Co-continuous metal-ceramic article and method for manufacture thereof

• US 20070009754A1
• Filed: 06/30/2005
• Published: 01/11/2007
• Est. Priority Date: 02/03/2003
• Status: Abandoned Application

• Current Assignee: Rapid Ceramic Technologies Ltd.
• Original Assignee: Rapid Ceramic Technologies Ltd.
• Inventors: Dzugan, Robert, Bardes, Bruce
• Application Number:
  US11/171,829
• Publication Number:
  US 20070009754A1
• Time in Patent Office: Days
• US Class Current: 428/539.500
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: C22C 1/1036 starting from a melt
• CPC Class Codes: C22C 1/1057 Reactive infiltration
• CPC Class Codes: Y02P 10/25 Process efficiency
• CPC Class Codes: Y10T 428/24997 Of metal-containing material

Abstract

A co-continuous metal-ceramic (CCMC) article resulting from a chemical reaction between a ceramic preform and a molten metal is disclosed. The ceramic preform is produced by intermixing a precursor material and a particulate ceramic material, shaping that mixture into a predetermined configuration, and transforming the precursor material into a ceramic matrix. Shaping the preform, whether through a simple molding process, or through a sophisticated rapid prototyping process, is disclosed. CCMC articles having regions of different composition and/or properties are also disclosed.

Claims

1. A CCMC article comprising interlocking metallic and ceramic phases, each of which is substantially continuous therethrough;

wherein the CCMC is manufactured by reacting a liquid metal with a ceramic preform; and

wherein the ceramic preform results from a chemical interaction between a particulate ceramic mineral and a ceramic matrix material;

wherein;

the particulate ceramic material and a precursor material are intermixed, so that particles of the particulate ceramic material are in intimate contact with the precursor material;

at least a portion of the precursor material is chemically transformed to form the ceramic matrix material; and

the chemical interaction between the particulate ceramic material and the ceramic matrix material produces a chemical bond therebetween.

2. The CCMC article as recited in claim 1, wherein the liquid metal is selected from the group consisting of:

aluminum, iron, nickel, cobalt, magnesium, and alloys of any of the aforementioned metals.

3. The CCMC article as recited in claim 1, wherein the precursor material is provided in liquid form.

4. The CCMC article as recited in claim 3, wherein the precursor material comprises a silicone resin.

5. The CCMC article as recited in claim 4, wherein the precursor material is chemically transformed by oxidation, and wherein the ceramic matrix comprises at least one member of a group consisting of silica and silicates.

6. The CCMC article as recited in claim 1, wherein the precursor material is provided in gaseous form.

7. The CCMC article as recited in claim 1, wherein the particulate ceramic material comprises at least one member of the group consisting of silica, titania, alumina, zirconia, yttria, magnesia;

analogous nitrides, carbides and sulfides;

mixtures thereof; and

intermediate compounds therebetween.

8. The CCMC article as recited in claim 1, wherein the precursor material comprises a plurality of chemical species.

9. The CCMC article as recited in claim 1, wherein the ceramic preform has a configuration developed through use of rapid prototyping process.

10. The CCMC article as recited in claim 9, wherein the rapid prototyping process comprises stereolithography.

11. The CCMC article as recited in claim 9, wherein the rapid prototyping process comprises three-dimensional printing.

12. The CCMC article as recited in claim 9, wherein the rapid prototyping process comprises fused deposition modeling.

13. The CCMC article as recited in claim 9, wherein the rapid prototyping process comprises selective laser sintering.

14-30. -30. (canceled)

31. A CCMC composite article made by a process comprising the steps of:

(a) selecting a plurality of particulate ceramic materials, each comprising at least one chemical species;

(b) intermixing a precursor material with at least a portion of each particulate ceramic material to achieve intimate contact between the precursor material and the portion of each particulate ceramic material, thereby creating a plurality of intermixed materials;

(c) shaping the intermixed materials into a predetermined configuration, thereby creating a preform characterized by regions of differing compositions, each such region having a characteristic composition attributable to the specific combination of particulate ceramic material and precursor material employed therein;

(d) chemically transforming at least a portion of the precursor material in the preform to a ceramic matrix material;

(e) chemically interacting at least a portion of the particulate ceramic material with at least a portion of the ceramic matrix material to create a ceramic preform; and

(f) chemically reacting the ceramic preform with a molten metal, thereby creating the CCMC article.