Ceramics with engineered microstructures via 3D printing and templated grain growth

Patent metadata

Field	Value
Publication number	US-10112873-B2
Application number	US-201514725203-A
Country	US
Kind code	B2
Filing date	May 29, 2015
Priority date	May 29, 2015
Publication date	Oct 30, 2018
Grant date	Oct 30, 2018

Abstract

A three-dimensional (3D) printing composition includes ceramic filaments comprising an additive having an aspect ratio of at least 2:1. 3D printed ceramic articles include the ceramic filaments.

First claim

What is claimed is:

1. A three-dimensional (3D) printing composition, comprising:
ceramic filaments, each ceramic filament comprising an additive and having an extrusion direction, at least 50% of the additive of each ceramic filament being aligned with respect to the extrusion direction, and each additive having an aspect ratio of at least 2:1.

2. The 3D printing composition of claim 1 , wherein the additive is present in an amount of at least 2 weight % (wt. %).

3. The 3D printing composition of claim 1 , further comprising a dispersant.

4. The 3D printing composition of claim 1 , wherein the additive is a seed crystal.

5. The 3D printing composition of claim 1 , wherein the additive is a dopant, a fiber, a whisker, a needle, a carbon nanotube, or any combination thereof.

6. The 3D printing composition of claim 1 , wherein the 3D printing composition further comprises a binder.

7. A method of making a 3D ceramic article, the method comprising:
forming ceramic filaments comprising an additive having an aspect ratio of at least 2:1, at least 50% of the additive being aligned with respect to an extrusion direction of the ceramic filaments;
3D printing the ceramic filaments in successive layers to form a 3D structure; and
densifying to form the 3D ceramic article.

8. The method of claim 7 , wherein the additive is a seed crystal, a dopant, a fiber, a whisker, a needle, a carbon nanotube, or any combination thereof.

9. The method of claim 7 , wherein the 3D ceramic article has a textured surface.

10. The method of claim 7 , wherein forming the ceramic filaments comprises extruding a ceramic composition comprising the additive in an amount of at least 2 wt. %.

11. The method of claim 7 , wherein forming ceramic filaments comprises mixing ceramic powder and a dispersant in a solvent and then drying to form a coated ceramic composition.

12. The method of claim 11 , further comprising mixing the coated ceramic mixture with the additive and a binder.

13. The method of claim 7 , wherein 3D printing is filament deposition modeling.

14. The method of claim 7 , wherein densifying is removing a binder, sintering, hot isostatic pressing, or any combination thereof.

Assignees

• Raytheon Co

Inventors

• Nordahl Christopher S

Classifications

• C04B35/803

  Chemistry & Metallurgy · mapped topic

• C04B35/505 Primary

  based on yttrium oxide · CPC title

• C04B2235/3873

  Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride · CPC title

• C04B2235/5296

  with a defined aspect ratio, e.g. indicating sphericity · CPC title

• C04B35/553

  based on fluorides · CPC title