The invention relates to a method for producing a non-oxide ceramic powder comprising a nitride, a carbide, a boride or at least one MAX phase with the general composition Mn+1AXn, where M=at least one element from the group of transition elements (Sc, Ti, V, Cr, Zr, Nb, Mo, Hf and Ta), A=at least one A group element from the group (Si, Al, Ga, Ge, As, Cd, In, Sn, Tl and Pb), X=carbon (C) and/or nitrogen (N) and/or boron (B), and n=1, 2 or 3. According to the invention, corresponding quantities of elementary starting materials or other precursors are mixed with at least one metal halide salt (NZ), compressed (pellet), and heated for synthesis with a metal halide salt (NZ). The compressed pellet is first enveloped with another metal halide salt, compressed again, arranged in a salt bath and heated therewith until the melting temperature of the salt is exceeded. Optionally, melted silicate can be added, which prevents the salt from evaporating at high temperatures. Advantageously, the method can be carried out in the presence of air.

Described are molds that include a ceramic material at a surface, as well as methods of forming the molds, and methods of using the molds; the ceramic material is constituted substantially, mostly, or entirely of three elemental components designated M, A, and X; the “M” component is at least one transition metal; the “A” component is one or a combination of Si, Al, Ge, Pb, Sn, Ga, P, S, In, As, Tl, and Cd; and the “X” component is carbon, nitrogen, or a combination thereof.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

An alumina/titanium silicon carbide composite material is prepared by making titanium aluminum carbide (Ti.sub.3AlC.sub.2) in uniform contact with silicon monoxide (SiO), and carrying out vacuum sintering. The composite material is obtained through mutual diffusion of aluminum and silicon and has high compactness and stable performance. In the composite material, the alumina is generated by means of a reaction between the titanium aluminum carbide and the silicon monoxide, and can be uniformly wrapped around surfaces of titanium silicon carbide crystals to form a relatively compact oxide film, such that substance exchange between a matrix and the outside is hindered, and overall antioxidation of the composite material is improved. Toughness of the composite material is enhanced by means of the titanium silicon carbide. The prepared composite material has relatively high purity, relatively low sintering temperature, and relatively high bending strength. The process is simple and convenient for industrial production.

An alumina/titanium silicon carbide composite material is prepared by making titanium aluminum carbide (Ti.sub.3AlC.sub.2) in uniform contact with silicon monoxide (SiO), and carrying out vacuum sintering. The composite material is obtained through mutual diffusion of aluminum and silicon and has high compactness and stable performance. In the composite material, the alumina is generated by means of a reaction between the titanium aluminum carbide and the silicon monoxide, and can be uniformly wrapped around surfaces of titanium silicon carbide crystals to form a relatively compact oxide film, such that substance exchange between a matrix and the outside is hindered, and overall antioxidation of the composite material is improved. Toughness of the composite material is enhanced by means of the titanium silicon carbide. The prepared composite material has relatively high purity, relatively low sintering temperature, and relatively high bending strength. The process is simple and convenient for industrial production.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

A cutting element comprises a supporting substrate, and a cutting table attached to an end of the supporting substrate. The cutting table comprises inter-bonded diamond particles, and a thermally stable material within interstitial spaces between the inter-bonded diamond particles. The thermally stable material comprises a carbide precipitate having the general chemical formula, A.sub.3XZ.sub.n-1, where A comprises one or more of Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Ac, Th, Pa, and U; X comprises one or more of Al, Ga, Sn, Be, Bi, Te, Sb, Se, As, Ge, Si, B, and P; Z comprises C; and n is greater than or equal to 0 and less than or equal to 0.75. A method of forming a cutting element, an earth-boring tool, a supporting substrate, and a method of forming a supporting substrate are also described.

The present invention relates to the field of MAX-phase ceramic-based composites, specifically to a short-fiber-reinforced oriented MAX-phase ceramic-based composite and a preparation method therefor. By using a new process with a fiber, a nano lamellar MAX-phase ceramic powder, other additives, etc., for preparing a fiber-reinforced MAX-phase ceramic-based composite, a novel ternary composite is prepared, wherein a matrix is composed of a highly oriented lamellar MAX-phase ceramic, the fiber is distributed parallel to the lamellar MAX-phase ceramic in an axial direction, and a granulate ceramic phase enhancement phase is dispersed in the matrix. Thus, the problems of a MAX-phase ceramic-based composite matrix material prepared by an existing method, such as coarse grains, multiple internal defects and a low strength, and a poor fracture toughness; and a reaction sintering temperature being too high such that fibers are chemically and physically damaged in a substrate, resulting in performance degradation, are solved. Fibers prepared by the method are suitable for large-scale industrial preparation and have properties that are far superior to those of any existing known fiber MAX-phase composite.

Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of ceramic materials and components with a thickness greater than three millimeters (3 mm). A sulfur-free 3D printable formulation comprises a liquid inorganic polymer resin using Stereolithograpy (SLA) printers and Digital Light Processing (DLP) curing of the polymer resin via the chemical bonding of the materials rather than sintering. Thus, the process has shorter manufacturing intervals, significantly lower energy use and produces larger scale ceramic components having less linear shrinkage, less mass loss and high ceramic yield with no corrosive sulfur compounds present in the ceramic component.