Grains for the production of a sintered refractory product, a batch for the production of a sintered refractory product, a process for the production of a sintered refractory product and a sintered refractory product.

Systems and methods for preparing a three-dimensional printing material derived from aluminosilicate material are provided. The method includes the steps of heating an amount of aluminosilicate powder to a temperature between approximately 1,100° C. and approximately 1,750° C. to form a molten aluminosilicate material; maintaining the molten aluminosilicate material at a temperature between approximately 1,100° C. and approximately 1,750° C. between about one minute and approximately 45 minutes; extruding molten aluminosilicate material through a nozzle to form an elongated bead of molten aluminosilicate material; and cooling the molten aluminosilicate material to form a hardened aluminosilicate material. Once hardened, the aluminosilicate material includes between about 50% and 90% feldspar and demonstrates a strength of between about 5,000 psi and 30,000 psi. The systems and methods enable the construction of structures using raw, in-situ natural resources without the need for additives to adjust or modify the viscosity of the molten material prior to extrusion or printing.

Disclosed is a ceramic composition comprising a plurality of at least semi-coherent particles with an average diameter ranging from 1 nm to 50 nm included within a matrix, wherein the matrix comprises one metal carbonate salt, metal oxide or metalloid oxide, the particles and the matrix share at least one metal element and the metal element is 10% to 80% of the total content of said matrix, and the composition has a lattice mismatch of less than 5%. Disclosed are also an article and methods for making the ceramic composition of the present invention.

This invention relates to a refractory ceramic batch and to a method for producing a refractory ceramic product.

The invention relates to a batch for producing an unshaped refractory ceramic product, to a method for producing an unshaped refractory ceramic product, and to an unshaped refractory ceramic product produced by the method.

Grains for the production of a sintered refractory product, a batch for the production of a sintered refractory product, a process for the production of a sintered refractory product and a sintered refractory product

A foamed lightweight monolithic refractory castable is provided. The castable includes one or more refractory aggregates as a main constituent, one or more foaming additives in a range of 0.1 wt % to 3.0 wt %, one or more cellulosic powder air-entraining additives in a range of 0.005 wt % to 2.0 wt %, one or more binders in a range of 1 wt % to 40 wt %, and one or more superplasticizers in a range of 0.05 wt % to 0.5 wt %. The refractory aggregates include at least one of alumina and silica. The foaming additives include at least one of alkylbenzene sulfonates, alkene sulfonates, and hydroxylalkane sulfates. The superplasticizers include at least one of sodium polyacrylates, naphthalene sulfonates, polyethylene glycols, polycarboxylates, polyacrylates, and polycarboxylate ethers.

The invention relates to a fire-resistant ceramic product, a batch for manufacturing a product of said type, and a process for manufacturing a product of said type.

A refractory composition for forming a working lining in a metallurgical vessel contains a coarse-grain refractory particle fraction and a fine-grain refractory particle fraction, or at least 0.25% additive calcium oxide, or at least 0.25% titanium dioxide. The coarse-grain refractory particles can include alumina particles, magnesia particles, magnesium aluminate spinel particles, zirconia particles, or doloma particles, or a combination of any of these particles. The fine-grain refractory particles can be comprised of any low-magnesia refractory oxide. The refractory composition can be applied to a metallurgical vessel by spraying, gunning, shotcreting, vibrating, casting, troweling, or positioning preformed refractory shapes, or a combination of any of these techniques. When contacted by molten metal, the molten metal penetrates into the refractory material, wetting the coarse-grain refractory particles, and forming a refractory-metal composite barrier layer that decreases or blocks oxygen transport through the refractory lining.

Disclosed is a ceramic composition comprising a plurality of at least semi-coherent particles with an average diameter ranging from 1 nm to 50 nm included within a matrix, wherein the matrix comprises one metal carbonate salt, metal oxide or metalloid oxide, the particles and the matrix share at least one metal element and the metal element is 10% to 80% of the total content of said matrix, and the composition has a lattice mismatch of less than 5%. Disclosed are also an article and methods for making the ceramic composition of the present invention.