Methods for preparation of three-dimensional bodies

Mulligan, Anthony C.; Rigali, Mark J.; Sutaria, Manish P.; Artz, Gregory J.; Gafner, Felix H.; Vaidyanathan, K. Ranji

Title: Methods for preparation of three-dimensional bodies

Abstract

Processes for mechanically fabricating two and three-dimensional fibrous monolith composites include preparing a fibrous monolith filament from a core composition of a first powder material and a boundary material of a second powder material. The filament includes a first portion of the core composition surrounded by a second portion of the boundary composition. One or more filaments are extruded through a mechanically-controlled deposition nozzle onto a working surface to create a fibrous monolith composite object. The objects may be formed directly from computer models and have complex geometries.

Inventors:: Mulligan, Anthony C.; Rigali, Mark J.; Sutaria, Manish P.; Artz, Gregory J.; Gafner, Felix H.; Vaidyanathan, K. Ranji

Issue Date:: 2004-09-28

Research Org.:: Advanced Ceramics Research, Inc., Tucson, AZ (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1175056

Patent Number(s):: 6797220

Application Number:: 10/005,656

Assignee:: Advanced Ceramics Research, Inc. (Tucson, AZ)

Patent Classifications (CPCs):: Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER

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Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
Y02P10/25 - by increasing the energy efficiency of the process

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F3/004 - {Filling molds with powder

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/634 - Polymers
C04B35/645 - Pressure sintering

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F3/15 - Hot isostatic pressing
B22F3/10 - Sintering only

C - CHEMISTRY C08 - ORGANIC MACROMOLECULAR COMPOUNDS C08K - Use of inorganic or non-macromolecular organic substances as compounding ingredients
C08K3/18 - Oxygen-containing compounds, e.g. metal carbonyls

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
Y10T428/2929 - Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/806 - {The matrix of the ceramic products consisting of non-oxides only}
C04B35/638 - Removal thereof
C04B2235/6021 - Extrusion moulding
C04B2235/3826 - Silicon carbides
C04B35/6303 - {Inorganic additives}

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F2998/00 - Supplementary information concerning processes or compositions relating to powder metallurgy

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/5622 - {based on zirconium or hafnium carbides}

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C43/006 - {Pressing and sintering powders, granules or fibres}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B2235/524 - Non-oxidic, e.g. borides, carbides, silicides or nitrides

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F2999/00 - Aspects linked to processes or compositions used in powder metallurgy
B22F3/14 - simultaneously

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
B29K2105/06 - containing reinforcements, fillers or inserts

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C48/06 - Rod-shaped

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F2203/01 - To-be-deleted with administrative transfer to B22F2203/00

B - PERFORMING OPERATIONS B28 - WORKING CEMENT, CLAY, OR STONE B28B - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
B28B3/20 - wherein the material is extruded {

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/6286 - {Carbides}

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F1/004 - {Fibre structure
B22F3/20 - by extruding

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/6455 - {Hot isostatic pressing}
C04B35/632 - Organic additives

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F1/025 - {Metallic coating}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B2235/96 - Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
C04B2235/77 - Density

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
B33Y10/00 - Processes of additive manufacturing

B - PERFORMING OPERATIONS B28 - WORKING CEMENT, CLAY, OR STONE B28B - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
B28B17/0081 - {Process control}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B2235/3839 - Refractory metal carbides

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DOE Contract Number:: FC02-96CH10861

Resource Type:: Patent

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE

Citation Formats


                    Mulligan, Anthony C., Rigali, Mark J., Sutaria, Manish P., Artz, Gregory J., Gafner, Felix H., and Vaidyanathan, K. Ranji. Methods for preparation of three-dimensional bodies.  United States: N. p., 2004. 
        Web.

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                    Mulligan, Anthony C., Rigali, Mark J., Sutaria, Manish P., Artz, Gregory J., Gafner, Felix H., & Vaidyanathan, K. Ranji. Methods for preparation of three-dimensional bodies.  United States.

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                    Mulligan, Anthony C., Rigali, Mark J., Sutaria, Manish P., Artz, Gregory J., Gafner, Felix H., and Vaidyanathan, K. Ranji. Tue .  
        "Methods for preparation of three-dimensional bodies".  United States.  https://www.osti.gov/servlets/purl/1175056.

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@article{osti_1175056,

  title        = {Methods for preparation of three-dimensional bodies},

  author       = {Mulligan, Anthony C. and Rigali, Mark J. and Sutaria, Manish P. and Artz, Gregory J. and Gafner, Felix H. and Vaidyanathan, K. Ranji},

  abstractNote = {Processes for mechanically fabricating two and three-dimensional fibrous monolith composites include preparing a fibrous monolith filament from a core composition of a first powder material and a boundary material of a second powder material. The filament includes a first portion of the core composition surrounded by a second portion of the boundary composition. One or more filaments are extruded through a mechanically-controlled deposition nozzle onto a working surface to create a fibrous monolith composite object. The objects may be formed directly from computer models and have complex geometries.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2004},

  month        = {9}

}

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Works referenced in this record:

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Journal of Materials Science, Vol. 15, Issue 2
https://doi.org/10.1007/BF00551699

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Title: Methods for preparation of three-dimensional bodies

Abstract

Citation Formats

Silicon carbide fibre reinforced glass-ceramic matrix composites exhibiting high strength and toughness journal, August 1982

Experimental and numerical studies of foam-filled sections journal, May 2000

Fibrous monoliths: non-brittle fracture from powder-processed ceramics journal, June 1995

Silicon Carbide Monofilament-Reinforced Silicon Nitride or Silicon Carbide Matrix Composites journal, April 1989

Fibrous Monolithic Ceramics journal, October 1997

On the modeling of crush behavior of a closed-cell aluminum foam structure journal, April 1998

Mesoscopic simulation of inhomogeneous metallic foams with respect to energy absorption journal, December 1999

Heat transfer in open-cell metal foams journal, June 1998

High-strength silicon carbide fibre-reinforced glass-matrix composites journal, February 1980

Silicon carbide fibre reinforced glass-ceramic matrix composites exhibiting high strength and toughness
journal, August 1982

Experimental and numerical studies of foam-filled sections
journal, May 2000

Fibrous monoliths: non-brittle fracture from powder-processed ceramics
journal, June 1995

Silicon Carbide Monofilament-Reinforced Silicon Nitride or Silicon Carbide Matrix Composites
journal, April 1989

Fibrous Monolithic Ceramics
journal, October 1997

On the modeling of crush behavior of a closed-cell aluminum foam structure
journal, April 1998

Mesoscopic simulation of inhomogeneous metallic foams with respect to energy absorption
journal, December 1999

Heat transfer in open-cell metal foams
journal, June 1998

High-strength silicon carbide fibre-reinforced glass-matrix composites
journal, February 1980