公开(公告)号：US11427902B2

公开(公告)日：2022-08-30

申请号：US16575842

申请日：2019-09-19

Applicant: CORNERSTONE INTELLECTUAL PROPERTY, LLC

Inventor： John Kang ,  Ricardo Salas ,  Evelina Vogli

IPC: C22C45/02 ,  B33Y10/00 ,  B33Y70/00 ,  B22F1/05 ,  B22F1/10 ,  C21D6/00 ,  B23K26/342 ,  C22C33/00 ,  B33Y40/10 ,  B23K20/10 ,  B23K103/02

Abstract: Embodiments disclosed herein relate to production of amorphous alloys having compositions of iron, chromium, molybdenum, carbon and boron for usage in additive manufacturing, such as in layer-by-layer deposition to produce multi-functional parts. Such parts demonstrate ultra-high strength without sacrificing toughness and also maintain the amorphous structure of the materials during and after manufacturing processes. An Amorphous alloy composition has a formula Fe100-(a+b+c+d)CraMobCcBd, wherein a, b, c and d represent an atomic percentage, wherein: a is in the range of 10 at. % to 35 at. %; b is in the range of 10 at. % to 20 at. %; c is in the range of 2 at. % to 5 at. %; and d is in the range of 0.5% at. % to 3.5 at. %.

公开(公告)号：US20210198777A1

公开(公告)日：2021-07-01

申请号：US16731609

申请日：2019-12-31

Applicant: CORNERSTONE INTELLECTUAL PROPERTY, LLC

Inventor： JOHN KANG ,  Evelina Vogli ,  Ricardo Salas

IPC: C22C45/04 ,  C23C4/12 ,  C23C4/08 ,  C23C4/18 ,  C04B35/58 ,  C04B35/56 ,  C04B35/622 ,  C04B35/65

Abstract: An embodiment relates to a material comprising a ceramic formed from an amorphous metal alloy (amorphous metal ceramic composite), wherein the composite exhibits a higher corrosion resistance than that of Haynes 230 when exposed to molten chlorides such as KCl or MgCl2 or combinations thereof at temperatures up to 750° C. Yet, another embodiment relates to a method comprising obtaining a substrate, forming a coating of an amorphous metal alloy, heating the coating, and transforming at least a portion the amorphous metal alloy into an amorphous metalceramic composite.

公开(公告)号：US20210096003A1

公开(公告)日：2021-04-01

申请号：US16584085

申请日：2019-09-26

Applicant: CORNERSTONE INTELLECTUAL PROPERTY

Inventor： John Kang ,  Evelina Vogli ,  Ted Ward

IPC: G01D11/24 ,  C23C4/06 ,  C23C4/11 ,  C22C45/10

Abstract: Embodiments disclosed herein relate to the production of a housing enclosure designed for sensors or RFIDS to be attached to thin-walled components in the oil and gas industries being sent downhole during drilling and extraction. A metal-based coating, which may be crystalline, amorphous, or partially amorphous in structure, is deposited onto a substrate in layers via thermal spraying. The coating may then be machined so that an opening is created to receive the sensor or RFID. The coating may also provide other functions such as wear, corrosion or erosion protection to the thin-walled components applied.

公开(公告)号：US20220372604A1

公开(公告)日：2022-11-24

申请号：US17882525

申请日：2022-08-05

Applicant: CORNERSTONE INTELLECTUAL PROPERTY LLC

Inventor： John KANG ,  Ricardo Salas ,  Evelina Vogli

IPC: C22C45/02 ,  B22F1/05 ,  B33Y70/00

Abstract: Embodiments disclosed herein relate to the production of amorphous metals having compositions of iron, chromium, molybdenum, carbon and boron for usage in additive manufacturing, such as in layer-by-layer deposition to produce multi-functional parts. Such parts demonstrate ultra-high strength without sacrificing toughness and also maintain the amorphous structure of the materials during and after manufacturing processes. Two additive manufacturing techniques are provided: (1) the complete melting of amorphous powder and re-solidifying to amorphous structure to eliminate the formation of crystalline structure therein by controlling a heating source power and cooling rate without affecting previous deposited layers; and (2) partial melting of the outer surface of the amorphous powder, and solidifying powder particles with each-other without undergoing a complete melting stage. Amorphous alloy compositions have oxygen impurities in low concentration levels to optimize glass forming ability (GFA). Specific techniques of additive manufacturing include those based on lasers, electron beams and ultrasonic sources.

公开(公告)号：US11814711B2

公开(公告)日：2023-11-14

申请号：US16731609

申请日：2019-12-31

Applicant: CORNERSTONE INTELLECTUAL PROPERTY, LLC

Inventor： John Kang ,  Evelina Vogli ,  Ricardo Salas

IPC: C22C45/04 ,  C23C4/12 ,  C23C4/08 ,  C23C4/18 ,  C04B35/58 ,  C04B35/56 ,  C04B35/65 ,  C04B35/622 ,  C22C32/00 ,  C23C4/129

CPC classification number: C22C45/04 ,  C04B35/56 ,  C04B35/5805 ,  C04B35/62222 ,  C04B35/65 ,  C22C32/0047 ,  C23C4/08 ,  C23C4/12 ,  C23C4/18 ,  C04B2235/3804 ,  C04B2235/3817 ,  C04B2235/405 ,  C04B2235/9669 ,  C23C4/129

Abstract: An embodiment relates to a material comprising a ceramic formed from an amorphous metal alloy (amorphous metal ceramic composite), wherein the composite exhibits a higher corrosion resistance than that of Haynes 230 when exposed to molten chlorides such as KCl or MgCl2 or combinations thereof at temperatures up to 750° C. Yet, another embodiment relates to a method comprising obtaining a substrate, forming a coating of an amorphous metal alloy, heating the coating, and transforming at least a portion the amorphous metal alloy into an amorphous metalceramic composite.

公开(公告)号：US11781205B2

公开(公告)日：2023-10-10

申请号：US16731292

申请日：2019-12-31

Applicant: Cornerstone Intellectual Property, LLC

Inventor： John Kang ,  Evelina Vogli

IPC: C22C45/02 ,  B22F3/00 ,  B22F5/12 ,  B22F3/105 ,  C23C28/02 ,  B22F1/08

CPC classification number: C22C45/02 ,  B22F1/08 ,  B22F3/006 ,  B22F3/105 ,  B22F5/12 ,  C23C28/026 ,  B22F2003/1051 ,  B22F2301/058 ,  B22F2301/35 ,  B22F2303/30

Abstract: Embodiments disclosed herein relate to the production of bulk amorphous metal (BAM) alloys comprising chromium, manganese, molybdenum, tungsten, silicon, carbon, boron, and the balance of iron to replace tungsten carbide-based welded material. The BAM alloy embodied herein can be applied through PTA welding, HVOF, TWAS, flame spraying, plasma spraying, laser, their combinations, and other coating and welding processes. When used as welded material, the density of the embodiment of around 7 grams per CC, which is less dense than the tungsten carbide customarily used, resulting in even hard faces during welding spread uniformly across the weld, therefore creating a harder and more wear-resistant weld.

公开(公告)号：US11078560B2

公开(公告)日：2021-08-03

申请号：US16599138

申请日：2019-10-11

Applicant: CORNERSTONE INTELLECTUAL PROPERTY, LLC

Inventor： John Kang ,  Evelina Vogli ,  Ricardo Salas

IPC: C22C45/02 ,  C22C45/04 ,  C23C4/08 ,  C22C45/00 ,  E21B17/10 ,  E21B7/04

Abstract: An embodiment relates to a composition comprising an amorphous alloy having a low coefficient of friction (COF) of 0.15 or less, wherein the amorphous alloy is substantially free of phosphor (P) and substantially free of boron (B). An embodiment relates to a method comprising solidifying a molten layer of an amorphous feedstock on a preexisting layer by controlling a heating source and a cooling rate so as to avoid formation of crystals in the molten layer and not affect a crystalline structure of the preexisting layer, and forming a specimen; wherein, the at least a portion specimen has the low COF. Another embodiment relates to a system comprising a drill string, wherein the drill string comprises a drilling bit and a drill pipe connected thereto, wherein at least a portion of the drill pipe comprises a coating having the low COF.