Slurry Mixtures for 3-D Slurry Extrusion of Artifacts
A slurry composition for forming an article using additive manufacturing is provided. The slurry composition comprises a carrier having a viscosity of at least 0.001 cP at normal temperature and pressure. The carrier is adapted to be flowable through a nozzle. The slurry composition further comprises a material selected from the group of a metal-containing material, a ceramic-containing material, an inorganic carbon-containing material, a silica-containing material, and combinations thereof.
1 . A slurry composition for forming an article using additive manufacturing, the slurry composition comprising:
a carrier having a viscosity of at least 0.001 cP at normal temperature and pressure, wherein the carrier is adapted to be flowable through a nozzle; and
a material selected from the group of a metal-containing material, a ceramic-containing material, an inorganic carbon-containing material, a silica-containing material, and combinations thereof.
2 . The slurry composition of claim 1 , wherein the carrier comprises a binder, a thickener, or a combination thereof.
3 . The slurry composition of claim 2 , wherein thickener is selected from the group of a gel-based thickener, a wax-based thickener, a silicone-based thickener, and combinations thereof.
4 . The slurry composition of claim 3 , wherein the carrier comprises the gel-based thickener, and the gel-based thickener comprises a gum.
5 . The slurry composition of claim 3 , wherein the carrier comprises the gel-based thickener, and the gel-based thickener comprises a sol-gel of a hydroxyethyl cellulose.
6 . The slurry composition of claim 3 , wherein the carrier comprises the wax-based thickener, and the wax-based thickener comprises a polyethylene glycol.
7 . The slurry composition of claim 3 , wherein the carrier comprises the silicone-based thickener, and the silicone-based thickener comprises a siloxane.
8 . The slurry composition of claim 2 , wherein the carrier is selected from the group of a gel-based binder, an acetate-based binder, a silicate-based binder, a carbonate-based binder, a hydroxy-functional binder, a photo-curable binder, and combinations thereof.
9 . The slurry composition of claim 8 , wherein the carrier comprises the acetate-based binder, and the acetate-based binder comprises sodium acetate.
10 . The slurry composition of claim 8 , wherein the carrier comprises the silicate-based binder, and the silicate-based binder comprises sodium silicate.
11 . The slurry composition of claim 8 , wherein the carrier comprises the carbonate-based binder, and the carbonate-based binder comprises polypropylene carbonate.
12 . The slurry composition of claim 8 , wherein the carrier comprises the hydroxy-functional binder, and the hydroxy-functional binder is selected from the group of a phenolic binder, a furfurol alcohol, a polyethylene glycol, and combinations thereof.
13 . The slurry composition of claim 8 , wherein the carrier comprises the photo-curable binder, and the photo-curable binder comprises a photo-curable acrylic.
14 . The slurry composition of claim 1 , wherein the material is present in the form of a powder, a fiber, a microbead, or combinations thereof.
15 . The slurry composition of claim 1 further comprising a sintering aid.
16 . The slurry composition of claim 15 , wherein the sintering aid is selected from the group of graphene, a nickel-containing sintering aid, a ceramic-containing sintering aid, and combinations thereof.
17 . A method of forming an article using additive manufacturing, the method comprising:
providing the slurry composition of claim 1 ; and
applying the slurry composition to a substrate to form the article.
18 . The method of claim 17 further comprising densifying the article to form a processed article.
19 . The method of claim 18 , wherein densifying the article comprises:
(A) combining the article and a polymeric composition to form the processed article;
(B) exposing the article to heat at a temperature of from about 600° C. to about 2500° C. to form the processed article;
(C) exposing the article to heat at a temperature of from about 800° C. to about 2000° C. and then combining the article and a molten metal to form the processed article;
(D) exposing the article to a vacuum and heat at a temperature of from about 400° C. to about 2000° C. in the presence of a precursor to form a deposit on the article thereby forming the processed article;
(E) combining the article and a carbon precursor and then exposing the article to heat at a temperature of from about 600° C. to about 1400° C. to form the processed article;
(F) exposing the article to irradiation to form the processed article; or (G) any combination of (A) to (F).