Bonded refractory ceramic and metal article

Abstract

A method is disclosed for mechanically bonding a metal component to a ceramic material, comprising providing a metal component comprising an anchor material attached to at least a first portion of one surface of the metal component; providing a ceramic material having a first surface and a second surface, wherein the ceramic material defines at least one conduit extending from the first surface to the second surface, wherein the at least one conduit has a first open end defined by the first surface, a second open end defined by the second surface, a continuous sidewall and a cross sectional area; positioning the ceramic material such that at least a portion of the at least one conduit is in overlying registration with at least a portion of the anchor material; and applying a bonding agent into at least a portion of the at least one conduit.

What is claimed is: 
     
         1 . An article comprising:
 a metal component;   an anchor material attached to at least a first portion of one surface of the metal component;   a ceramic material having a first surface and a second surface, wherein the ceramic material defines at least one conduit extending from the first surface to the second surface, wherein the at least one conduit has a first open end defined by the first surface, a second open end defined by the second surface, a continuous sidewall, and a cross sectional area;   the ceramic material positioned with respect to the metal component such that at least a portion of at least one of the first open end and the second open end of the at least one conduit is in overlying registration with at least a portion of the anchor material; and   a castable ceramic bonding agent located within at least a portion of the at least one conduit, wherein the castable ceramic bonding agent is located at one or more of: (1) an opening in at least a portion of the anchor material located at an opposing end of the at least one conduit; (2) around at least a portion of the anchor material located at the opposing end of the at least one conduit; and (3) over at least a portion of the anchor material located at the opposing end of the at least one conduit, and wherein the castable ceramic bonding agent forms a mechanical bond between the metal component and the ceramic material.   
     
     
         2 . The article of  claim 1 , wherein the castable ceramic bonding agent forms the mechanical bond capable of enduring temperatures above 1400° C. 
     
     
         3 . The article of  claim 1 , further comprising a plurality of anchor materials attached to the metal component. 
     
     
         4 . The article of  claim 1 , wherein the ceramic material defines a plurality of conduits, wherein each conduit has a first open end defined by the first surface, a second open end defined by the second surface, a continuous sidewall, and a cross sectional area. 
     
     
         5 . The article of  claim 1 , wherein at least a portion of the second surface of the ceramic material is in contact with at least a portion of the one surface of the metal component. 
     
     
         6 . The article of  claim 1 , wherein the cross sectional area of the at least one conduit is larger at the first surface or the second surface than at any other point of the at least one conduit. 
     
     
         7 . The article of  claim 1 , wherein the cross sectional area of the at least one conduit is larger at both the first and second surfaces than at any other point of the at least one conduit. 
     
     
         8 . The article of  claim 1 , wherein the continuous sidewall of the at least one conduit has a stepped profile, and wherein the cross sectional area at a center of the at least one conduit is smaller than the cross sectional area of at least one of the first surface and the second surface of the at least one conduit. 
     
     
         9 . The article of  claim 1 , wherein the anchor material comprises a metal mesh, and wherein the metal mesh has multiple openings within which there is located at least a portion of the castable ceramic bonding agent. 
     
     
         10 . The article of  claim 1 , wherein the anchor material comprises platinum, a platinum alloy, or a combination thereof. 
     
     
         11 . The article of  claim 1 , wherein the anchor material comprises a plurality of metal particles, and wherein at least a portion of the castable ceramic bonding agent is located around at least a portion of the plurality of metal particles. 
     
     
         12 . The article of  claim 11 , wherein the plurality of metal particles have at least one of following: (1) a regular shape; (2) an irregular shape; and (3) varying shapes. 
     
     
         13 . The article of  claim 1 , wherein the anchor material comprises a sheet metal structure. 
     
     
         14 . The article of  claim 13 , wherein the sheet metal structure is a corrugated piece of metal that accepts and interlocks the castable ceramic bonding agent. 
     
     
         15 . The article of  claim 13 , wherein the sheet metal structure is a formed piece of metal that accepts and interlocks the castable ceramic bonding agent. 
     
     
         16 . The article of  claim 1 , wherein the metal component comprises at least one noble metal and noble metal alloy thereof, at least one platinum group metal and platinum group metal alloy thereof, or a combination thereof. 
     
     
         17 . The article of  claim 1 , wherein the metal component comprises platinum, a platinum alloy, or a combination thereof. 
     
     
         18 . The article of  claim 1 , wherein the metal component comprises at least one of a noble metal and a noble metal alloy thereof. 
     
     
         19 . An article comprising:
 a metal component;   an anchor material attached to at least a portion of the metal component;   a ceramic material having a first surface and a second surface, wherein the first and second surfaces define at least one conduit extending from the first surface to the second surface, wherein the at least one conduit has a continuous sidewall and a cross sectional area, the ceramic material being positioned on at least a portion of an exterior surface of the metal component and in overlying registration with at least a portion of the anchor material; and,   wherein at least a portion of the at least one conduit comprises a bonding agent, and wherein at least a portion of the anchor material is substantially embedded in at least a portion of the bonding agent.   
     
     
         20 . The article of  claim 19 , wherein the bonding agent comprises a refractory oxide ceramic material. 
     
     
         21 . An article made by a method comprising:
 providing a metal component comprising an anchor material attached to at least a first portion of one surface of the metal component;   providing a ceramic material having a first surface and a second surface, wherein the ceramic material defines at least one conduit extending from the first surface to the second surface, wherein the at least one conduit has a first open end defined by the first surface, a second open end defined by the second surface, a continuous sidewall, and a cross sectional area;   positioning the ceramic material such that at least a portion of at least one of the first and/or second open ends of the at least one conduit is in overlying registration with at least a portion of the anchor material; and   applying a bonding agent into at least a portion of the at least one conduit.