A batch composition containing pre-reacted inorganic spheroidal particles and pore- former spheroidal particles. The pre-reacted inorganic spheroidal particles have a particle size distribution wherein 10 mDI.sub.50<50 m, and DIb2.0, and the pore-former spheroidal particles have a particle size distribution wherein 0.40 DP.sub.50DI.sub.50<0.90 DP.sub.50, and DPb1.32, wherein DI50 is a median particle diameter of the distribution of pre-reacted inorganic spheroidal particles, DP.sub.50 is a median particle diameter of the pore-former particle size distribution, DIb is a breadth factor of the pre-reacted particle size distribution of the pre- reacted inorganic spheroidal particles, and DPb is a breadth factor of the pore-former particle size distribution. Also, green honeycomb bodies manufactured from the batch compositions, and methods of manufacturing a honeycomb body using the batch compositions, are provided.

A batch composition containing pre-reacted inorganic spheroidal particles and pore- former spheroidal particles. The pre-reacted inorganic spheroidal particles have a particle size distribution wherein 10 mDI.sub.50<50 m, and DIb2.0, and the pore-former spheroidal particles have a particle size distribution wherein 0.40 DP.sub.50DI.sub.50<0.90 DP.sub.50, and DPb1.32, wherein DI50 is a median particle diameter of the distribution of pre-reacted inorganic spheroidal particles, DP.sub.50 is a median particle diameter of the pore-former particle size distribution, DIb is a breadth factor of the pre-reacted particle size distribution of the pre- reacted inorganic spheroidal particles, and DPb is a breadth factor of the pore-former particle size distribution. Also, green honeycomb bodies manufactured from the batch compositions, and methods of manufacturing a honeycomb body using the batch compositions, are provided.

An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

A porous ceramic structure has a porous ceramic aggregate configured from a plurality of porous ceramic particles, and the ratio of the number of corners at locations where two other porous ceramic particles are facing a corner of a porous ceramic particle with respect to the number of corners of the porous ceramic particles included in the porous ceramic aggregate is 80% or greater.

A porous ceramic structure has a porosity of 20% to 99%, and includes one principal surface and another principal surface opposite to the one principal surface. At least one cut is formed from the one principal surface toward the other principal surface. An aspect ratio of a divided portion divided by the cut is greater than or equal to 3.

A method of forming a composite component is provided. The method includes locating a fibrous preform, providing a slurry, mixing the slurry with sacrificial fibers, injecting the slurry into the fibrous preform, heating the fibrous preform, forming channels in the fibrous preform, and densifying the fibrous preform. The sacrificial fibers are suspended in the fibrous preform along an injection pathway such that heating the sacrificial fibers forms the channels along the injection pathway as the sacrificial fibers are burned away.

An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

An illustrated example method of making a porous carbon composite includes mixing a carbon-based material, a binder and pore former particles to establish a mixture. The mixture is placed into a mold where it is subjected to pressure at an ambient temperature to form a compacted body. Subsequently, the compacted body is heated to a temperature that causes at least partial removal of the pore former particles to establish pores in place of at least some of the pore former particles.

A ceramic composite material comprises a ceramic compound, a plurality of shaping particles dispersed in the ceramic compound, and a plurality void spaces dispersed in the ceramic compound. The plurality of shaping particles are contained within the plurality of void spaces, and each of the plurality of void spaces is a closed cell. The plurality of shaping particles also comprise nanostructures have a length to diameter ratio of less than or equal to 10 to 1 and a length of less than or equal to 500 nanometers.