# US 11,299,816 B2 · Methods of three-dimensional electrophoretic deposition for ceramic and cermet applications and systems thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,299,816 B2 - Document ID: US11299816B2 - Status: Granted - Kind: B2 - Application number: 16/683,101 - Filed: 2019-11-13 - Published: 2020-03-12 - Granted: 2022-04-12 - Earliest claimed: 2010-04-13 - Assignees: Lawrence Livermore National Security, LLC - Applicants: Lawrence Livermore National Security, LLC - Inventors: Klint A. Rose; Joshua D. Kuntz; Marcus A. Worsley - Web page: https://patentgrep.com/patent/US11299816B2 ## CPC - C25D 13/02: with inorganic material - B32B 15/00: Layered products comprising {a layer of} metal - B33Y 10/00: Processes of additive manufacturing - C04B 37/001: {directly with other burned ceramic articles} - C04B 37/025: {consisting of glass or ceramic material} - C25D 13/12: characterised by the article coated - C25D 13/20: Pretreatment - C25D 13/22: Servicing or operating {apparatus or multistep processes} - C04B 2235/5296: with a defined aspect ratio, e.g. indicating sphericity - C04B 2235/775: Products showing a density-gradient - C04B 2235/787: Oriented grains - C04B 2235/9653: Translucent or transparent ceramics other than alumina - C04B 2237/083: Carbide interlayers, e.g. silicon carbide interlayers - C04B 2237/32: Ceramic - C04B 2237/402: Aluminium - Y10T 428/12458: having composition, density, or hardness gradient - Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] - Y10T 428/24992: Density or compression of components - Y10T 428/252: Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.] - C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract 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. ## Claims ### Claim 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. ### Claim 2 (depends on 1) 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. ### Claim 3 (depends on 1) 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. ### Claim 4 (depends on 1) 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. ### Claim 5 (depends on 1) 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. ### Claim 6 (depends on 5) 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: AlMgB14, titanium boride, silicon carbide, and boron carbide. ### Claim 7 (depends on 5) 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. ### Claim 8 (depends on 1) 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. ### Claim 9 (depends on 1) The ceramic, cermet, and/or metal composition as recited in claim 1, wherein the ceramic, cermet, and/or metal composition is optically transparent. ### Claim 10 (depends on 1) 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. ### Claim 11 (depends on 1) 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. ### Claim 12 (depends on 1) 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. ### Claim 13 (depends on 1) The ceramic, cermet, and/or metal composition as recited in claim 1, wherein the first composition and the second composition are different. ### Claim 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. ### Claim 15 (depends on 1) The ceramic, cermet, and/or metal composition as recited in claim 1, wherein the first density and the second density are different. ### Claim 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. ### Claim 17 (depends on 1) 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. ### Claim 18 (depends on 1) 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. ### Claim 19 (depends on 1) 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. ### Claim 20 (depends on 1) 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.