Process and apparatus for hot-forging synthetic ceramic

Abstract

The embodiments of the invention are directed to a synthetic ceramic comprising pyroxene-containing crystalline phase, a clast, and a glass phase, wherein at least a portion of the synthetic ceramic is plastically deformable in a certain temperature range. Other embodiments of the invention relate to a method of making a synthetic ceramic, comprising heating a green ceramic material to 900-1400° C., to a temperature sufficient to initiate partial melting of at least a portion of the green ceramic material, transferring the heated green ceramic material to a press, pressing the heated green ceramic material in a die at 1,000 to 10,000 psi, and transferring the heated, pressed green ceramic material to a furnace for cooling to form the synthetic ceramic.

1 . A synthetic ceramic comprising pyroxene-containing crystalline phase, a clast, and a glass phase, wherein at least a portion of the synthetic ceramic is plastically deformable in a certain temperature range. 
     
     
         2 . The synthetic ceramic of  claim 1 , wherein the synthetic ceramic is recyclable. 
     
     
         3 . The synthetic ceramic of  claim 1 , wherein the clast contains silicon or a silicon-containing compound. 
     
     
         4 . The synthetic ceramic of  claim 1 , wherein glass phase is continuous or co-continuous. 
     
     
         5 . The synthetic ceramic of  claim 1 , wherein the pyroxene-containing crystalline phase is continuous or discrete. 
     
     
         6 . The synthetic ceramic of  claim 1 , wherein the clast comprises remnant clasts of natural origin. 
     
     
         7 . The synthetic ceramic of  claim 1 , wherein the glass phase is distributed as a matrix with the clast interspersed therein. 
     
     
         8 . The synthetic ceramic of  claim 1 , wherein the glass phase is distributed as a matrix with the pyroxene-containing crystalline phase interspersed therein. 
     
     
         9 . The synthetic ceramic of  claim 1 , wherein the pyroxene-containing crystalline phase contains crystals formed from a melt with a mineral composition comprising a mineral selected from the group consisting of wollastonite, plagioclase feldspar, anhydrite, calcium sulfate and combinations thereof. 
     
     
         10 . The synthetic ceramic of  claim 1 , wherein the pyroxene contains an element selected from the group consisting of Mg, Ca, Fe, Na, Mn, Al, Ti, Si, O and combinations thereof. 
     
     
         11 . The synthetic ceramic of  claim 1 , wherein the pyroxene-containing crystalline phase comprises crystallites having a chemistry consistent with members of the pyroxene group of minerals having the chemistry (Ca,Na,Mg,Fe 2+ ,Mn,Fe 3+ ,Al,Ti) 2  [(Si,Al) 2 O 6 ]. 
     
     
         12 . The synthetic ceramic of  claim 1 , wherein the pyroxene-containing crystalline phase comprises crystallites having a chemistry consistent with members of the pyroxene group of minerals having the chemistry (Mg,Fe 2+ Ca)(Mg,Fe 2+ )[Si 2 O 6 ]. 
     
     
         13 . The synthetic ceramic of  claim 1 , wherein the pyroxene-containing crystalline phase comprises crystallites having a chemistry consistent with members of the pyroxene group of minerals having the chemistry Ca(Mg,Fe)[Si 2 O 6 ]. 
     
     
         14 . The synthetic ceramic of  claim 1 , wherein the synthetic ceramic has an open porosity of less than 0.5 percent. 
     
     
         15 . The synthetic ceramic of  claim 1 , wherein the synthetic ceramic has a modulus of rupture in the range of about 8,000 to 12,000 psi. 
     
     
         16 . The synthetic ceramic of  claim 1 , wherein the synthetic ceramic has water absorption of less than 0.5 percent. 
     
     
         17 . The synthetic ceramic of  claim 1 , wherein the synthetic ceramic has a Taber abrasive wear index in the range of 50-400. 
     
     
         18 . The synthetic ceramic of  claim 1 , wherein the synthetic ceramic has a breaking strength of greater than 500 lbs. 
     
     
         19 . The synthetic ceramic of  claim 1 , wherein said at least a portion of the synthetic ceramic is physically deformable in the range of 200-1500° C. 
     
     
         20 . The synthetic ceramic of  claim 1 , wherein said at least a portion of the synthetic ceramic is physically deformable in the range of 900-1400° C. 
     
     
         21 . A method of making a synthetic ceramic, comprising heating a green ceramic material to 900-1400° C., to a temperature sufficient to initiate partial melting of at least a portion of the green ceramic material, transferring the heated green ceramic material to a press, pressing the heated green ceramic material in a die at 1,000 to 10,000 psi, and transferring the heated, pressed green ceramic material to a furnace for cooling to form the synthetic ceramic. 
     
     
         22 . The method of  claim 21 , wherein the method does not require a heated die. 
     
     
         23 . The method of  claim 21 , wherein the method does not require exposing the green ceramic material, the heated green ceramic material or the heated pressed green ceramic material to vacuum. 
     
     
         24 . The method of  claim 21 , wherein the synthetic ceramic is a ceramic tile. 
     
     
         25 . The method of  claim 21 , wherein the green ceramic material is made by mixing quarry fines with water to form a mixture and extruding the mixture through a die. 
     
     
         26 . The method of  claim 21 , wherein the green ceramic material contains no binder. 
     
     
         27 . The method of  claim 21 , wherein the heating the green ceramic material is to 1000-1200° C. 
     
     
         28 . The method of  claim 21 , wherein the pressing the heated green ceramic material in a die is at 1,600 to 6,000 psi. 
     
     
         29 . The method of  claim 21 , wherein the cooling to form the synthetic ceramic is in the range of 600-1000° C. 
     
     
         30 . The method of  claim 21 , wherein the cooling to form the synthetic ceramic is in the range of about 775-825° C.