA) US Pat 4 843 045 (27June 1989) 1-4 tool % of a reactive, densifiable oxide ceramic matrix is selected from the group containing mono and polymetal spinels with 1-1.5 tool % of a metal salt of one or more oxides. The mixture is shaped and heated to a temperature sufficient to cause the metal salt to decompose and the mixture to sinter. The microstructure consists of an oxide matrix surrounding the metal oxide produced from the salt as discrete islands in the matrix. Method and apparatus for spraying an inorganic hydraulic material composition containing reinforcing short fibres Miyata, S. et al. (Railway Technical Research Institute and Sumitomo Cement Co., Tokyo, Japan) US Pat 4 844 340 (4 July 1989) A blast of compressed air is used to spray a wet composition containing inorganic hydraulic material and reinforcing fibres. Method for preparing alumina powder and products Clark, D. and Wistrom, K. (University of Florida, USA) US Pat 4 844 848 (4 July 1989) Alumina gel powder is milled in the size range 200-400 mesh and mixed with a reinforcement before pressing and firing at high temperature to form a composite. Silicon nitride-alumina composites and their method of manufacture Inoguchi, K., Nunogaki, N. and Toyama, T.
C O M P O S I T E S . M A Y 1990
273
(Nippon Soken Inc., Nishio, Japan) US Pat 4 845 061 (4July 1989) A mixture of alumina and silicon nitride particles is made, the alumina particles having twice the average diameter of the silicon nitride. The mixture is sintered to form silicon nitride o~-alumina and [3'-sialon crystals. The sialon surrounds the alumina particles. Process for preparing heat-resistant composite body Tsukada, K. (Ibiden Co. Ltd., Ogaki, Japan)
US Pat 4 846 673 (11 July 1989) Silicon carbide powder is shaped and sintered in a non-oxidizing atmosphere to form a porous body. Metallic silicon is then permeated into the porous body. The improvement is associated with the SiC particle size distribution and the shaping process which is a pressing operation which collapses the surface of the SiC particles to give bonding but not the inside.
Process for preparing a fibre reinforced resin matrix preform Aldrich, D.C., Square, K., Buchanan, R.C. and Sollinger, J.F. (E.I. Du Pont de Nemours and Co., Wilmington, DE, USA) US Pat 4
846 908 (11 July 1989) The composite article preform is made by dissolving the resin in a solvent and applying the solution to a fibre while braiding into a preform shape on a mandrel. After several heating and drying steps to remove volatiles the preform is consolidated under pressure and heat. Method of fabricating a metal aluminide composite Ghosh, A.K. (Rockwell International Corp, E1 Segundo, CA, USA) US Pat 4 847044 (11
July 1989) The composite is made from a reinforcing phase, a metal aluminide alloy and a metal softer than the aluminidc from the group
consisting of aluminium, aluminium-base alloys, a metal constituent of the metal aluminide and an alloy of the metal constituent. The softer metal is placed in contact with the reinforcement and the metal aluminide with the softer metal. The body is pressed at a temperature above the softening point of the soft metal.
Method of making ceramic composites Lesher, H.D., Kennedy, C.R., White, D.R. and Urquhart, A.W. (Lanxide Technology Co., Newark, DE, USA) US Pat 4 847220 The ceramic matrix is made by oxidizing aluminium metal to form a polycrystalline material made of oxidation reaction product and a vapour phase oxidant and a filler infiltrated by the matrix. The filler material is coated with a silicon source possessing intrinsic doping properties.
Fourth International Conference
ADHESION '90 10- 12 September 1990 Queen's College, Cambridge, UK Organised by the Adhesives Group of the Plastics and Rubber Institute, this 3-day International Conference will review state of the art developments on the theory, manufacture, and use of adhesives. Acknowledged experts from around the world will present 70 papers during both oral and poster sessions, and Dr. L.H. Sharpe will present a special lecture inaugurated in memory of the Honorary President of the PRI Adhesives Group - Dr. William C. Wake. Full programme and registration forms from: Conference Department, Plastics and Rubber Institute, 11 Hobart Place, London SWIW 0HL. Telephone: (071) 245 9555 Fax: (071) 823 1379
274
C O M P O S I T E S . M A Y 1990
Ethylene eopolymers reacted with metal oxides Neill, P.L., Lancaster, G.M. and Bryce, K.L. (The Dow Chemical Co., Midland, MI, USA) US Pat 4 847164 (11 July 1989) A substrate has a melt-reacted blend injection moulded onto its surface. The blend is a mix of ethylene/carboxylic acid copolymer with a minor addition of masterbatch comprising a metal oxide/ethylene polymer blend. The melt-reacted blend is caused to be substantially homogeneous by virtue of having had the metal oxide in the masterbatch uniformly mixed with the ethylene/ copolymer. Fibre-reinforced metallic composite material Maeda, H., Minato, S. and Nishio, K-I. (Sumitomo Chemical Co. Ltd., Osaka, Japan) US Pat 4 847167 (11 July 1989) The composite comprises a chemically inactive metal alloy matrix with a lower melting point than magnesium and reinforcing inorganic fibres of 15-70 volume %.
COMPONENTS Armour plate composite with ceramic impact layer Vogelesang, L.B., Verbruggen, M. and Paalvast, C. (Akzo nv., Arnhem, Netherlands) US Pat 4 836 084 (6 June 1989) The composite armour plating is based on a hard impact layer of ceramic material and an energy absorbing sub-layer containing fibres impregnated with a bonding aluminium alloy. Two piece metallic and composite golf shaft Pompa, J. (Palm Harbor, FL, USA) US Pat 4 836 545 (6June 1989) A hollow, circular cross section, two piece golf shaft is made of a lower metal tip and an upper composite section with a sliding fit into the metal section. Composite sliding surface bearing Baureis, H-P., Bickle, W. and Lankreijer, W. (Kolbenschmidt Aktiengesellschaft, Neckarsulm, FRG) US Pat 4 836 695 (6 June 1989) The bearing for use in highly-loaded internal combustion engines comprises a backing layer of steel, a bearing aluminium alloy layer and a surface layer composed of zinc phosphate deposited on a layer of the aluminium alloy. Composite long rod penetrator Jackson, R.P. (US Army, Washington DC, USA) US Pat4841 868 (27June 1989) The metal matrix fibre-reinforced rod has a forward ogive end and an aft end with a larger volume of fibres in the aft end conferring a hardness gradient increasing toward the aft. Composite refractory member Klcinevoss, A. and Kopia, J. (Didier-Werke AG, Wiesbaden FRG) US Pat 4 842 172 (27 June 1989) The refractory gate for allowing passage of molten metal has two parts: one of oxide ceramic, one of chemically setting refractory concrete including low iron sintered magnesia.
Composites with improved fibre-resin interfacial adhesion Cizmecioglu, M. (CIT, Pasadena, CA, USA) US Pat 4 842 933 (27June 1989) The composite is made of a dispersion of 10-80 weight % graphite fibres containing a precoated layer from a monolayer to 1000 ,~ thick of the thermoplastic matrix resin. Fibres for reinforcing plastic composites and reinforced plastic composites made from them Cordova, D.S., Coffin, D.R., Lazarus, S.D., Rowan, H. and Marshall, R. (Allied-Signal Inc., Morristown, N J, USA) US Pat 4 842 934 (27June 1989) The fibre-reinforced composite has a cured resin matrix reinforced with a high tenacity polyester fibre that is treated to enhance adhesion with the matrix. Composite tread for track laying vehicle Ranner, D. (Bombardier-Rotax-Wien Productions, Vienna, Austria) US Pat 4 844 562 (4 July 1989) The composite tread member comprises a metal support member embedded in a monofilament reinforced polymer which defines the wear surface of the tread member. Lightweight durable plumbing fixture fabricated from a delamination-resistant multilayer polymeric composite Grafe, P. and Kuszaj, K. (American Standard Inc., NY, USA) US Pat 4 844 944 (4 July 1989) The fixture is made of a thin polymer cosmetic layer and a suhstrate layer including a thick reinforced thermosetting mixture of polyester and polyether dense foam resin. Ceramic composite material lining for metallurgical smelting furnaces Hon, P.O. and Sonju, O. (Elkem a/s, Trondheim, Norway) US Pat 4 846 680 (11 July 1989) The furnace wall lining comprises a network of metal fibres bonded metallically to the wall and extending from the wall into the furnace. A ceramic material forms a cohesive mass around and between the fibres and forms the furnace first wall. The fibres occupy about 60-95% of the surface area of the first wall. The second interior wall is comprised solely of the ceramic material. Hollow composite body having an axis of symmetry Smith, J.B. (Fiber Materials Inc., Biddeford, ME, USA) US Pat 4 847 063 (11 July 1989) The body is a carbon-carbon composite made by shaping the surface of a refractory mandrel and covering with one or more plies of carbon filaments. The plies are impregnated with a carbonizable impregnant while on the mandrel which is then heat treated to carbonize the impregnant.
PROCESSES Method of testing composite materials for structural damage Martin, D.A. (Lockheed Corporation, Calabasas, CA, USA) US Pat 4 836 030 (6 June 1989) A method of detecting non-moulded defects
or damage in composite structural components. The technique involves embedding an optical fibre within the component during manufacture and comparing the intensity of radiation passed through the fibre to an undamaged reference.
Manufacture of composite structures Bell, J., Eerkes, T., Diaz, C. and Mankins, W.L. (Inco Ltd., Toronto, Canada) US Pat 4 836 979 (6 June 1989) The process produces a low expansion, high electrical and heat conductive material. The low expansion component is a nickel-iron alloy and the high electric and heat conductive material is selected from a group consisting of copper, silver and copper-silver alloys. A green compact is formed from powders of both materials and heated for 2-60 min at 550-750°C in a protective atmosphere to give a composite of at least 95% density. Rapid solidification of metal-second phase composites Brupbacher, J.M., Christodoulou, L. and Nagle, D.M. (Martin Marietta Corpn., Bethesda, MD, USA) US Pat 4 836 982 (6 June 1989) The method comprises precipitating at least one second phase in a metal matrix by contacting reactive, second-phase forming constituents in the presence of a non-reactive solvent matrix metal. Method of making a wear-resistant film Freller, H. and Schack, P. (Siemens, Munich, FRG) US Pat 4 842 710 (27June 1989) The method produces a mixed nitride film of at least two metals by reactively electric arc depositing a compound film on a substrate. Process of making ceramic composites with improved thermal shock resistance Smyth, R.M. and Henslee, W.W. (The Dow Chemical Co., Midland, MI, USA) US Pat 4 843 045 (27June 1989) 1-4 tool % of a reactive, densifiable oxide ceramic matrix is selected from the group containing mono and polymetal spinels with 1-1.5 tool % of a metal salt of one or more oxides. The mixture is shaped and heated to a temperature sufficient to cause the metal salt to decompose and the mixture to sinter. The microstructure consists of an oxide matrix surrounding the metal oxide produced from the salt as discrete islands in the matrix. Method and apparatus for spraying an inorganic hydraulic material composition containing reinforcing short fibres Miyata, S. et al. (Railway Technical Research Institute and Sumitomo Cement Co., Tokyo, Japan) US Pat 4 844 340 (4 July 1989) A blast of compressed air is used to spray a wet composition containing inorganic hydraulic material and reinforcing fibres. Method for preparing alumina powder and products Clark, D. and Wistrom, K. (University of Florida, USA) US Pat 4 844 848 (4 July 1989) Alumina gel powder is milled in the size range 200-400 mesh and mixed with a reinforcement before pressing and firing at high temperature to form a composite. Silicon nitride-alumina composites and their method of manufacture Inoguchi, K., Nunogaki, N. and Toyama, T.
C O M P O S I T E S . M A Y 1990
273
(Nippon Soken Inc., Nishio, Japan) US Pat 4 845 061 (4July 1989) A mixture of alumina and silicon nitride particles is made, the alumina particles having twice the average diameter of the silicon nitride. The mixture is sintered to form silicon nitride o~-alumina and [3'-sialon crystals. The sialon surrounds the alumina particles. Process for preparing heat-resistant composite body Tsukada, K. (Ibiden Co. Ltd., Ogaki, Japan)
US Pat 4 846 673 (11 July 1989) Silicon carbide powder is shaped and sintered in a non-oxidizing atmosphere to form a porous body. Metallic silicon is then permeated into the porous body. The improvement is associated with the SiC particle size distribution and the shaping process which is a pressing operation which collapses the surface of the SiC particles to give bonding but not the inside.
Process for preparing a fibre reinforced resin matrix preform Aldrich, D.C., Square, K., Buchanan, R.C. and Sollinger, J.F. (E.I. Du Pont de Nemours and Co., Wilmington, DE, USA) US Pat 4
846 908 (11 July 1989) The composite article preform is made by dissolving the resin in a solvent and applying the solution to a fibre while braiding into a preform shape on a mandrel. After several heating and drying steps to remove volatiles the preform is consolidated under pressure and heat. Method of fabricating a metal aluminide composite Ghosh, A.K. (Rockwell International Corp, E1 Segundo, CA, USA) US Pat 4 847044 (11
July 1989) The composite is made from a reinforcing phase, a metal aluminide alloy and a metal softer than the aluminidc from the group
consisting of aluminium, aluminium-base alloys, a metal constituent of the metal aluminide and an alloy of the metal constituent. The softer metal is placed in contact with the reinforcement and the metal aluminide with the softer metal. The body is pressed at a temperature above the softening point of the soft metal.
Method of making ceramic composites Lesher, H.D., Kennedy, C.R., White, D.R. and Urquhart, A.W. (Lanxide Technology Co., Newark, DE, USA) US Pat 4 847220 The ceramic matrix is made by oxidizing aluminium metal to form a polycrystalline material made of oxidation reaction product and a vapour phase oxidant and a filler infiltrated by the matrix. The filler material is coated with a silicon source possessing intrinsic doping properties.
Fourth International Conference
ADHESION '90 10- 12 September 1990 Queen's College, Cambridge, UK Organised by the Adhesives Group of the Plastics and Rubber Institute, this 3-day International Conference will review state of the art developments on the theory, manufacture, and use of adhesives. Acknowledged experts from around the world will present 70 papers during both oral and poster sessions, and Dr. L.H. Sharpe will present a special lecture inaugurated in memory of the Honorary President of the PRI Adhesives Group - Dr. William C. Wake. Full programme and registration forms from: Conference Department, Plastics and Rubber Institute, 11 Hobart Place, London SWIW 0HL. Telephone: (071) 245 9555 Fax: (071) 823 1379
274
C O M P O S I T E S . M A Y 1990