METHODS OF THREE-DIMENSIONAL ELECTROPHORETIC DEPOSITION FOR CERAMIC AND CERMET APPLICATIONS AND SYSTEMS THEREOF

• US 20190330756A1
• Filed: 07/08/2019
• Published: 10/31/2019
• 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 A.
• Granted Patent: US 11,718,924 B2
• Time in Patent Office: Days
• 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 spherical constituents C04B2235/528
• 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 method for forming a ceramic according to one embodiment includes electrophoretically depositing a plurality of layers of particles of a non-cubic material. The particles of the deposited non-cubic material are oriented in a common direction.

Claims

1. A method for forming a ceramic, the method comprising:

electrophoretically depositing a plurality of layers comprising particles of a non-cubic material, wherein the particles are oriented in a common direction.

2. The method for forming a ceramic as recited in claim 1, comprising applying an alternating current (AC) electric field in a direction parallel to a plane of deposition of the plurality of layers.

3. The method for forming a ceramic as recited in claim 1, comprising sintering the plurality of layers to form a ceramic, wherein the non-cubic material is selected such that the ceramic is transparent.

4. The method for forming a ceramic as recited in claim 1, wherein the plurality of layers are deposited above a non-planar electrode.

5. The method for forming a ceramic as recited in claim 1, 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 the particles to the EPD chamber;

applying a voltage difference across the first electrode and the second electrode; and

electrophoretically depositing the particles above the first electrode to form the layers.

6. The method for forming a ceramic as recited in claim 5, wherein the plurality of layers include a first layer having a first composition, a first microstructure, and a first density;

and a second layer having a second composition, a second microstructure, and a second density, wherein at least one of the following provisos is satisfied;

the first and second compositions are different;

the first and second microstructures are different; and

the first and second densities are different.

7. The method for forming a ceramic as recited in claim 6, wherein the second composition, the second microstructure, and the second density are each different than the first composition, the first microstructure, and the first density.

8. The method for forming a ceramic as recited in claim 6, wherein a gradient exists between a first of the layers and a second of the layers, the gradient being a transition from the first composition, the first microstructure, and/or the first density, to the second composition, the second microstructure, and/or the second density.

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

10. The method for forming a ceramic as recited in claim 8, wherein the gradient from the first layer to the second layer is gradual.

11. The method for forming a ceramic as recited in claim 6, wherein the first and second compositions are the same.

12. The method for forming a ceramic as recited in claim 6, wherein the first and second microstructures are the same.

13. The method for forming a ceramic as recited in claim 6, wherein the first and second densities are the same.

14. The method for forming a ceramic as recited in claim 5, 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 some of the particles are electrophoretically deposited above the photoconductive layer according to the first pattern.

15. The method for forming a ceramic as recited in claim 14, comprising:

providing light in a second pattern to the photoconductive layer,

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

wherein the particles are electrophoretically deposited above the photoconductive layer according to the second pattern, and

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

16. The method for forming a ceramic as recited in claim 15, 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 the plurality of layers, wherein the z-direction is perpendicular to the x-y plane.

17. The method for forming a ceramic as recited in claim 5, wherein the first electrode has a non-planar shape.