Slurry Mixtures for 3-D Slurry Extrusion of Artifacts

Abstract

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.

What is claimed is: 
     
         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).