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

Abstract

In one embodiment, a method for forming a ceramic, metal, or cermet includes: providing a first solution comprising a first solvent and a first material to a device including an electrophoretic deposition (EPD) chamber; applying a voltage difference across a first electrode and a second electrode of the device; electrophoretically depositing the first material above the first electrode to form a first layer; introducing a second solution including a second solvent and a second material to the EPD chamber; applying a voltage difference across the first electrode and the second electrode; and electrophoretically depositing the second material above the first electrode to form a second layer. The first layer has a first composition, a first microstructure, and a first density, while the second layer has a second composition, a second microstructure, and a second density. At least one of the foregoing features of the first and second layers are different.

Inventors:

Rose, Klint Aaron; Kuntz, Joshua D.; Worsley, Marcus

Issue Date:

2019-09-10

Research Org.:

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1576329

Patent Number(s):

10407792

Application Number:

15/236,313

Assignee:

Lawrence Livermore National Security, LLC (Livermore, CA)

Patent Classifications (CPCs):

C - CHEMISTRY C25 - ELECTROLYTIC OR ELECTROPHORETIC PROCESSES C25D - PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

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C - CHEMISTRY C25 - ELECTROLYTIC OR ELECTROPHORETIC PROCESSES C25D - PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS

C25D13/12 - characterised by the article coated

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/252 - Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2237/083 - Carbide interlayers, e.g. silicon carbide interlayers
C04B2235/787 - Oriented grains
C04B2237/32 - Ceramic

C - CHEMISTRY C25 - ELECTROLYTIC OR ELECTROPHORETIC PROCESSES C25D - PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS

C25D13/02 - with inorganic material
C25D13/20 - Pretreatment

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/5296 - with a defined aspect ratio, e.g. indicating sphericity
C04B2235/775 - Products showing a density-gradient

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/24992 - Density or compression of components

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B37/001 - {directly with other burned ceramic articles}
C04B2237/402 - Aluminium

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

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/9653 - Translucent or transparent ceramics other than alumina

B - PERFORMING OPERATIONS B32 - LAYERED PRODUCTS B32B - LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

B32B15/00 - Layered products comprising {a layer of} metal

C - CHEMISTRY C25 - ELECTROLYTIC OR ELECTROPHORETIC PROCESSES C25D - PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS

C25D13/22 - Servicing or operating {apparatus or multistep processes}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B37/025 - {consisting of glass or ceramic material}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/12458 - having composition, density, or hardness gradient
Y10T428/24802 - Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

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DOE Contract Number:  

AC52-07NA27344

Resource Type:

Patent

Resource Relation:

Patent File Date: 2016 Aug 12

Country of Publication:

United States

Language:

English

Subject:

36 MATERIALS SCIENCE