US 11,753,345 B2
Systems and methods for making ceramic powders and ceramic products
James C. McMillen, Pittsburgh, PA (US); Lance M. Sworts, New Kensington, PA (US); and Benjamin D. Mosser, Pittsburgh, PA (US)
Assigned to ALCOA USA CORP., Pittsburgh, PA (US)
Filed by ALCOA USA CORP., Pittsburgh, PA (US)
Filed on Dec. 20, 2018, as Appl. No. 16/228,295.
Application 16/228,295 is a continuation of application No. PCT/US2017/039048, filed on Jun. 23, 2017.
Claims priority of provisional application 62/353,880, filed on Jun. 23, 2016.
Prior Publication US 2019/0127282 A1, May 2, 2019
Int. Cl. C04B 35/58 (2006.01); C04B 35/626 (2006.01); C01B 35/04 (2006.01)
CPC C04B 35/58071 (2013.01) [C01B 35/04 (2013.01); C04B 35/58 (2013.01); C04B 35/626 (2013.01); C04B 2235/3241 (2013.01); C04B 2235/3258 (2013.01); C04B 2235/3272 (2013.01); C04B 2235/3275 (2013.01); C04B 2235/3279 (2013.01); C04B 2235/405 (2013.01); C04B 2235/42 (2013.01); C04B 2235/425 (2013.01); C04B 2235/52 (2013.01); C04B 2235/5292 (2013.01); C04B 2235/5436 (2013.01); C04B 2235/6586 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A method, comprising:
(a) preparing a precursor mixture, wherein the preparing comprises adding at least one additive to a plurality of reagents;
(i) wherein the plurality of reagents comprise titanium dioxide, a boron source, and a carbon source;
(ii) wherein the at least one additive is intentionally added and selected from the group consisting of:
(A) a salt of elements of Fe, Ni, Co, W, and Cr;
(B) a pure metal of elements of Fe, Ni, Co, W, and Cr;
(C) an alloy of elements of Fe, Ni, Co, W, and Cr; and
(D) combinations of (A)-(C); and
(b) carbothermically reacting the precursor mixture to form a titanium diboride particles, the titanium diboride particles defining a titanium diboride powder;
(i) wherein, at least partially due to the at least one additive, the titanium diboride particles realize a morphology selected from the group consisting of irregular, equiaxed, plate-like, and combinations thereof; and
(ii) wherein, at least partially due to the at least one additive, the titanium diboride powder produced by the titanium diboride particles realizes a fine particle size distribution, wherein the D50 of the titanium diboride particles is less than 3 micrometers;
wherein the preparing step (a) comprises adding from 0.001 to 0.75 wt. % of the at least one additive to the plurality of reagents based on a total weight of the titanium diboride powder.