Precursor material for additive manufacturing of low-density, high-porosity ceramic parts and methods of producing the same

Patent metadata

Field	Value
Publication number	US-10029949-B2
Application number	US-201615332683-A
Country	US
Kind code	B2
Filing date	Oct 24, 2016
Priority date	Oct 24, 2016
Publication date	Jul 24, 2018
Grant date	Jul 24, 2018

Abstract

A precursor material is provided for additive manufacturing of a low-density, high-porosity ceramic part. The precursor material comprises a body of refractory fibers and a binder in admixture with the body of refractory fibers. The precursor material further comprises a viscosity control additive in admixture with the binder and the body of refractory fibers to provide an overall mixture with a viscosity between about 0.3 centipoise and about 150,000 centipoise. The overall mixture can be extruded through a nozzle to manufacture the low-density, high porosity ceramic part. The precursor material is produced by obtaining a refractory fiber slurry, and adding a viscosity control additive to the slurry to provide the slurry with a viscosity that is suitable for extrusion through a nozzle to manufacture a low-density, high-porosity ceramic part.

First claim

What is claimed is:

1. A method of producing a precursor material for additive manufacturing of a low-density, high-porosity ceramic part, the method comprising:
obtaining a refractory fiber slurry comprising a binder and a body of ceramic fibers including about 50 weight percent to about 80 weight percent silica fibers and about 20 weight percent to about 50 weight percent alumina fibers;
adding a viscosity control additive to the refractory fiber slurry to provide a slurry with a viscosity between about 0.3 centipoise and about 150,000 centipoise; and
placing the slurry into a three-dimensional printer.

2. The method according to claim 1 further comprising:
heating the refractory fiber slurry.

3. The method according to claim 2 wherein the heating the refractory fiber slurry includes:
heating the refractory fiber slurry to boil off about 50 weight percent of water of the refractory fiber slurry.

4. The method according to claim 2 wherein the viscosity control additive comprises xanthan gum.

5. The method according to claim 4 further comprising:
mixing isopropyl alcohol with the xanthan gum before the xanthan gum is added to the binder and the body of ceramic fibers.

6. The method according to claim 5 further comprising:
off-axis centrifugally mixing a mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers for about 15 seconds to about 180 seconds.

7. The method according to claim 6 further comprising:
stir mixing the mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers for about 0.25 hours to about 5.0 hours.

8. The method according to claim 7 further comprising:
removing the isopropyl alcohol after the mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers has been stir mixed.

9. A method of producing a precursor material for additive manufacturing of a low-density, high-porosity ceramic part, the method comprising:
obtaining an aqueous ceramic fiber slurry comprising a binder and a body of ceramic fibers including about 50 weight percent to about 80 weight percent silica fibers and about 20 weight percent to about 50 weight percent alumina fibers;
adding xanthan gum that has a weight between about 0.25 percent and about 2.5 percent of a weight of the binder and the body of ceramic fibers before the aqueous ceramic fiber slurry is heated to provide the slurry with a viscosity between about 0.3 centipoise and about 150,000 centipoise; and
placing the slurry into a three-dimensional printer.

10. The method according to claim 9 wherein the obtaining the aqueous ceramic fiber slurry includes:
heating the aqueous ceramic fiber slurry to boil off about 50 weight percent of water of the aqueous ceramic fiber slurry.

11. The method according to claim 9 further comprising:
mixing isopropyl alcohol with the xanthan gum before the xanthan gum is added to the binder and the body of ceramic fibers;
off-axis centrifugally mixing a mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers for about 15 seconds to about 180 seconds;
stir mixing the mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers for about 0.25 hours to about 5.0 hours; and
removing the isopropyl alcohol after the mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers has been stir mixed.

12. The method according to claim 11 wherein the off-axis centrifugally mixing comprises off-axis centrifugally mixing the mixture of the isopropyl alcohol, the xanthan gum, the binder, and the body of ceramic fibers for about 30 seconds.

13. The method according to claim 11 wherein a density of the precursor material produced is between about four pounds per cubic foot and about 25 pounds per cubic foot.

14. The precursor material formed according to the method of claim 1 .

15. A low-density, high-porosity ceramic part manufactured using the precursor material of claim 14 .

16. The precursor material of claim 14 comprising:
a body of refractory fibers;
a binder in admixture with the body of refractory fibers; and
the viscosity control additive.

17. The precursor material of claim 16 wherein the body of refractory fibers comprise a body of ceramic fibers including about 50 weight percent to about 80 weight percent silica fibers and about 20 weight percent to about 50 weight percent alumina fibers.

18. The precursor material of claim 16 wherein the viscosity control additive comprises xanthan gum.

19. The precursor material of claim 16 wherein the viscosity control additive comprises polyethylene glycol.

20. The precursor material of claim 16 wherein the viscosity control additive comprises polyethylene oxide.

Assignees

• Boeing Co

Inventors

• Schubert Randall
• Yahata Brennan
• Kolodziejska Joanna
• Lehman Stephen E
• Heng Vann

Classifications

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• F16L59/028

  Compositions for or methods of fixing a thermally insulating material · CPC title

• C04B35/638

  Removal thereof · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C04B35/632

  Organic additives · CPC title