Composite ceramic material

Abstract: The invention relates to composite ceramic materials strengthened by the incorporation of ceramic fibres and to a method of making such materials. A novel composite ceramic material comprises an alumina matrix (11) containing mullite formations (12) formed from a colloidal silica filler and alumina fibres (10), part at least of the mullite growth (12) being on the surface of the fibres (10). The composite ceramic material is made by forming an aqueous slurry containing a dispersion of the fibres, filler, colloidal silica and rheological agents, forming the slurry to the desired shape and firing the product. The ceramic matrix material is particularly suitable for the manufacture of ceramic foam filters.

Description: This invention relates to novel composite ceramic materials, to methods of making them and to products made therefrom. The ceramic materials of the invention may have applicability in a wide range of end products but are particularly useful for ceramic foam products such as are used for hot gas filtration, catalyst carriers and filters for molten metals, e.g. aluminium and its alloys with magnesium and copper. Composite ceramic materials are known in which a ceramic matrix of, for example, silicon carbide, alumina, silica, pre-fused mullite, zirconia or mixtures thereof, together with suitable binders and additives to give the desired rheological and other properties, is strengthened by the addition of a small proportion of fibres. The fibres are preferably ceramic fibres. FR-A-2610923 teaches a lightweight refractory material of improved heat resistance which is formed by mixing a relatively large proportion of aluminous fibres with a relatively large amount of amorphous silica together with no more than an equal amount of refractory particles and shaping and firing the mixture at 1400°C to 1600°C until it contains no detectable crystobalite. US-A-4342664 teaches that a ceramic slurry containing alumina and fibres may be used to impregnate a polyurethane foam and then to burn off the polyurethane foam to leave a fired ceramic replica of the foam. We have now found that by selection of the matrix material and the fibre constituent a novel composite material can be formed. The fired material has surprising constructional features and advantageous properties and it may be possible to obtain these advantages by firing at relatively low temperatures. Accordingly, in one aspect the invention provides a method of making a composite ceramic material comprising forming an aqueous slurry containing a dispersion of fibres, filler, colloidal silica, and rheological agents, forming the slurry to the desired shape and firing the product, characterised in that the fibres are alumina fibres in an amount of up to 5% by weight of the fibre-containing slurry and the colloidal silica is incorporated in an amount of from 1% to 6% by weight of the fibre-containing slurry. The method of the invention results in a composite ceramic structure in which the silica is largely or entirely converted to mullite and this may be so even if a relatively low temperature firing is used. Although not wishing to be limited to any particular theory, it is believed that the alumina fibres are not only acting as a conventional reinforcing agent but they are acting to catalyse the conversion of the silica to mullite and thereby forming a ceramic bond. Accordingly, in a further aspect, the invention provides a composite ceramic material comprising an alumina matrix, made by firing a shaped product formed from an aqueous ceramic slurry containing alumina fibres, filler and colloidal silica, the matrix containing mullite formations from the colloidal silica filler and alumina fibres, part at least of the mullite growth being on the surface of the fibres, characterised in that the matrix contains globular areas substantially uniformly distributed throughout the matrix, the globular areas being substantially remote from the fibres and being associated with areas of porosity. The mullite formations on the surfaces of the fibres bond the fibres more effectively to the ceramic matrix and the strength of the resulting material is enhanced. Moreover, the shrinkage rate of the ceramic matrix on firing is reduced and this has a significant effect on the reduction of cracking, and hence, the reject rate, which can be extremely important, particularly in the manufacture of ceramic foam products such as large, cast-house filters. In order to increase these beneficial effects, it is preferred to form the aqueous slurry to be used in the method of the invention by first dispersing the alumina fibres in the colloidal silica and a proportion, for example about half, of the total amount of water to be used. When the fibres are fully dispersed, the remaining ingredients can then be added to the slurry and dispersed therein. By this means the fibres are more effectively coated with the colloidal silica and mullite formation is thereby encouraged on the fibres during the firing stage. As indicated above, we have also, surprisingly, found that these mullite formations may be obtained by utilising the process of the invention but when firing at relatively low temperatures. By 'low temperature' here is meant treatment to temperatures not exceeding about 1350°C. As indicated above, the colloidal silica is incorporated into the aqueous slurry from which the ceramic material is to be made in an amount of from 1% to 6% by weight of silica. This may conveniently be achieved using a colloidal silica sol in an amount of from 2% to 12% by weight, typical sols having a solids content of silica of from about 30% to 50% by weight. The alumina is preferably present in an amount of from 15% to 70%, especially 40% to 60% by weight. The alumina preferably has a particle size of from 60 to 1 micron for example, about 7 microns -D50. An inert filler, preferably zircon, should be included, preferably in an amount of from 15% to 30% by weight. The inert filler helps to rigidise the structure on firing and to limit shrinkage. It should preferably be of a size from 80 to 1 micron, e.g. 15 to 25 microns -D50. Additionally, an active filler, e.g. titania or magnesia, should preferably be included in an amount of 0.5% to 5% by weight. For example, a pigment grade of titania of average particle size (D50) of 2 microns could preferably be used. Reactive rheological agents such as clay and fumed silica may also be used in amounts up to about 5% by weight each. Minor amounts of stabilisers and coating aids may be added if desired. The water content of the slurry will depend on the product to be made and may be, for example, from 5 to 25% by weight. The fibre content of the slurry is preferably from 0.25% to 3% by weight. The alumina fibres used should preferably be of low alpha phase and may have lengths of, for example, from 600 to 60 microns. Particularly suitable fibres are those commercially available under the name SAFFIL (which is a Trade Mark of I.C.I.). Preferably, by alumina fibre is meant high alumina fibres which have an alumina content of not less than 80%, preferably not less than 95%. The method of the invention has been found to be particularly useful for the manufacture of ceramic foam filters. Such filters and methods of making them are well known, see for example, US-A-4342664 referred to above. Typically, a reticulated, open-cell flexible polyurethane foam is impregnated with a suitable ceramic slurry, excess slurry is expelled by compression of the foam and the impregnated foam is then fired at a temperature sufficiently high to burn off the polyurethane foam and to leave a fired open-cell ceramic foam replica. Accordingly, in one embodiment the invention provides a method of making the composite ceramic material as an open-cell ceramic foam material in which a reticulated, open-cell, flexible polyurethane foam is impregnated with an aqueous slurry formed according to Claim 1 below and the impregnated foam is dried and fired to burn off the polyurethane foam whereby a fired ceramic foam filter is obtained. We have found that the mullite formation that is obtained by the process of the invention is particularly advantageous in the production of ceramic foam filters. Microscopic examination of the ceramic composite material of the invention, including Scanning Electron Microscope (SEM) examination, has confirmed the novel features of the structure of the ceramic matrix. Thus, the structure contains 'globular' areas which are fairly uniformly distributed throughout the matrix and contain evenlydistributed areas of relatively fine porosity. These areas are remote from the fibres but experiments with equivalent slurries excluding the fibres have not resulted in the ordered formations of these globules. These formations strengthen the ceramic and halt crack propagation, this latter effect also being assisted by the areas of porosity. The reasons for the formation of these globules are not fully understood. Polished sections of composite products when photographed at low power magnification indicate that the globules, which contain alumina, silica and mullite in varying proportions and their associated porosity regions are formed in an orderly structure through the ceramic matrix whereas the particles of inert filler such as zircon, are randomly distributed. Thus, the products of the invention have a particular, novel and advantageous matrix constitution. The invention is illustrated by way of example only in the accompanying drawings in which: Figure 1 is an SEM photograph taken at 7700 magnification of a portion of a composite ceramic product of the invention; Figure 2 is an SEM photograph taken at 800 magnification showing the grain orientation within the ceramic matrix. In Figure 1 an alumina fibre 10 can be seen embedded in the ceramic matrix 11, the fibre exhibiting clearly mullite formations 12 on its normally smooth surface and nodules 13 of mullite extending from the fibre into the matrix, thereby improving the bonding effect. In Figure 2, can be seen globular areas 14 containing relatively fine voids or areas of porosity 15. Particles 16 of inert filler are randomly distributed in the ceramic matrix. One embodiment of the invention will now be illustrated by way of the following specific Example in which all parts are by weight. EXAMPLE Ceramic foam filters suitable for the filtration of molten aluminium were made as follows: A ceramic slurry of the following formulation was made in the manner described below. Parts by weight alumina (particle size D50 = 7 microns) 52.44 fumed silica 2.43 polyvinyl alcohol (coating aid) 3.01 colloidal silica (30% Sol) 6.88 titania 0.95 zircon (200 mesh) 20.11 rheological thickener/dispersant 0.05 anti-foam agent 0.16 clay 2.65 SAFFIL fibres (150 microns) 1.06 Water 10.26 The alumina fibre was dispersed in the colloidal silica and half of the water together with the dispersant. When the fibres were fully dispersed the anti-foam agent, thickener, then fumed silica, clay, titania, zircon and alumina were added and then the polyvinyl alcohol, with continued stirring. Stirring was continued until the slurry reached a dough-like state. Further stirring and addition of the remainder of the water resulted in a smooth, creamy slurry. Reticulated, open-cell flexible polyurethane foam pieces were impregnated with the slurry and then dried at 180 to 190°C. They were then fired at 1300°C for two hours. The polyurethane foam burned out leaving open-cell ceramic foam filters that were eminently suitable for use as filters for molten aluminium and its alloys. Examination of the filters by X-Ray diffraction and SEM showed that the silica was entirely converted to mullite and strong, crack-free products had been obtained.

Claims: A method of making a composite ceramic material comprising forming an aqueous slurry containing a dispersion of fibres, filler, colloidal silica and rheological agents, forming the slurry to the desired shape and firing the product, characterised in that the fibres are alumina fibres in an amount of up to 5% by weight of the fibre-containing slurry and the colloidal silica is incorporated in an amount of from 1% to 6% by weight of the fibre-containing slurry. A method according to Claim 1, characterised in that the alumina fibres are of low alpha phase and have lengths from 60 to 600 microns. A method according to Claim 1 or 2, characterised in that the firing is carried out at a temperature not exceeding about 1350°C. A method according to claim 1, 2 or 3, characterised in that the filler includes an inert filler in an amount of from 15% to 30% by weight of the fibre-containing slurry. A method according to any one of the preceding claims, characterised in that the filler includes an active filler in an amount of from 0.5% to 5% by weight of the fibre-containing slurry. A method according to any one of the preceding claims, characterised in that the alumina fibres are first dispersed in the colloidal silica and a proportion of the total water to be used. A method according to any one of the preceding claims, characterised in that a reticulated, open-cell, flexible polyurethane foam is impregnated with the aqueous ceramic slurry and the impregnated foam is dried and fired to burn off the polyurethane foam, whereby a fired ceramic foam filter is obtained. A composite ceramic material comprising an alumina matrix, made by firing a shaped product formed from an aqueous ceramic slurry containing alumina fibres, filler and colloidal silica, the matrix (11) containing mullite formations (12) from the colloidal silica filler and alumina fibres (10), part at least of the mullite growth being on the surface of the fibres (10), characterised in that the matrix (11) contains globular areas (14) substantially uniformly distributed throughout the matrix (11), the globular areas being substantially remote from the fibres (10) and being associated with areas of porosity. A composite ceramic material according to Claim 8, characterised in that the alumina fibres (10) are of low alpha phase. A composite ceramic material according to Claim 8 or 9, characterised in that the alumina fibres (10) have an alumina content of at least 80%. A composite ceramic material according to Claim 8, 9 or 10, characterised in that it contains an inert filler (16) randomly distributed throughout the matrix (11). A composite ceramic material according to any one of Claims 8 to 11, characterised in that the mullite growths (12) on the surface of the fibres (10) include nodules (13) of mullite extending from the fibre (10) into the matrix (11), thereby improving the bonding effect.

Inventors: GEORGE RAYMOND DOUGLAS, JONES DAVID LLEWELLYN, PLOWMAN ANDREW MARTIN, GEORGE, RAYMOND DOUGLAS, JONES, DAVID LLEWELLYN, PLOWMAN, ANDREW MARTIN
Applicants: FOSECO INT, FOSECO INTERNATIONAL LIMITED
Application year: 1990
Main classification: C04B35
IPC codes: C04B35, C04B38, B01D39