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

• US 10,533,261 B2
• Filed: 08/12/2016
• Issued: 01/14/2020
• 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): Sheikh, Humera N
• Assistant Examiner(s): Wang, Xiaobei
• Application Number:
  US15/236,308
• Publication Number:
  US 20160348262A1
• Time in Patent Office: 1,250 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

A product according to one embodiment includes a first layer comprising a first material, the first layer having a gradient in composition, microstructure and/or density in an x-y plane, and the x-y plane being oriented parallel to a plane of deposition of the first layer. The first material includes non-spherical particles; and the product is optically transparent. A ceramic according to another embodiment includes a plurality of layers comprising non-spherical particles of a non-cubic material. Each layer is individually characterized by the non-spherical particles thereof being aligned in a common direction. A product in another embodiment includes a first layer having a first composition, a first microstructure, and a first density; and a second layer above the first layer, the second layer having: a second composition, a second microstructure, and/or a second density. A gradient in composition, microstructure, and/or density exists between the first layer and the second layer.

Claims

1. A product, comprising:

a first layer comprising a first material, the first layer having a gradient in composition, microstructure and/or density in an x-y plane, and the x-y plane being oriented parallel to a plane of deposition of the first layer;

wherein the first material includes non-spherical particles; and

wherein the product is optically transparent.

2. The product as recited in claim 1, wherein the first layer comprises the first material arranged in a first pattern.

3. The product as recited in claim 1, wherein the first material is deposited above a non-planar electrode.

4. The product as recited in claim 1, further comprising a second layer above the first layer, wherein the second layer has a second gradient in composition, microstructure and/or density in the x-y plane.

5. The product as recited in claim 4, wherein the second layer comprises a second material and/or the first material arranged in a second pattern.

6. The product as recited in claim 4, wherein the second gradient is defined by the first material being arranged in a third pattern within the second layer, and a second material being arranged in a fourth pattern within the second layer;

wherein the third pattern is complementary to the fourth pattern;

wherein the first material is arranged in a first pattern in the first layer; and

wherein the first pattern is different from the third pattern.

7. The product as recited in claim 4, wherein a third gradient exists between the first layer and the second layer in a z-direction perpendicular to the x-y plane of the first layer, the third gradient being from:

a first composition, a first microstructure, and/or a first density of the first layer to;

a second composition, a second microstructure, and/or a second density of the second layer.

8. The product as recited in claim 7, wherein the third gradient is defined by a series of discrete, incremental steps.

9. The product as recited in claim 7, wherein the third gradient is defined by a smooth transition from the first composition, the first microstructure, and/or the first density of the first layer to the second composition, the second microstructure, and/or the second density of the second layer.

10. The product as recited in claim 7, wherein at least one of the following provisos is satisfied:

the first composition and the second composition are different;

the first microstructure and the second microstructure are different; and

the first density and the second density are different.

14. The product as recited in claim 1, further comprising a second layer above the first layer, wherein the product is functionally graded in three dimensions.

11. A ceramic, comprising:

a plurality of layers comprising non-spherical particles of a non-cubic material,

wherein the non-spherical particles are characterized by a longitudinal length that is at least three times longer than a width of the non-spherical particles, and

wherein each layer is individually characterized by the non-spherical particles thereof being aligned in a common direction.

12. The ceramic as recited in claim 11, wherein the plurality of layers are deposited above a non-planar electrode.

13. The ceramic as recited in claim 11, wherein the ceramic is transparent.