Ceramics product manufacturing method and ceramics product

Patent metadata

Field	Value
Publication number	US-12409579-B2
Application number	US-202418753120-A
Country	US
Kind code	B2
Filing date	Jun 25, 2024
Priority date	Apr 24, 2018
Publication date	Sep 9, 2025
Grant date	Sep 9, 2025

Abstract

Provided are a method of manufacturing a ceramic article in which the improvement of mechanical strength, wear resistance, and machinability is achieved using a direct modeling system, and a ceramic article. The manufacturing method includes the steps of: (i) arranging powder containing ceramics as a main component on a base; (ii) irradiating a part or an entirety of the arranged powder with an energy beam to melt and solidify the powder, to thereby obtain an intermediate modeled article; (iii) causing the modeled article to absorb a metal component-containing liquid to impregnate the modeled article therewith; and (iv) subjecting the modeled article having absorbed the metal component-containing liquid to heat treatment.

First claim

What is claimed is:

1. A ceramic article comprising three phases of:
an X-phase of a first oxide containing a first element;
a Y-phase of a second oxide containing a second element different from the first element; and a
Z-phase of a third oxide containing a third element different from the first element and the second element,
wherein the ceramic article is modeled by additive modeling,
wherein the first oxide is an oxide contained in the X-phase in a largest molar ratio, the second oxide is an oxide contained in the Y-phase in a largest molar ratio, and the third oxide is an oxide contained in the Z-phase in a largest molar ratio,
wherein the three phases form a eutectic structure with one another,
wherein an average particle diameter x of crystal grains forming the X-phase, an average particle diameter y of crystal grains forming the Y-phase, and an average particle diameter z of crystal grains forming the Z-phase satisfy relationships of z/x<0.5 and z/y<0.5, and
wherein the average particle diameter x and the average particle diameter y are each 5 μm or more.

2. The ceramic article according to claim 1 , wherein the average particle diameters x, y, and z satisfy relationships of z/x<0.35 and z/y<0.35.

3. The ceramic article according to claim 1 , wherein the average particle diameters x and y are each 5 μm to 30 μm.

4. The ceramic article according to claim 1 , wherein the average particle diameter z is less than 5 μm.

5. The ceramic article according to claim 1 , wherein a material forming the Z-phase is a metal oxide having a fluorite structure.

6. The ceramic article according to claim 1 , wherein the Z-phase contains a rare earth element in a ratio of 0.20 mol to 0.40 mol with respect to 1 mol of the third element contained in the Z-phase.

7. The ceramic article according to claim 1 , wherein the ceramic article contains the third element in an amount of 0.2 mol % to less than 3 mol % in metal elements forming the ceramic article.

8. The ceramic article according to claim 1 , wherein the third element is zirconium or hafnium.

9. The ceramic article according to claim 1 , wherein the first element is aluminium.

10. The ceramic article according to claim 1 , wherein the first element is silicon.

11. The ceramic article according to claim 1 , wherein the first element is silicon and the third element is aluminum.

12. The ceramic article according to claim 1 , wherein the second element is a rare earth element.

13. The ceramic article according to claim 1 , wherein the first element is aluminum or silicon, the second element is a rare earth element, and the third element is zirconium or hafnium.

14. The ceramic article according to claim 1 , wherein the second element is gadolinium or yttrium.

15. The ceramic article according to claim 1 , wherein the second element is terbium or praseodymium.

16. The ceramic article according to claim 1 , wherein the Y-phase contains the first element.

17. The ceramic article according to claim 1 , wherein the Z-phase contains a rare earth element.

18. The ceramic article according to claim 1 , wherein the crystal grains forming the Z-phase include a crystal grain contacting with at lease one of two crystal grains in the crystal grains forming the X-phase or two crystal grains in the crystal grains forming the Y-phase.

Assignees

• Canon Kk

Inventors

• Oshima Kanako
• Yasui Nobuhiro
• Yabuta Hisato
• Kubota Makoto
• Kotani Yoshinori
• Ohashi Yoshihiro

Classifications

• C04B2235/665

  Local sintering, e.g. laser sintering · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title

• C04B2235/6026

  Computer aided shaping, e.g. rapid prototyping · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title

• C04B2235/3418

  Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint · CPC title