A method of forming a super hard polycrystalline construction comprises forming a liquid suspension of nano-sized super hard particles and particles of super hard material having an average particle or grain size of 1 or more microns, dispersing the particles in the liquid suspension to form a substantially homogeneous suspension which is then dried and sintered to form a body of polycrystalline super hard material comprising a first and second fractions of super hard grains, the nano-sized particles forming the second fraction. The super hard grains in the first fraction are bonded along at least a portion of the peripheral surface(s) thereof to at least a portion of a plurality of nano-sized grains in the second fraction, the grains in the first fraction having a greater average grain size than that of the grains in the second fraction which is less than 999 nm, the average grain size of the first fraction being around 1 micron or more

Multi-step milling processes to prepare cBN composite powder forms a first powder mixture by adding a binder and a first cBN component, mills the first powder mixture for a first time period, combines a second cBN component with the milled first powder mixture to form a second powder mixture, and mills the second powder mixture for a second time period (less than the first time period) to form the cBN composite powder. A ratio of the D50 value of the second cBN component to the D50 value of the first cBN component is at least 3.0. Two-step milling with different milling times for the two cBN component fractions controls the amount of mill debris in the cBN composite powder mixture. Further processing of the cBN composite powder under HPHT conditions forms a cBN-based ceramic with an average value of a cBN particle free diameter of less than 2.0 microns.

A cBN sintered material comprising cBN particles and a binder phase, in which the binder phase contains AlN and AlB.sub.2, a content proportion of cBN particles is 70 to 97 vol %, cBN sintered material has a volume resistivity up to 5×10.sup.−3 Ωcm, a rate of a peak intensity derived from Al with respect to a peak intensity derived from cBN particles is less than 1.0%, cBN particles include fine particles and coarse particles, coarse particles optionally include ultra-coarse particles, with respect to the entire cBN particles, a content proportion α of fine particles is from 10 vol %, a content proportion β of coarse particles is from 30 vol %, a content proportion γ of ultra-coarse particles is 25 vol % or less, and a total of the content proportion α of fine particles and the content proportion β of coarse particles is 50 to 100 vol %.

A method of forming a ceramic matrix composite includes depositing particles on a ceramic fabric formed from a plurality of ceramic tows, applying a binder to at least the particles to form a stabilized ceramic fabric, forming a preform using the stabilized ceramic fabric, and densifying the preform. The ceramic tows are formed from a first material and the particles are formed from at least a second material.

A method for producing a ceramic matrix composite component is disclosed. The method includes providing a plurality of first ceramic fiber plies including a plurality of interconnected tows and a plurality of first pores positioned between adjacent tows. The method includes applying a plurality of first ceramic particles within the plurality of first pores. Next, the method includes applying a plurality of second ceramic fiber plies onto an outer surface of the plurality of first ceramic fiber plies. The second ceramic fiber plies include a plurality of interconnected tows and a plurality of second pores positioned between adjacent tows. The method then includes applying a plurality of second ceramic particles within the plurality of second pores. Further, the plurality of second ceramic particles are larger than the plurality of first ceramic particles. Lastly, the method includes densifying the ceramic matrix composite preform to form the ceramic matrix composite component.

In some examples, a method including forming a layer of a slurry composition between a first ceramic or CMC part and a second ceramic or CMC part. The slurry composition includes a carrier material; and a plurality of solid particles in the carrier material. The plurality of solid particles includes first silicon carbide (SiC) particles defining a first average particle size, second SiC particles defining a second average particles size that is less than the first average particles size, and reactive additive particles. The method includes heating the layer of slurry composition to react the plurality of reactive additive particles to fuse the plurality of first SiC particles and the plurality of second SiC particles together with the reactive additive particles, wherein the fused layer of the slurry composition forms a joint layer that joins the first ceramic or CMC part to the second ceramic or CMC part.

The honeycomb filter of the present invention comprises a ceramic honeycomb substrate formed from a porous body of sintered ceramic particles, and a filter layer formed on the surface of the cell walls, wherein a portion of the filter layer penetrates from the surface of the cell walls into pores formed by the ceramic particles to form inter-particle filtration bodies, these inter-particle filtration bodies are formed from a plurality of spherical ceramic particles and crosslinking bodies which bind the spherical ceramic particles to each other, and the spherical ceramic particles and the crosslinking bodies form a three-dimensional network structure.

Disclosed is a method of manufacturing a porous ceramic body, which includes: (S1) mixing silica powders having a particle size of 0.045˜0.5 mm, zircon flour and wax, thus preparing a ceramic mixture; (S2) placing the ceramic mixture into a mold, thus producing a green body; and (S3) sintering the green body at high temperature, thus obtaining a porous ceramic body, wherein the silica having a particle size of 0.1˜0.5 mm is contained in an amount of 50˜80 wt % based on the total weight of the porous ceramic body; and also which produces a bulk porous ceramic body having good strength and leaching properties with excellent dimensional stability and shape stability.

A method for producing a form-stable phase-change material to nucleate sugar alcohols includes directionally freezing a slurry of solid chitosan and solvent and additives, providing a frozen slurry including unidirectional pillars of frozen solvent that force suspended solid particles into interstices, exposing the frozen slurry to conditions causing sublimation of the solvent of the frozen slurry to remove frozen solvent and provide a body having pillars of vacancies therein, sintering the body to provide a scaffold including the pillars of vacancies therein, graphitizing the scaffold by heating in argon, treating the scaffold with aqueous base, and adding a molten sugar alcohol phase-change material to the scaffold such that the molten phase-change material is drawn into the pillars of vacancies by capillary action to provide the form-stable phase-change material having reduced hysteresis of the melting point of the sugar alcohol phase-change material.

A method includes forming a ceramic matrix composite component by infiltrating an array of ceramic-based fibers with a ceramic-based matrix; forming a plurality of cooling holes in the ceramic matrix composite component; applying a slurry of particles in a carrier fluid to the ceramic matrix composite component such that the slurry passes through the cooling holes and wicks into the ceramic matrix composite material; and processing the ceramic matrix composite component to remove the carrier fluid, thereby leaving a filler at a wall surface of the plurality of cooling holes. A component is also disclosed.