Polycrystalline textured materials exhibiting heterogeneous templated grain growth, methods of forming the same, and related systems

Patent metadata

Field	Value
Publication number	US-2018282901-A1
Application number	US-201715765964-A
Country	US
Kind code	A1
Filing date	Sep 8, 2017
Priority date	Sep 9, 2016
Publication date	Oct 4, 2018
Grant date	—

Abstract

Embodiments disclosed herein are related to polycrystalline textured materials exhibiting heterogeneous templated grain growth, methods of forming such materials, and related systems. An example of a method of forming a polycrystalline textured material exhibiting heterogeneous templated grain growth includes providing a plurality of seeds. The method also includes aligning at least some of the plurality of seeds (e.g., single-crystal seeds) so that a selected crystallographic orientation of at least some of the plurality of seeds are substantially aligned with each other. Additionally, the method includes positioning the plurality of seeds in a powder matrix. The method then includes pressing the plurality of seeds and the powdered matrix to form a green body. Further, the method includes sintering the green body at a temperature that is sufficient to grow a plurality of grains from corresponding ones of the plurality of seeds to form the polycrystalline textured material.

First claim

1 . A method to form a polycrystalline textured material exhibiting heterogeneous template grain growth, the method comprising:
providing a plurality of seeds; aligning at least some of the plurality of seeds so that coordinate systems of unit cells of the at least some of the plurality of seeds are substantially aligned with each other; positioning the at least some of the plurality of seeds in a powder matrix; pressing the at least some of the plurality of seeds and the powder matrix to form a green body; and sintering the green body at a temperature that is sufficient to grow a plurality of grains from corresponding ones of the at least some of the plurality of seeds to form the polycrystalline textured material.

2 . The method of claim 1 , wherein the plurality of seeds includes a plurality of single-crystal seeds.

3 . The method of claim 1 , wherein providing a plurality of seeds includes providing at least one first seed exhibiting a first crystallographic orientation and at least one second seed exhibiting a second crystallographic orientation.

4 . The method of claim 1 , wherein the plurality of seeds exhibits a minimum dimension that is at least about 15 μm.

5 . The method of claim 1 , wherein the plurality of seeds exhibits a minimum dimension that is less than about 15 μm.

6 . The method of claim 1 , wherein providing a plurality of seeds includes cutting the plurality of seeds from at least one single-crystal block.

7 . The method of claim 6 , wherein cutting the plurality of seeds from the single-crystal block includes:
forming a first plurality of cuts in a first direction extending through at least a portion of the at least one single-crystal block; and forming a second plurality of cuts in a second direction extending through at least a portion of the at least one single-crystal block, the second plurality of cuts intersecting the first plurality of cuts; wherein forming the first and second plurality of cuts forms the plurality of seeds extending from a base.

8 . The method of claim 7 , further comprising separating the plurality of seeds from the base.

9 . The method of claim 8 , wherein separating the plurality of seeds from the base includes:
enclosing the plurality of seeds in removable material; separating the plurality of seeds from the base; and after separating the plurality of seeds from the base, removing the removable material from the plurality of seeds.

10 . The method of claim 1 , wherein each of the plurality of seeds exhibits an elongated shape that exhibits an anisometric geometry.

11 . The method of claim 1 , wherein positioning the at least some of the plurality of seeds in a powder matrix includes forming a plurality of layers each of which includes some of the plurality of seeds and some of the powder matrix.

12 . The method of claim 11 , wherein forming a plurality of layers includes forming a first layer, wherein forming a first layer includes:
disposing a first quantity of the plurality of seeds in a container or on a platform; and after disposing a first quantity of the plurality of seeds in a container or on a platform, disposing a first quantity of the powder matrix about the first quantity of the plurality of seeds.

13 . The method of claim 12 , wherein forming a plurality of layers includes, after forming the first layer, forming a second layer, wherein forming the second layer includes:
disposing a second quantity of the plurality of seeds on the first layer; and after disposing a second quantity of the plurality of seeds on the first layer, disposing a second quantity of the powder matrix about the second quantity of the plurality of seeds.

14 . The method of claim 1 , wherein the act of positioning the at least some of the plurality of seeds in a powder matrix is performed before or substantially simultaneously with the act of aligning at least some of the plurality of seeds.

15 . The method of claim 1 , wherein aligning the plurality of seeds includes disposing the plurality of seeds in a wet bag.

16 . The method of claim 1 , wherein positioning the at least some of the plurality of seeds in a powder matrix includes positioning the plurality of seeds in a dry powder matrix.

17 . The method of claim 1 , wherein pressing the at least some of the plurality of seeds and the powder matrix includes pressing the plurality of seeds and the powder matrix using a hot or cold isostatic press.

18 . The method of claim 1 , wherein sintering the green body includes sintering the green body in a vacuum or an inert atmosphere.

19 . The method of claim 1 , wherein sintering the green body includes sintering the green body for about 1 hour to about 72 hours.

20 . The method of claim 1 , wherein sintering the green body includes sintering the green body at a temperature of about 100° C. to about 2000° C.

21 . The method of claim 1 , wherein, after sintering the green body, the polycrystalline textured material exhibits a first plurality of grains exhibiting a first crystallographic orientation and a second plurality of grains exhibiting a second crystallographic orientation that is different than the first crystallographic orientation.

22 . A method to form a polycrystalline textured material exhibiting heterogeneous template grain growth, the method comprising:
providing a plurality of seeds that each exhibits an elongated shape, the elongated shape exhibiting a long axis, a medium axis, and a short axis; aligning at least some of the plurality of seeds so that:
the long axes of the at least some of the plurality of seeds are substantially aligned with each other;
the medium axes of the at least some of the plurality of seeds are substantially aligned with each other; and
the short axes of the at least some of the plurality of seeds are substantially aligned with each other;
positioning the at least some of the plurality of seeds in a powder matrix; pressing the at least some of the plurality of seeds and the powder matrix to form a green body; and sintering the green body at a temperature that is sufficient to grow a plurality of grains from corresponding ones of the at least some of the plurality of seeds to form the polycrystalline textured material.

23 . The method of claim 22 , wherein:
providing a plurality of seeds includes providing at least one first seed exhibiting a first crystallographic orientation and at least one second seed exhibiting a second crystallographic orientation; and aligning at least some of the plurality of seeds includes aligning the at least one first seed and the at least one second seed such that the first crystallographic orientation of the at least one first seed is not substantially aligned with the second crystallographic orientation of the at least one second seed.

24 . The method of claim 22 , wherein providing a plurality of seeds includes providing a plurality of seeds exhibiting a generally right rectangular prism.

25 . The method of claim 22 , wherein the plurality of seeds exhibits a minimum dimension that is at least about 15 μm.

26 . The method of claim 22 , wherein the plurality of seeds exhibits a minimum dimension that is less than about 15 μm.

27 . The method of claim 22 , wherein providing a plurality of seeds includes cutting the plurality of seeds from at least one single-crystal block.

28 . The method

Assignees

• Univ Brigham Young

Inventors

• Johnson Oliver Kent
• Frandensen Dallin James

Classifications

• C04B2235/6567

  Treatment time · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C30B28/02 Primary

  directly from the solid state · CPC title

• C04B2235/5436

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

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title