Methods of three-dimensional electrophoretic deposition for ceramic and cermet applications and systems thereof

• US 10,407,792 B2
• Filed: 08/12/2016
• Issued: 09/10/2019
• Est. Priority Date: 04/13/2010
• Status: Active Grant

• Current Assignee: Lawrence Livermore National Security LLC (Government of the United States of America)
• Original Assignee: Lawrence Livermore National Security LLC (Government of the United States of America)
• Inventors: Rose, Klint Aaron, Kuntz, Joshua D., Worsley, Marcus
• Primary Examiner(s): Mayekar, Kishor
• Application Number:
  US15/236,313
• Publication Number:
  US 20160355944A1
• Time in Patent Office: 1,124 Days
• Field of Search: None
• CPC Class Codes: B32B 15/00 Layered products comprising a layer of metal
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: C04B 2235/5296 with a defined aspect ratio, e.g. indicating sphericity
• CPC Class Codes: C04B 2235/775 Products showing a density-gradient
• CPC Class Codes: C04B 2235/787 Oriented grains
• CPC Class Codes: C04B 2235/9653 Translucent or transparent ceramics other than alumina
• CPC Class Codes: C04B 2237/083 Carbide interlayers, e.g. silicon carbide interlayers
• CPC Class Codes: C04B 2237/32 Ceramic
• CPC Class Codes: C04B 2237/402 Aluminium
• CPC Class Codes: C04B 37/001 directly with other burned ceramic articles
• CPC Class Codes: C04B 37/025 consisting of glass or ceramic material
• CPC Class Codes: C25D 13/02 with inorganic material
• CPC Class Codes: C25D 13/12 characterised by the article coated
• CPC Class Codes: C25D 13/20 Pretreatment
• CPC Class Codes: C25D 13/22 Servicing or operating apparatus or multistep processes
• CPC Class Codes: Y10T 428/12458 having composition, density, or hardness gradient
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24992 Density or compression of components
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]

Abstract

In one embodiment, a method for forming a ceramic, metal, or cermet includes: providing a first solution comprising a first solvent and a first material to a device including an electrophoretic deposition (EPD) chamber; applying a voltage difference across a first electrode and a second electrode of the device; electrophoretically depositing the first material above the first electrode to form a first layer; introducing a second solution including a second solvent and a second material to the EPD chamber; applying a voltage difference across the first electrode and the second electrode; and electrophoretically depositing the second material above the first electrode to form a second layer. The first layer has a first composition, a first microstructure, and a first density, while the second layer has a second composition, a second microstructure, and a second density. At least one of the foregoing features of the first and second layers are different.

Claims

1. A method for forming a ceramic, metal, or cermet using an electrophoretic deposition (EPD) device comprising an EPD chamber, a first electrode positioned toward one end of the EPD chamber, and a second electrode positioned toward an opposite end of the EPD chamber, the method comprising:

providing a first solution to the EPD chamber using an automated injection system, the first solution comprising a first solvent and a first material;

applying a first voltage difference across the first electrode and the second electrode after providing the first solution to the EPD chamber;

electrophoretically depositing the first material above the first electrode to form a first layer, wherein the first layer has a first composition, a first microstructure, and a first density;

introducing a second solution to the EPD chamber using the automated injection system, the second solution comprising a second solvent and a second material;

applying a second voltage difference across the first electrode and the second electrode after providing the second solution to the EPD chamber; and

electrophoretically depositing the second material above the first electrode to form a second layer, wherein the second layer has a second composition, a second microstructure, and a second density,

wherein the first and second layers form a composite layer having a gradient in at least one characteristic of the composite layer along a line extending parallel to a plane of deposition of the composite layer, the at least one characteristic being selected from the group consisting of;

composition, microstructure, and density,

wherein at least one of the following provisos are satisfied;

the first and second compositions are different,

the first and second microstructures are different, and

the first and second densities are different.

2. The method for forming a ceramic, metal, or cermet as recited in claim 1, comprising:

providing light in a first pattern to a photoconductive layer positioned near the first electrode, wherein the first electrode is transparent or semi-transparent and the photoconductive layer is between the first electrode and the second electrode,

wherein portions of the photoconductive layer become conductive in response to the light according to the first pattern, and

wherein the first material is electrophoretically deposited above the photoconductive layer according to the first pattern.

3. The method for forming a ceramic, metal, or cermet as recited in claim 2, comprising:

providing light in a second pattern to the photoconductive layer after introducing the second solution to the EPD chamber,

wherein portions of the photoconductive layer become conductive in response to the light according to the second pattern,

wherein the second material is electrophoretically deposited above the photoconductive layer according to the second pattern, and

wherein the first and second patterns direct the deposition of the first and second materials to form a gradient in composition, microstructure and/or density in a direction parallel to a surface of the photoconductive layer facing the composite layer.

4. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein the first electrode has a non-planar shape.

5. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein the first solvent and the second solvent are the same and the first and second materials are different.

6. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein the first solvent and the second solvent are different and the first and second materials are the same.

7. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein a gradient exists between the first layer and the second layer, the gradient being a transition from the first composition, the first microstructure, and the first density, to the second composition, the second microstructure, and the second density.

8. The method for forming a ceramic, metal, or cermet as recited in claim 7, wherein the gradient from the first layer to the second layer is abrupt.

9. The method for forming a ceramic, metal, or cermet as recited in claim 7, wherein the gradient from the first layer to the second layer is gradual.

10. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein at least one additional characteristic of the composite layer is selected from the group consisting of:

the first and second composition are the same, the first and second microstructure are the same, and the first and second density are the same.

11. The method for forming a ceramic, metal, or cermet as recited in claim 1, further comprising expelling the first solution from the EPD chamber prior to introducing the second solution to the EPD chamber.

12. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein the first layer comprises boron carbide and the second layer comprises aluminum.

13. The method for forming a ceramic, metal, or cermet as recited in claim 1, wherein the composite layer is planar.

14. A method for forming a ceramic, metal, or cermet, the method comprising:

providing an electrophoretic deposition (EPD) device comprising;

an EPD chamber;

a first electrode positioned at an end of the EPD chamber; and

a second electrode positioned at an opposite end of the EPD chamber;

providing a first solution to the EPD chamber using an automated injection system, the first solution comprising a first solvent and a first material;

applying a first voltage difference across the first electrode and the second electrode after providing the first solution to the EPD chamber;

electrophoretically depositing the first material above the first electrode to form a first layer, wherein the first layer has a first composition, a first microstructure, and a first density;

introducing a second solution to the EPD chamber using the automated injection system, the second solution comprising a second solvent and a second material;

applying a second voltage difference across the first electrode and the second electrode after providing the second solution to the EPD chamber;

electrophoretically depositing the second material above the first electrode to form a second layer, wherein the second layer has a second composition, a second microstructure, and a second density,

wherein at least one of the following provisos are satisfied;

the first and second composition are different;

the first and second microstructures are different; and

the first and second density are different;

providing light in a first pattern to a photoconductive layer positioned near the first electrode, wherein the first electrode is transparent or semi-transparent and the photoconductive layer is between the first electrode and the second electrode,

wherein portions of the photoconductive layer become conductive in response to the light according to the first pattern, and

wherein the first material is electrophoretically deposited above the photoconductive layer according to the first pattern; and

providing light in a second pattern to the photoconductive layer after introducing the second solution to the EPD chamber,

wherein portions of the photoconductive layer become conductive in response to the light according to the second pattern,

wherein the second material is electrophoretically deposited above the photoconductive layer according to the second pattern, and

wherein the first and second patterns direct the deposition of the first and second materials to form a gradient in composition, microstructure and/or density in an x-y plane oriented parallel to a plane of the photoconductive layer,

wherein the first pattern and/or the second pattern are dynamically altered to modify a gradient in composition, microstructure and/or density in a z-direction across a plurality of layers, wherein the z-direction is perpendicular to the x-y plane.

15. A method for forming a ceramic, metal, or cermet using an electrophoretic deposition (EPD) device comprising an EPD chamber, a first electrode positioned at an end of the EPD chamber, and a second electrode positioned at an opposite end of the EPD chamber, the method comprising:

providing a first solution to the EPD chamber using an automated injection system, the first solution comprising a first solvent and a first material;

applying a first voltage difference across the first electrode and the second electrode for electrophoretically depositing the first material above the first electrode;

introducing a second solution to the EPD chamber using the automated injection system, the second solution comprising a second solvent and a second material; and

applying a second voltage difference across the first electrode and the second electrode for electrophoretically depositing the second material above the first electrode to form a layer having both the first and second materials,

the layer having a defined gradient in at least one characteristic thereof as measured along a line extending parallel to a plane of deposition of the layer,

the characteristic being selected from the group consisting of;

composition, microstructure, and density.

16. The method for forming a ceramic, metal, or cermet as recited in claim 15, comprising:

providing light in a first pattern to a photoconductive layer positioned near the first electrode, wherein the first electrode is at least semi-transparent and the photoconductive layer is between the first electrode and the second electrode,

wherein portions of the photoconductive layer become conductive in response to the light according to the first pattern, and

wherein the first material is electrophoretically deposited above the photoconductive layer according to the first pattern.

17. The method for forming a ceramic, metal, or cermet as recited in claim 15, wherein the layer is planar.

18. The method for forming a ceramic, metal, or cermet as recited in claim 15, wherein the layer has a defined gradient in at least two of the characteristics.