Malleable Ceramics

Abstract

The malleable ceramics taught in this application are formed from silica or silicon dioxide and transition metal compounds comprising titanium dioxide, iron (II) oxide, manganese (II) oxide, cobalt (II) oxide (MO) or salts thereof in a process of sintering or melting together in a suitable crucible within a specific mol ratio. The selected M/Si mol ratio comprises 1.6/1.0 to 1.9/1.0.

These materials sinter above 1,100° C., where sintered parts exhibit densities near 3 grams/cubic centimeter and melt at higher temperatures. Thus, these materials form in a temperature range comprising 1,100° C. to 1,800° C. Malleable ceramic materials prepared as described herein deform when struck firmly with a hammer and do not fracture. Repeated striking increases the deformation or denting just like a piece of low alloy steel.

Claims

1. A process for formation of malleable ceramic materials comprising sintering or melting together transition metal compounds, comprising titanium dioxide, iron (II) oxide, manganese (II) oxide, cobalt (II) oxide (MO) or salts thereof, in combination with silicon dioxide or compounds thereof in a selected M/Si mol ratio comprising 1.6/1.0 to 1.9/1.0 in a suitable crucible.

2. A process for formation of malleable ceramic materials comprising sintering or melting together transition metal compounds, comprising titanium dioxide, iron (II) oxide, manganese (II) oxide, cobalt (II) oxide (MO) or salts thereof, in combination with silicon dioxide or compounds thereof in a selected M/Si mol ratio comprising 1.6/1.0 to 1.9/1.0 in a suitable crucible in a temperature range comprising 1,100° C. to 1,800° C.

3. A process for formation of malleable ceramic materials comprising sintering or melting together transition metal compounds comprising titanium dioxide, iron (II) oxide, manganese (II) oxide, cobalt (II) oxide (MO) or salts thereof, in combination with silicon dioxide or compounds thereof in a selected M/Si mol ratio comprising 1.6/1.0 to 1.9/1.0 in a suitable crucible in a temperature range comprising 1,100° C. to 1,800° C., for which the cooled ceramic deforms under sharp impact from a hammer and does not fracture.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0008] Ceramics are materials having physical characteristics different from metals. Common ceramics are not electrically or thermally conductive, they readily fracture and break under applied stress rather than being malleable and are not composed of a single element. Ceramic materials are typically hard and are good insulators. Malleable ceramics are therefore a dichotomy in that, while they are not electrically or thermally conductive and are not made of a single element, they do not readily fracture under applied stress. The malleable ceramics disclosed in this application are formed from common silica combined with transition metal compounds comprising titanium dioxide, iron oxide, manganese oxide, cobalt oxide or salts thereof.

[0009] Iron silicate can be prepared from iron salts comprising iron(II) chloride or iron(II) sulfate by mixing together aqueous solutions of hydrated iron(II) chloride and sodium silicate or sodium hydrogen silicate in a Fe/Si mol ratio comprising 1.6/1.0 to 1.9/1.0. The solid that forms can be filtered, rinsed and dried. Heating the resulting dried iron silicate in the temperature range of 1,100° C. to 1,800° C. forms a malleable ceramic. It may also be formed by heating a uniform mixture of iron (II) oxide and silica in the same mol ratio. Malleable ceramic materials comprising titanium silicate materials, manganese silicate materials, iron silicate materials or cobalt silicate materials are also formed by these methods. Product formation occurs in air as no inert or other gases are required other than gases used to protect furnace heating elements.

[0010] Ceramic materials may be formed by sintering although melting produces a product of higher density. Sintered iron silicate malleable ceramic materials exhibited higher than typical ceramic densities near 3.0 grams/cubic centimeter whereas common ceramics possess densities more in the range of 2.2 to 2.4 grams/cubic centimeter. Manganese silicate malleable ceramic materials also exhibited higher than normal densities. Ceramic materials prepared as described herein deform when struck firmly with a hammer. Repeated striking increases the deformation or denting just like a piece of low alloy steel. A repeatedly struck piece can splay and fracture on its end without chipping or breaking. These materials can also be drilled or cut like low alloy steels. They do not corrode or oxidize as they are fully oxidized as prepared.

PREPARATION EXAMPLES

Ceramic 1

[0011] A malleable ceramic material, iron silicate, may be prepared by mixing together 68.4 grams to 69.1 grams of iron (II) chloride tetrahydrate dissolved in pure water with 100.0 grams of sodium hydrogen silicate solution having a density of 1.397 grams/cubic centimeter. The resulting precipitate was filtered, rinsed with pure water and heated at 125° C. or higher until dry. The malleable ceramic was formed by heating the dry iron silicate material at 1,100° C. to 1,650° C. in a suitable crucible for at least 15 minutes. The sintered material formed near 1,100° C. while the molten material formed above 1,600° C.

[0012] Upon cooling the sintered material was a non-crystalline solid, brown in color having a measured density of 2.97 grams/cubic centimeter. Upon striking with a hammer the solid displayed a dent but no fractures or chips.

Ceramic 2

[0013] A malleable ceramic material, manganese silicate, may be prepared by mixing together 124.1 grams of manganese (II) oxide and 60.1 grams of silicon dioxide. A malleable ceramic was formed by heating at 1,700° C. to 1,800° C. in a suitable crucible for at least 15 minutes.

Ceramic 3

[0014] A malleable ceramic material, cobalt silicate, may be prepared by mixing together 131.1 grams of cobalt (II) oxide and 60.1 grams of silicon dioxide. A malleable ceramic was formed by heating at 1,700° C. to 1,800° C. in a suitable crucible for at least 15 minutes.