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