Patent ID: 8206792

Claim:
A method for forming a silicon carbide containing composite structure comprising the steps of (a) feeding an agglomerate having an average particle size of 50-100 μm comprising: (i) 30-97 weight percent of silicon carbide with an average particle size of about 20 μm or less (ii) 15 weight percent or less of a binder and (iii) the balance of the agglomerate being silicon with an average particle size of 25 μm or less into a thermal spray apparatus, (b) spraying the silicon carbide and silicon onto a substrate, whereby the silicon carbide and silicon deposit on the surface of the substrate, and (c) keeping the silicon on the substrate surface at a temperature which is at least 0.75 times the melting temperature in Kelvin of the silicon and at most 100 K above the melting temperature of the silicon during spraying at least in the region where the silicon carbide and silicon actually strikes the surface.