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

Patent metadata

Field	Value
Publication number	US-11299816-B2
Application number	US-201916683101-A
Country	US
Kind code	B2
Filing date	Nov 13, 2019
Priority date	Apr 13, 2010
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

Abstract

A product according to one embodiment includes a first layer having a first composition, a first microstructure, and a first density; and a second layer above the first layer, the second layer having: a second composition, a second microstructure, and/or a second density. A gradient in composition, microstructure, and/or density exists between the first layer and the second layer, and either or both of the first layer and the second layer comprise non-spherical particles aligned along a longitudinal axis thereof.

First claim

What is claimed is:

1. A ceramic, cermet, and/or metal composition, comprising:
a first layer having a first composition, a first microstructure, and a first density; and
a second layer above the first layer, the second layer having: a second composition, a second microstructure, and/or a second density;
wherein a gradient in composition, microstructure, and/or density exists between the first layer and the second layer; and
wherein:
the first layer comprises first non-spherical particles aligned along a longitudinal axis of the first non-spherical particles;
the second layer comprises second non-spherical particles aligned along a longitudinal axis of the second non-spherical particles; or

the first layer comprises first non-spherical particles aligned along a longitudinal axis of the first non-spherical particles, and the second layer comprises second non-spherical particles aligned along a longitudinal axis of the second non-spherical particles.

2. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the gradient is a transition from the first composition, to the second composition.

3. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the gradient from the first layer to the second layer is defined by a discrete boundary.

4. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first layer and the second layer are each deposited above a non-planar electrode.

5. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first layer comprises a relatively harder, heavier material and the second layer comprises a relatively lighter material.

6. The ceramic, cermet, and/or metal composition as recited in claim 5 , wherein the first layer comprises at least one material selected from the group consisting of: AlMgB 14 , titanium boride, silicon carbide, and boron carbide.

7. The ceramic, cermet, and/or metal composition as recited in claim 5 , wherein the second layer comprises at least one material selected from the group consisting of: aluminum, Al—Mg, and Al—Mg—Li.

8. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein either or both of the first layer and the second layer comprise a ceramic or a cermet.

9. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the ceramic, cermet, and/or metal composition is optically transparent.

10. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first non-spherical particles are a non-cubic material, and/or wherein the second non-spherical particles are a non-cubic material.

11. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first non-spherical particles are aligned in a common direction; and wherein the second non-spherical particles are aligned in the common direction.

12. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first non-spherical particles are characterized by a first longitudinal length that is at least three times longer than a width of the first non-spherical particles, and/or wherein the second non-spherical particles are characterized by a second longitudinal length that is at least three times longer than a width of the second non-spherical particles.

13. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first composition and the second composition are different.

14. A ceramic, cermet, and/or metal composition, comprising:
a first layer having a first composition, a first microstructure, and a first density; and
a second layer above the first layer, the second layer having: a second composition, a second microstructure, and/or a second density;
wherein a gradient in composition, microstructure, and/or density exists between the first layer and the second layer;
wherein:
the first layer comprises first non-spherical particles aligned along a longitudinal axis of the first non-spherical particles;
the second layer comprises second non-spherical particles aligned along a longitudinal axis of the second non-spherical particles; or
the first layer comprises first non-spherical particles aligned along a longitudinal axis of the first non-spherical particles, and the second layer comprises second non-spherical particles aligned along a longitudinal axis of the second non-spherical particles; and

wherein the first microstructure and the second microstructure are different.

15. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first density and the second density are different.

16. A ceramic, cermet, and/or metal composition, comprising:
a first layer having a first composition, a first microstructure, and a first density; and
a second layer above the first layer, the second layer having: a second composition, a second microstructure, and/or a second density;
wherein a gradient in composition, microstructure, and/or density exists between the first layer and the second layer;
wherein:
the first layer comprises first non-spherical particles aligned along a longitudinal axis of the first non-spherical particles;
the second layer comprises second non-spherical particles aligned along a longitudinal axis of the second non-spherical particles; or
the first layer comprises first non-spherical particles aligned along a longitudinal axis of the first non-spherical particles, and the second layer comprises second non-spherical particles aligned along a longitudinal axis of the second non-spherical particles; and

wherein the first layer is characterized by a gradient in composition, microstructure and/or density, the gradient being defined in an x-y plane, and the x-y plane being oriented parallel to a plane of deposition of the first layer.

17. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the second layer is characterized by a gradient in composition, microstructure and/or density, the gradient being defined in an x-y plane, and the x-y plane being oriented parallel to a plane of deposition of the second layer.

18. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the gradient between the first layer and the second layer is defined by a plurality of discrete, incremental steps.

19. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the gradient between the first layer and the second layer is defined by at least one pattern.

20. The ceramic, cermet, and/or metal composition as recited in claim 1 , wherein the first layer is defined by a first gradient in microstructure, composition, and/or density, the first gradient being defined by a first pattern;
wherein second first layer is defined by a second gradient in microstructure, composition, and/or density, the second gradient being defined by a second pattern; and
wherein the first pattern and the second pattern are complementary.

Assignees

• L Livermore Nat Security Llc

Inventors

• Rose Klint A
• Kuntz Joshua D
• Worsley Marcus A

Classifications

• C04B2235/775

  Products showing a density-gradient · CPC title

• C04B2235/787

  Oriented grains · CPC title

• Y10T428/24992

  Density or compression of components · CPC title

• C04B2237/32

  Ceramic · CPC title

• C25D13/02 Primary

  with inorganic material · CPC title