Containerless infiltration with electromagnetic levitation

Abstract

The present invention is directed to new processes in which electromagnetic levitation forces are used to infiltrate a porous matrix with a solid infiltrant. In such processes, controlled heating of these components, melting the infiltrant while both components are subjected to levitation forces, and containerless transportation and subsequent contact of both components results in the infiltration of the porous matrix. Such containerless processing provides for infiltrated porous matrices which are free of contaminants generally introduced by the containers used in traditional methods of infiltration.

What is claimed is:  
     
         1 . A process comprising the steps of: 
 a) subjecting a porous matrix and a solid infiltrant to containerless processing;    b) melting said solid infiltrant to provide a molten infiltrant; and    c) contacting said porous matrix with said molten infiltrant to provide an infiltrated product.    
     
     
         2 . The process of  claim 1  further comprising a step of cooling the infiltrated product to provide a densified, infiltrated product.  
     
     
         3 . The process of  claim 1 , wherein the infiltrated product is additionally coated with the infiltrant material.  
     
     
         4 . The process of  claim 1 , wherein said containerless processing comprises electromagnetic levitation of the infiltrant.  
     
     
         5 . The process of  claim 1 , wherein said containerless processing comprises electromagnetic levitation of the infiltrant and the porous matrix.  
     
     
         6 . The process of  claim 1 , wherein the porous matrix is supported during at least a portion of the containerless processing.  
     
     
         7 . The process of  claim 1 , wherein said porous matrix comprises material selected from the group consisting of metals, fibers, ceramics, and combinations thereof.  
     
     
         8 . The process of  claim 1 , wherein said solid infiltrant comprises a material selected from the group consisting of Fe, Al, Ti, Co, alloys thereof, and combinations thereof.  
     
     
         9 . The process of  claim 8 , wherein said solid infiltrant further comprises at least one additional material dispersed within the solid infiltrant, said additional material being selected from the group consisting of nanoparticles, nanotubes, nanofibers, polymeric materials, and combinations thereof.  
     
     
         10 . The process of  claim 1 , wherein said melting is carried out using a heat source, wherein said heat source is selected from the group consisting of laser-generated radiation, microwave radiation, induction heating, and combinations thereof, and wherein said heat source provides for controlled heating.  
     
     
         11 . The process of  claim 1 , wherein said contacting comprises infiltrating said porous matrix with said molten infiltrant.  
     
     
         12 . The process of  claim 11 , wherein said contacting further comprises containerless transportation.  
     
     
         13 . The process of  claim 1   1 , wherein such infiltrating occurs via capillary uptake.  
     
     
         14 . The process of  claim 1  further comprising a step of adding additional species to the infiltrant while it is in a molten state and being levitated, wherein said additional species are selected from the group consisting of nanoparticles, nanofibers, nanotubes, polymeric material, and combinations thereof.  
     
     
         15 . The process of  claim 14 , wherein said porous matrices are infiltrated by both the solid infiltrant material and said additional species.  
     
     
         16 . The process of  claim 1 , wherein said process is carried out in an environment selected from the group consisting of Ar, N 2 , He, Kr, H 2 , NH 3 , vacuum, and combinations thereof.  
     
     
         17 . A process comprising the steps of: 
 a) providing a porous matrix;    b) levitating a solid infiltrant using electromagnetic levitation;    c) melting said solid infiltrant to provide a molten infiltrant; and    d) infiltrating said porous matrix with said molten infiltrant to provide an infiltrated product, wherein such infiltration occurs via capillary uptake.    
     
     
         18 . The process of  claim 17  further comprising a step of cooling the infiltrated product that provides a densified, infiltrated product.  
     
     
         19 . The process of  claim 17 , wherein the infiltrated product is additionally coated.  
     
     
         20 . The process of  claim 17 , wherein said porous matrix is levitated while it is infiltrated with said molten infiltrant.  
     
     
         21 . The process of  claim 17 , wherein the porous matrix is supported during at least a portion of the infiltrating.  
     
     
         22 . The process of  claim 17 , wherein said porous matrix comprises material selected from the group consisting of metals, fibers, ceramics, and combinations thereof.  
     
     
         23 . The process of  claim 17 , wherein said solid infiltrant comprises a material selected from the group consisting of Fe, Al, Ti, Co, alloys thereof, and combinations thereof.  
     
     
         24 . The process of  claim 23 , wherein said solid infiltrant further comprises at least one additional material dispersed within the solid infiltrant, said additional material being selected from the group consisting of nanoparticles, nanofibers, nanotubes, polymeric material, and combinations thereof.  
     
     
         25 . The process of  claim 24 , wherein said additional material is dispersed during the step of melting.  
     
     
         26 . The process of  claim 17 , wherein said melting is carried out using a heat source, wherein said heat source is selected from the group consisting of laser-generated radiation, microwave radiation, induction heating, and combinations thereof, and wherein said heat source provides for controlled heating.  
     
     
         27 . The process of  claim 17 , wherein said process is carried out in an environment selected from the group consisting of Ar, N 2 , He, Kr, H 2 , NH 3 , vacuum, and combinations thereof.  
     
     
         28 . A process comprising the steps of: 
 a) providing a porous free-form fabricated object;    b) electromagnetically levitating a solid infiltrant;    c) melting said solid infiltrant to provide a molten infiltrant; and    d) contacting said porous free-form fabricated object with said molten infiltrant so as to infiltrate the porous free-form fabricated object and provide an infiltrated product.    
     
     
         29 . The process of  claim 28  further comprising a step of cooling the infiltrated product that provides a densified, infiltrated product.  
     
     
         30 . The process of  claim 28 , wherein the infiltrated product is additionally coated.  
     
     
         31 . The process of  claim 28 , wherein the porous matrix is supported during at least a portion of the contacting.  
     
     
         32 . The process of  claim 28 , wherein said porous matrix comprises a material selected from the group consisting of metals, fibers, ceramics, and combinations thereof.  
     
     
         33 . The process of  claim 28 , wherein said solid infiltrant comprises a material selected from the group consisting of Fe, Al, Ti, Co, alloys thereof, and combinations thereof.  
     
     
         34 . The process of  claim 33 , wherein said solid infiltrant further comprises at least one additional material dispersed within the solid infiltrant, said additional material being selected from the group consisting of nanoparticles, nanofibers, nanotubes, polymeric material, and combinations thereof.  
     
     
         35 . The process of  claim 34 , wherein said additional material is introduced during the melting of said solid infiltrant.  
     
     
         36 . The process of  claim 28 , wherein said melting is carried out using a heat source, wherein said heat source is selected from the group consisting of laser-generated radiation, microwave radiation, induction heating, and combinations thereof, and wherein said heat source provides for controlled heating.  
     
     
         37 . The process of  claim 36 , wherein such infiltrating occurs via capillary uptake.  
     
     
         38 . The process of  claim 28 , wherein said process is carried out in an environment selected from the group consisting of Ar, N 2 , He, Kr, H 2 , NH 3 , vacuum, and combinations thereof.