Hybrid slip casting-electrophoretic deposition (epd) process

2:

• A product of manufacture for hybrid slip casting-Electrophoretic Deposition (EPD) comprising a system as set forth in FIG. 1.

4:

• The process of claim 3, wherein the powder comprises Al2O3, SiC, ZrO2, zeolite 3A, zeolite 5A, TiO2, Ni, Cu, equivalents thereof or any combination thereof;
• or, the particle charging agent comprises n-butylamine as the particle-charging additive.

5:

• The process of claim 3, wherein the mold comprises an aligned porous structure, and optionally the aligned porous structure is made by a unidirectional freezing followed by freeze-drying and sintering;
• after the aligned porous structures were sintered they are impregnated by brushing gold;
• and optionally after annealing at 600° C., gold wires having diameters ranging from several hundreds of nanometers to several micrometers were applied.

7:

• The process of claim 6, wherein the powder comprises Al2O3, SiC, ZrO2, zeolite 3A, zeolite 5A, TiO2, Ni, Cu, equivalents thereof or any combination thereof.

8:

• The process of claim 6, wherein the particle charging agent comprises n-butylamine as the particle-charging additive.

9:

• The method of claim 6, wherein said gypsum mold is a water permeable mold, optionally made from plaster of Paris, and optionally part of the said gypsum mold is covered with organic glue while the area to be deposited is exposed.

10:

• The method of claim 6, wherein said suspensions comprise, or consist of:
• water, which optionally comprises distilled water, the said powders to be deposited, and a deflocculant, and optionally the powder concentration is from about 5% to 50% v/v, or from about 1% to 90%, or from about 10% to 40%, and optionally the suspension is processed for between about 1 to 60 minutes, or for about 10, 20, 30, 40, 50 or 60 or more minutes, wherein optionally the suspension is processed using a planetary ball mill.

11:

• The method of claim 6, wherein the said powders comprise metallic, ceramic or polymeric powders, and optionally the powders comprise a particle size ranging from about 40 nm to about 50 microns, or from about 30 nm to about 60 microns, or from about 10 nm to about 100 microns, and optionally the powder comprises any permutation of metallic, ceramic, polymeric, metal/ceramic composite, metal/polymer composite, polymer/ceramic composite, metal/ceramic/polymer composite.

12:

• The method of claim 6, wherein said silicone mold is capable of holding the said gypsum mold, and optionally the said gypsum mold separates the said silicone mold into the said chamber A and chamber B, and optionally the silicone mold has elasticity which can ensure that there is no mixing of liquid in chamber A and chamber B.

13:

• The method of claim 6, wherein said the electrodes are made of stainless steel.

14:

• The method of claim 6, wherein said ionic solution comprises a water, wherein optionally the water is DI water, and tetramethylammonium hydroxide (TMAH).

15:

• The method of claim 6, wherein the pH of the ionic solution rages from between about pH 9 to about pH 13, or about pH 8, pH 9, pH 10, pH 11, pH 12 or pH 13.

16:

• The method of claim 6, wherein said the electric filed comprises a DC voltage, and optionally the voltage ranges from between about 5 V to about 400 V, or about 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350 or 400 V.

17:

• The method of claim 6, wherein the mixing and deposition steps (processes) are simultaneous.

18:

• The method of claim 6, wherein the sintering is done with a minimum of warping, which can be achieved by the process comprising:
• using particle sizes to control the sintering rate, creating a variable temperature gradient (which optionally can be with laserbeam surface heating), microwave sintering, electric discharge through a stepped and/or use of a tapered die.

19:

• A Functionally Graded Material (FGM) made the process of claim 1, or claim 3.

20:

• A product of manufacture comprising the Functionally Graded Material (FGM) of claim 19.