Ceramics product manufacturing method and ceramics product

Patent metadata

Field	Value
Publication number	US-2021031403-A1
Application number	US-202017076328-A
Country	US
Kind code	A1
Filing date	Oct 21, 2020
Priority date	Apr 24, 2018
Publication date	Feb 4, 2021
Grant date	—

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 method of manufacturing a ceramic article comprising 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 a modeled article; (iii) causing the modeled article to absorb a metal component-containing liquid; and (iv) subjecting the modeled article having absorbed the metal component-containing liquid to heat treatment.

2 . The method of manufacturing a ceramic article according to claim 1 , wherein the metal component-containing liquid is changed to a metal compound by the heat treatment in the step (iv).

3 . The method of manufacturing a ceramic article according to claim 1 , wherein the metal component-containing liquid generates a phase that is to have a eutectic relationship with a phase forming the modeled article by the heat treatment in the step (iv).

4 . The method of manufacturing a ceramic article according to claim 3 , wherein, when a melting point of the phase generated from the metal component-containing liquid is represented by T m , a melting point of the phase forming the modeled article, which is to form a eutectic with the phase generated from the metal component-containing liquid, is represented by T i , and a eutectic temperature of the phase generated from the metal component-containing liquid and the phase forming the modeled article, which is to form a eutectic with the phase generated from the metal component-containing liquid, is represented by T E , the modeled article reaches a maximum temperature T S satisfying T E <T S <T m during the heat treatment in the step (iv).

5 . The method of manufacturing a ceramic article according to claim 4 , wherein the ceramics and the metal component-containing liquid are a combination satisfying a relationship of T m <T i .

6 . The method of manufacturing a ceramic article according to claim 2 , wherein the powder contains the metal compound in a content of less than 3 mol %.

7 . The method of manufacturing a ceramic article according to claim 1 , wherein the metal component-containing liquid contains any one of a metal alkoxide, a chloride, and a salt compound as a metal component.

8 . The method of manufacturing a ceramic article according to claim 7 , wherein the metal component-containing liquid contains the metal alkoxide, and further contains an organic solvent and a stabilizer.

9 . The method of manufacturing a ceramic article according to claim 8 , wherein the stabilizer is any one of materials of β-diketone compounds, β-ketoester compounds, and alkanolamines.

10 . The method of manufacturing a ceramic article according to claim 1 , wherein the powder contains aluminum oxide or silicon oxide as a main component.

11 . The method of manufacturing a ceramic article according to claim 10 , wherein the powder further contains an oxide of a rare earth element.

12 . The method of manufacturing a ceramic article according to claim 11 , wherein the oxide of a rare earth element is at least one kind selected from the group consisting of gadolinium oxide, terbium oxide, and praseodymium oxide.

13 . The method of manufacturing a ceramic article according to claim 10 , wherein the powder contains the silicon oxide as the main component, and the metal component-containing liquid contains a zirconium component or aluminum oxide.

14 . The method of manufacturing a ceramic article according to claim 10 , wherein the powder contains the aluminum oxide as the main component, and the metal component-containing liquid contains a zirconium component.

15 . The method of manufacturing a ceramic article according to claim 13 , wherein the metal component-containing liquid contains a zirconium alkoxide.

16 . The method of manufacturing a ceramic article according to claim 15 , wherein the metal component-containing liquid further contains 2-propanol and ethyl acetoacetate.

17 . The method of manufacturing a ceramic article according to claim 13 , wherein the step (iii) includes immersing the modeled article in the metal component-containing liquid containing the zirconium component, and degassing the modeled article under reduced pressure.

18 . The method of manufacturing a ceramic article according to claim 13 , wherein the heat treatment in the step (iv) has a maximum temperature of 1,600° C. or more and 1,710° C. or less.

19 . The method of manufacturing a ceramic article according to claim 1 , wherein the energy beam in the step (ii) is a laser beam or an electron beam.

20 . The method of manufacturing a ceramic article according to claim 1 , wherein the step (iii) and the step (iv) are repeated a plurality of times after the step (i) and the step (ii) are repeated a plurality of times.

21 . A ceramic article having a phase separation structure formed of three phases of an X-phase, a Y-phase, and a Z-phase,
wherein the three phases are made of materials having a eutectic relationship, and wherein the X-phase is formed of grains having an average particle diameter “x”, the Y-phase is formed of grains having an average particle diameter “y”, and the Z-phase is formed of grains having an average particle diameter “z”, the average particle diameters “x”, “y”, and “z” satisfying relationships of z/x<0.5 and z/y<0.5.

22 . The ceramic article according to claim 21 , wherein the average particle diameters “x”, “y”, and “z” satisfy relationships of z/x<0.35 and z/y<0.35.

23 . The ceramic article according to claim 21 , wherein the average particle diameters “x” and “y” are each 3 μm or more and 30 μm or less.

24 . The ceramic article according to claim 21 , wherein the average particle diameter “z” is less than 5 μm.

25 . The ceramic article according to claim 21 , wherein the Z-phase is a metal oxide having a fluorite structure.

26 . The ceramic article according to claim 21 ,
wherein the X-phase is a phase containing aluminum oxide or silicon oxide as a main component, wherein the Y-phase is a phase containing an oxide of a rare earth element as a main component, and wherein the Z-phase is a phase containing zirconium oxide as a main component.

27 . The ceramic article according to claim 26 , wherein the Z-phase contains a rare earth element in a ratio of 0.20 mol or more and 0.40 mol or less with respect to 1 mol of another metal element contained in the Z-phase.

28 . The ceramic article according to claim 26 , wherein the ceramic article contains a zirconium element in an amount of 0.2 mol % or more and less than 3 mol % in metal elements forming the ceramic article.

Assignees

• Canon Kk

Inventors

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

Classifications

• Y02P10/25

  Process efficiency · CPC title

• 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