Modified freeform fabricated part and a method for modifying the properties of a freeform fabricated part

Abstract

The present invention is a process for modifying the properties of a porous freeform fabricated part by increasing its density and reducing its porosity. The porosity and density of a freeform fabricated part are altered by packing the pores in a freeform part with an infiltrant, such as a preceramic polymer. The process includes drawing a vacuum on or pressurizing the freeform part while it is in an infiltrant bath, thereby forcing the infiltrant into the pores of the freeform part. After removing the densified freeform part from the infiltrant bath, the freeform part is subjected to a treating process, such that the infiltrant within the pores transforms to a ceramic or ceramic-containing phase to thereby increasing the density of the freeform part.

What is claimed is:  
     
         1 . A process for modifying one or more properties of a porous freeform fabricated part, comprising the steps of: 
 (a) depositing a porous freeform fabricated part in a bath comprising an infiltrant;    (b) infiltrating the porous freeform fabricated part such that the infiltrant enters at least a portion of the pores resulting in a densified freeform-fabricated part; and    (c) removing the densified freeform fabricated part from the bath.    
     
     
         2 . The process of    claim 1    wherein the step of infiltrating the porous freeform fabricated part comprises drawing a vacuum on the porous freeform fabricated part and the infiltrant such that the infiltrant enters at least a portion of the pores, resulting in a densified freeform fabricated part.  
     
     
         3 . The process of    claim 2    where the vacuum is drawn on the porous freeform fabricated part for from about five minutes to about sixty minutes.  
     
     
         4 . The process of    claim 2    wherein the pressure of the vacuum drawn on the porous freeform part is from about 100 torr to about 5×10 −3  torr.  
     
     
         5 . The process of    claim 2    further comprising the step of pressurizing the infiltrant.  
     
     
         6 . The process of    claim 5    further comprising the step of heating the infiltrant while pressurizing the infiltrant.  
     
     
         7 . The process of    claim 1    wherein the step of infiltrating the porous freeform fabricated part comprises pressurizing the infiltrant such that the infiltrant enters at least a portion of the pores, resulting in a densified freeform fabricated part.  
     
     
         8 . The process of    claim 7    further comprising the step of heating the infiltrant while pressurizing the infiltrant.  
     
     
         9 . The process of    claim 8    wherein the bath is pressurized for from about five minutes to about sixty minutes.  
     
     
         10 . The process of    claim 9    wherein the step of pressurizing the bath occurs at a pressure of about 100 torr to about 5×10 −3  torr.  
     
     
         11 . The process of    claim 1    further comprising the steps of removing the densified freeform fabricated part from the bath and treating the densified freeform fabricated part such that the infiltrant within the pores of the densified freeform fabricated part transform to a ceramic or a ceramic-containing phase.  
     
     
         12 . The process of    claim 11    wherein the treating step comprises curing the infiltrant within the densified freeform part.  
     
     
         13 . The process of    claim 12    wherein curing the infiltrant occurs by either chemical curing or radiation curing.  
     
     
         14 . The process of    claim 13    wherein radiation curing occurs through thermal curing.  
     
     
         15 . The process of    claim 14    wherein thermal curing occurs by subjecting the infiltrant within the densified freeform part to a temperature ranging from about 80° C. to about 250° C.  
     
     
         16 . The process of    claim 12    wherein the treating step further comprises heating the infiltrant within the densified freeform fabricated part such that the infiltrant transforms to a ceramic or ceramic containing phase.  
     
     
         17 . The process of    claim 16    wherein the infiltrant is heated at a rate of about two degrees Celsius per minute to about ten degrees Celsius per minute.  
     
     
         18 . The process of    claim 16    wherein the infiltrant is heated to a temperature ranging from about one hundred degrees Celsius to about one thousand two hundred degrees Celsius.  
     
     
         19 . The process of    claim 16    wherein the infiltrant is heated in an atmosphere containing a gas selected from the group consisting essentially of air, argon and nitrogen.  
     
     
         20 . The process of    claim 16    wherein the treating step further comprises annealing the ceramic or ceramic containing phase.  
     
     
         21 . The process of    claim 20    wherein the step of annealing the infiltrant in the freeform fabricated part includes heating the freeform fabricated part and the infiltrant at a temperature of about 1000 degrees Celsius to about 1800 degrees Celsius for about one hour to about eight hours.  
     
     
         22 . The process of    claim 20    wherein the treating step further comprises cooling the densified freeform fabricated part.  
     
     
         23 . The process of    claim 22    wherein the step of cooling the infiltrant and densified freeform fabricated part comprises cooling the infiltrant and freeform fabricated part at a rate of about two degrees Celsius per minute to about ten degrees Celsius per minute.  
     
     
         24 . The process of    claim 1    wherein the porous freeform fabricated part is fabricated by a method from the group consisting essentially of three-dimensional printing, stereolithography, selective laser sintering, fused deposition modeling, ballistic particle manufacturing, and photochemical machining.  
     
     
         25 . The process of    claim 1    wherein the porous freeform fabricated part is made of metal, ceramic or a mixture thereof.  
     
     
         26 . The process of    claim 1    wherein the porous freeform fabricated part is fabricated by a three dimensional printing process that bonds together the particles of silicon carbide powder using polymer emulsion as a binder.  
     
     
         27 . The process of    claim 1    wherein the porous freeform fabricated part is fabricated by a three dimensional printing process that bonds together the particles of aluminum oxide powder using a binder from the group consisting essentially of colloidal silica and polymer emulsion.  
     
     
         28 . The process of    claim 1    wherein the infiltrant is in the form of a solution selected from the group consisting essentially of a liquid, a liquid containing solid particles and an organic solvent based solution.  
     
     
         29 . The process of    claim 1    wherein the infiltrant comprises a precursor selected from the group consisting of alumina sol-gel, polysilane, polysilazane, silicon oxycarbide (SiOC), poly(methylvinylsilane), poly(aluminosilazane), perhydridopolysilazane, poly(borosilazane), polycarbosilazane, poly(siloxane), poly(carbosilane) and mixtures thereof.  
     
     
         30 . The process of    claim 29    wherein the infiltrant further comprises a powder selected from the group consisting essentially of metal, ceramic or ceramic metal.  
     
     
         31 . A process for modifying one or more properties of a porous freeform fabricated part, comprising the steps of: 
 (a) placing a porous freeform-fabricated part in a vacuum dessicator;    (b) drawing a vacuum on the porous freeform fabricated part; and    (c) introducing an infiltrant into the vacuum dessicator such that the infiltrant enters the pores within the porous freeform part.    
     
     
         32 . The process of    claim 31    further comprising the step of treating the densified freeform part such that the infiltrant within the densified freeform part transforms to a ceramic or ceramic-containing phase.  
     
     
         33 . A densified freeform-fabricated part produced by the process of: 
 (a) depositing a porous freeform fabricated part into a bath comprising an infiltrant;    (b) infiltrating the porous freeform fabricated part such that the infiltrant enters at least a portion of the pores resulting in a densified freeform fabricated part; and    (c) removing the densified freeform fabricated part from the bath.    
     
     
         34 . The densified freeform-fabricated part of    claim 33    further comprising the step of treating the densified freeform fabricated part such that the infiltrant within the densified freeform part transforms to a ceramic or a ceramic-containing phase.  
     
     
         35 . A densified freeform fabricated part, comprising: 
 (a) a freeform fabricated part having pores therein; and    (b) a ceramic or a ceramic containing-phase within a portion of said pores.    
     
     
         36 . The freeform-fabricated part of    claim 35    wherein the freeform fabricated part is either a metal, ceramic or a mixture thereof.  
     
     
         37 . The freeform fabricated part of    claim 35    wherein the ceramic or ceramic containing phase originated from a precursor selected from the group consisting essentially of alumina sol-gel, polysilane, polysilazane, silicon oxycarbide (SiOC), poly(methylvinylsilane), poly(aluminosilazane), perhydridopolysilazane, poly(borosilazane), polycarbosilazane, poly(siloxane), poly(carbosilane) and mixtures thereof.