Refractory metal ceramics and methods of making thereof
A composition having nanoparticles of a refractory-metal carbide or refractory-metal nitride and a carbonaceous matrix. The composition is not in the form of a powder. A composition comprising a metal component and an organic component. The metal component is nanoparticles or particles of a refractory metal or a refractory-metal compound capable of decomposing into refractory metal nanoparticles. The organic component is an organic compound having a char yield of at least 60% by weight or a thermoset made from the organic compound. A method of combining particles of a refractory metal or a refractory-metal compound capable of reacting or decomposing into refractory-metal nanoparticles with an organic compound having a char yield of at least 60% by weight to form a precursor mixture.
1. A composition comprising:
nanoparticles of a refractory-metal carbide or refractory-metal nitride;
wherein the refractory metal is titanium, zirconium, hafnium, tungsten, tantalum, niobium, molybdenum, or chromium; and
a carbonaceous matrix;
wherein the composition is not in the form of a powder; and
wherein the composition comprises at least 5% by weight of the nanoparticles.
2. The composition of claim 1 , wherein the nanoparticles comprise titanium carbide or titanium nitride.
3. The composition of claim 1 , wherein the nanoparticles comprise zirconium carbide, zirconium nitride, hafnium carbide, hafnium nitride, tungsten carbide, or tantalum carbide.
4. The composition of claim 1 , wherein the refractory metal is a group IV-VI transition metal, niobium, molybdenum, or chromium.
5. The composition of claim 1 , wherein the composition comprises at least 99% by weight of the nanoparticles.
6. The composition of claim 1 , wherein the average diameter of the nanoparticles is less than 100 nm.
7. The composition of claim 1 , wherein the carbonaceous matrix comprises graphitic carbon, carbon nanotubes, or amorphous carbon.
8. The composition of claim 1 , wherein the composition further comprises:
fibers, carbon fibers, ceramic fibers, or metal fibers.
9. The composition of claim 1 , wherein the composition contains less than 20% by volume of voids.
10. The composition of claim 1 ;
wherein the nanoparticles comprise tungsten carbide; and
wherein the composition contains less than 50% by volume of voids.
11. An article comprising the composition of claim 1 , wherein the article is in the form of a solid, unbroken mass having a surface and a minimum size of at least 1 mm in all dimensions.
12. The article of claim 11 , wherein the surface of the article comprises an oxide of the refractory metal.
13. An article having a surface comprising a composition comprising:
nanoparticles of a refractory-metal carbide or refractory-metal nitride; and
a carbonaceous matrix;
wherein the composition is not in the form of a powder; and
wherein the surface of the article comprises an oxide of the refractory metal.
14. The article of claim 13 , wherein the nanoparticles comprise titanium carbide or titanium nitride.
15. The article of claim 13 , wherein the nanoparticles comprise zirconium carbide, zirconium nitride, hafnium carbide, hafnium nitride, tungsten carbide, or tantalum carbide.
16. The article of claim 13 , wherein the refractory metal is a group IV-VI transition metal, niobium, molybdenum, chromium, or vanadium.
17. The article of claim 13 , wherein the composition comprises at least 5% by weight of the nanoparticles.
18. The article of claim 13 , wherein the composition comprises at least 99% by weight of the nanoparticles.
19. The article of claim 13 , wherein the average diameter of the nanoparticles is less than 100 nm.
20. The article of claim 13 , wherein the carbonaceous matrix comprises graphitic carbon, carbon nanotubes, or amorphous carbon.
21. The article of claim 13 , wherein the composition further comprises:
fibers, carbon fibers, ceramic fibers, or metal fibers.
22. The article of claim 13 , wherein the composition contains less than 20% by volume of voids.
23. The article of claim 13 ;
wherein the nanoparticles comprise tungsten carbide; and
wherein the composition contains less than 50% by volume of voids.
24. The article of claim 13 , wherein the article is in the form of a solid, unbroken mass having a minimum size of at least 1 mm in all dimensions.
25. A composition comprising:
nanoparticles of titanium carbide;
fibers, carbon fibers, ceramic fibers, or metal fibers; and
a carbonaceous matrix;
wherein the composition is not in the form of a powder; and
wherein the composition contains less than 20% by volume of voids.
26. The composition of claim 25 , wherein the composition comprises at least 5% by weight of the nanoparticles.
27. The composition of claim 25 , wherein the composition comprises at least 99% by weight of the nanoparticles.
28. The composition of claim 25 , wherein the average diameter of the nanoparticles is less than 100 nm.
29. The composition of claim 25 , wherein the carbonaceous matrix comprises graphitic carbon, carbon nanotubes, or amorphous carbon.
30. An article comprising the composition of claim 25 , wherein the article is in the form of a solid, unbroken mass having a surface and a minimum size of at least 1 mm in all dimensions.
31. The article of claim 30 , wherein the surface of the article comprises an oxide of the refractory metal.
32. An article having a surface comprising a composition comprising:
nanoparticles of a refractory-metal carbide or refractory-metal nitride;
wherein the refractory metal is titanium, zirconium, hafnium, tungsten, tantalum, niobium, molybdenum, or chromium; and
a carbonaceous matrix;
wherein the composition is not in the form of a powder; and
wherein the article is in the form of a solid, unbroken mass having a minimum size of at least 1 mm in all dimensions.
33. The article of claim 32 , wherein the nanoparticles comprise titanium carbide or titanium nitride.
34. The article of claim 32 , wherein the nanoparticles comprise zirconium carbide, zirconium nitride, hafnium carbide, hafnium nitride, tungsten carbide, or tantalum carbide.
35. The article of claim 32 , wherein the refractory metal is a group IV-VI transition metal, niobium, molybdenum, or chromium.
36. The article of claim 32 , wherein the composition comprises at least 99% by weight of the nanoparticles.
37. The article of claim 32 , wherein the average diameter of the nanoparticles is less than 100 nm.
38. The article of claim 32 , wherein the carbonaceous matrix comprises graphitic carbon, carbon nanotubes, or amorphous carbon.
39. The article of claim 32 , wherein the composition further comprises:
fibers, carbon fibers, ceramic fibers, or metal fibers.
40. The article of claim 32 , wherein the composition contains less than 20% by volume of voids.
41. The article of claim 32 ;
wherein the nanoparticles comprise tungsten carbide; and
wherein the composition contains less than 50% by volume of voids.
42. The article of claim 32 , wherein the surface of the article comprises an oxide of the refractory metal.
43. A composition comprising:
nanoparticles of a refractory-metal carbide or refractory-metal nitride;
fibers, carbon fibers, ceramic fibers, or metal fibers; and
a carbonaceous matrix;
wherein the composition is not in the form of a powder;
wherein the nanoparticles comprise titanium nitride, zirconium carbide, zirconium nitride, hafnium carbide, hafnium nitride, tungsten carbide, or tantalum carbide; or the refractory metal is a group V or VI transition metal, niobium, molybdenum, chromium, or vanadium; and
wherein the composition contains less than 20% by volume of voids.