Ceramic component containing inclusions
View Patent ↗A ceramic component is disclosed, including a sintered ceramic body from a composition comprising a first ceramic material, and a plurality of inclusions in the ceramic body, each inclusion comprising graphite and a second ceramic material.
1. A ceramic component, comprising:
a sintered ceramic body formed from a composition comprising a first ceramic material; and
a plurality of inclusions in the ceramic body, each inclusion comprising graphite and a second ceramic material, wherein the second ceramic material is the same material as the first ceramic material.
2. The ceramic component of claim 1 , wherein the first ceramic material comprises a material from the group consisting of SiC, ZrO 2 , B 4 C, AlN, and Al 2 O 3 , and combinations thereof.
3. The ceramic component of claim 1 , wherein the first and second ceramic materials comprise SiC.
4. The ceramic component of claim 1 , wherein the first and second ceramic materials comprise alpha SiC.
5. The ceramic component of claim 1 , wherein the second ceramic material comprises SiC, which is formed by conversion of SiO 2 into SiC during sintering.
6. The ceramic component of claim 1 , wherein the inclusions have an average size within a range of about 10 to about 400 microns.
7. The ceramic component of claim 6 , wherein the inclusions have an average size within a range of about 20 to about 200 microns.
8. The ceramic component of claim 7 , wherein the inclusions have an average size within a range of about 30 to about 150 microns.
9. The ceramic component of claim 1 , wherein the component has a density not less than about 90% of theoretical density.
10. A ceramic component comprising:
a sintered ceramic body formed from a composition comprising a first ceramic material; and
a plurality of inclusions in the ceramic body, each inclusion comprising graphite, and a second ceramic material, and being formed from granules containing the graphite and the second ceramic material.
11. The ceramic component of claim 10 , wherein the granules are present in an amount of not greater than about 35 wt % of a total of the composition forming the ceramic body and the granules.
12. The ceramic component of claim 10 , wherein the granules are present in an amount of not greater than about 25 wt % of a total of the composition forming the ceramic body and the granules.
13. The ceramic component of claim 10 , wherein the granules are present in an amount of about 5% to about 25 wt % of a total of the composition forming the ceramic body and the granules.
14. The ceramic component of claim 10 , wherein the granules contain about 5 wt % to about 65 wt % of the second ceramic material, the balance of the granules being substantially graphite.
15. The ceramic component of claim 10 , wherein the granules contain about 10 wt% to about 50 wt % of the second ceramic material, the balance of the granules being substantially graphite.
16. The ceramic component of claim 10 , wherein the second ceramic material is provided in the granules in an unsintered form, and is sintered with sintering of the ceramic body.
17. The ceramic component of claim 1 , wherein the ceramic component comprises about 2 wt % to about 20 wt % graphite.
18. The ceramic component of claim 1 , wherein the ceramic component comprises about 5 wt % to about 15 wt % graphite.
19. A ceramic component comprising:
a sintered ceramic body formed from a composition comprising a first ceramic material; and
a plurality of inclusions in the ceramic body, each inclusion comprising graphite and a second ceramic material, wherein the second ceramic material forms a continuous matrix phase in the inclusions, in which continuous matrix phase the graphite is embedded.
20. The ceramic component of claim 1 , wherein the ceramic component is a seal.
21. The ceramic component of claim 20 , wherein the seal is annular.
22. The ceramic component of claim 20 , wherein the seal is a water pump seal.
23. A ceramic component, comprising:
a sintered ceramic body formed from a composition comprising a first ceramic material; and
a plurality of inclusions in the ceramic body, each inclusion comprising (i) a first phase comprising a lubricious material, and (ii) a second phase comprising a second ceramic material, wherein the second ceramic material is the same material as the first ceramic material.
24. The ceramic component of claim 10 , wherein the second ceramic material is the same material as the first ceramic material.
25. The ceramic component of claim 24 , wherein the first and second ceramic materials comprise SiC.
26. The ceramic component of claim 24 , wherein the first and second ceramic materials comprise alpha SiC.