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

• US 9,453,289 B2
• Filed: 04/12/2011
• Issued: 09/27/2016
• 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
• Assistant Examiner(s): Wang, Lucas
• Application Number:
  US13/085,405
• Publication Number:
  US 20110250467A1
• Time in Patent Office: 1,995 Days
• Field of Search: 428/610
• US Class Current: 1/1
• 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 ceramic, metal, or cermet according to one embodiment includes a first layer having a gradient in composition, microstructure and/or density in an x-y plane oriented parallel to a plane of deposition of the first layer. A ceramic according to another embodiment includes a plurality of layers comprising particles of a non-cubic material, wherein each layer is characterized by the particles of the non-cubic material being aligned in a common direction. Additional products and methods are also disclosed.

Claims

1. A product, comprising:

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

wherein the first layer includes non-spherical particles, wherein the non-spherical particles are micro-rod and/or nano-rod particles; and

wherein the product is optically transparent.

2. The product as recited in claim 1, wherein the gradient of the first layer is structurally defined by a first material being arranged in a first predefined pattern and a second material being arranged in a second predefined pattern.

3. The product as recited in claim 2, wherein at least the first material has a structural characteristic of being deposited through an electrophoretic deposition (EPD) process according to the first predefined pattern.

4. The product as recited in claim 2, wherein at least the first material has a characteristic of being deposited through an electrophoretic deposition (EPD) process above a non-planar electrode according to the first predefined pattern.

5. The product as recited in claim 1, further comprising a second layer above the first layer, wherein the second layer has a gradient in composition, microstructure and/or density in an x-y plane oriented parallel to a plane of deposition of the second layer, wherein the second layer includes non-spherical particles.

6. The product as recited in claim 2, further comprising a second layer above the first layer, wherein the second layer has a gradient in composition, microstructure and/or density in an x-y plane oriented parallel to a plane of deposition of the second layer, wherein the gradient of the second layer is defined by the first material being arranged in a third predefined pattern and the second material being arranged in a fourth predefined pattern.

7. The product as recited in claim 6, wherein at least the first material in the second layer has a characteristic of being deposited through an electrophoretic deposition (EPD) process according to the third predefined pattern.

8. The product as recited in claim 6, wherein at least the first material in the second layer has a characteristic of being deposited through an electrophoretic deposition (EPD) process above a non-planar electrode according to the third predefined pattern.

9. The product as recited in claim 6, wherein the first predefined pattern is different from the third predefined pattern.

10. The product as recited in claim 5, wherein a 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 gradient being a transition from at least one of:

a first composition, a first microstructure, and a first density of the first layer to at least one of;

a second composition, a second microstructure, and a second density of the second layer, wherein at least one of;

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.

11. A high-powered laser comprising the product as recited in claim 1 as a ceramic optic in the laser.

12. The product as recited in claim 1, wherein the non-spherical particles include a material selected from the group consisting of:

chloroapatite, hydroxyapatite, and fluorapatite.

13. The product as recited in claim 1, wherein each of the non-spherical particles has a longitudinal axis oriented in a common direction perpendicular to the plane of deposition of the first layer.

14. The product as recited in claim 13, wherein each of the non-spherical has a longitudinal length that is at least three times longer than a width thereof.

15. The product as recited in claim 2, wherein the first material includes non-spherical particles of a first non-cubic material and the second material includes non-spherical particles of a second non-cubic material, the first non-cubic material being different than the second non-cubic material.

16. The product as recited in claim 1, wherein the first layer has a gradient in composition, microstructure and density in an x-y plane oriented parallel to the plane of deposition of the first layer.

17. The product as recited in claim 1, wherein the non-spherical particles include fluorapatite particles having a diameter of about 100 nm and a length of about 500 nm.

18. A product, comprising:

a first layer having a first gradient in at least one of;

a first composition, a first microstructure, and a first density,

wherein the first layer includes a first plurality of non-spherical particles,

wherein the first plurality of non-spherical particles are micro-rod and/or nano-rod particles,

wherein the product is an optically transparent ceramic.

19. The product as recited in claim 18, wherein each non-spherical particle in the first plurality of non-spherical particles has a longitudinal axis oriented in a single common direction perpendicular to a plane of deposition of the first layer.

20. The product as recited in claim 19, wherein the first plurality of non-spherical particles include a material selected from the group consisting of:

chloroapatite, hydroxyapatite and fluorapatite.

21. The product as recited in claim 19, wherein the first plurality of non-spherical particles include fluorapatite, the non-spherical particles each having a diameter of about 100 nm and a length of about 500 nm.

22. The product as recited in claim 18, further comprising a second layer deposited layer above the first layer, the second layer having a second gradient in at least one of:

a second composition, a second microstructure, and a second density, wherein the second layer incudes a second plurality of non-spherical particles, wherein the second plurality of non-spherical particles are micro-rod and/or nano-rod particles.

23. The product as recited in claim 22, wherein each non-spherical particle in the second plurality of non-spherical particles has a longitudinal axis oriented in a single common direction perpendicular to a plane of deposition of the second layer.

24. The product as recited in claim 22, wherein a third gradient exists between the first layer and the second layer, the third gradient being a transition from at least one of:

the first composition to the second composition, the first microstructure to the second microstructure, and the first density to the second density.

25. A ceramic, metal or cermet, comprising:

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

wherein the gradient is structurally defined by at least a first material and a second material being arranged in a first predefined pattern and a second predefined pattern, respectively,

wherein the first material in the first predefined pattern and the second material in the second predefined pattern lie in a common plane oriented parallel to the plane of deposition, wherein the first predefined pattern and the second predefined pattern form complementary checkerboard patterns.