公开(公告)号：US10857735B1

公开(公告)日：2020-12-08

申请号：US15958676

申请日：2018-04-20

Applicant: HRL LABORATORIES, LLC

Inventor： John H. Martin ,  Brennan D. Yahata ,  Eric Clough

IPC: B29C64/386 ,  G01N29/12 ,  G01N29/46 ,  B33Y10/00 ,  B33Y30/00 ,  B29C64/153 ,  B29C64/194 ,  B29C64/20 ,  B29C64/188 ,  B29C64/393 ,  B33Y50/02

Abstract: A method of additive manufacturing a part on a build plate includes additive manufacturing at least a first layer of the part on the build plate, supplying a series of frequencies to the build plate from a resonate probe connected to the build plate, processing a received response from an ultrasonic detector connected to the build plate, determining a series of resonant frequencies of the build plate and a corresponding series of peak intensities from the received response, comparing the resonant frequencies and the corresponding peak intensities to a set of reference resonant frequencies and a corresponding set of reference peak intensities, respectively, calculating an intensity difference between a peak intensity and a reference peak intensity or a frequency difference between a resonant frequency and a reference resonant frequency, and additive manufacturing a subsequent layer of the part if the intensity difference and the frequency difference are below a threshold.

公开(公告)号：US12027293B2

公开(公告)日：2024-07-02

申请号：US18209532

申请日：2023-06-14

Applicant: HRL Laboratories, LLC

Inventor： Brennan Yahata ,  Eric Clough ,  Christopher Henry ,  Amber Sucich ,  Darby Laplant ,  Tobias Schaedler

IPC: H01F1/055 ,  B33Y80/00 ,  C22C38/00 ,  C22C38/06 ,  C22C38/08 ,  C22C38/10 ,  C22C38/30 ,  H01F1/057 ,  H01F7/02 ,  H01F13/00 ,  H01F41/02

CPC classification number: H01F1/055 ,  B33Y80/00 ,  C22C38/005 ,  C22C38/06 ,  C22C38/08 ,  C22C38/105 ,  C22C38/30 ,  H01F1/0577 ,  H01F7/021 ,  H01F7/0278 ,  H01F13/003 ,  H01F41/0266 ,  H01F41/0273 ,  C22C2202/02

Abstract: This invention provides methods for fabricating a hard or soft magnet with tailorable magnetic and crystallographic orientations. Methods are disclosed to individually tailor three-dimensional voxels for selected crystallographic orientations and, independently, selected magnetic orientations with location specificity throughout a magnet. Some variations provide a method of making a magnet, comprising: providing a feedstock composition containing magnetic or magnetically susceptible materials; exposing the feedstock composition to an energy source for melting, thereby generating a first melt layer; solidifying the first melt layer in the presence of an externally applied magnetic field, thereby generating a magnetic metal layer containing a plurality of individual voxels; optionally repeating to generate a plurality of solid layers; and recovering a magnet comprising the magnetic metal layer(s), wherein the externally applied magnetic field has a magnetic-field orientation that is selected to control a magnetic axis and a crystallographic texture within the magnetic metal layer(s).

公开(公告)号：US11862369B2

公开(公告)日：2024-01-02

申请号：US17359556

申请日：2021-06-26

Applicant: HRL Laboratories, LLC

Inventor： Brennan Yahata ,  Eric Clough ,  Christopher Henry ,  Amber Sucich ,  Darby Laplant ,  Tobias Schaedler

IPC: H01F1/055 ,  C22C38/00 ,  C22C38/30 ,  C22C38/08 ,  C22C38/10 ,  C22C38/06 ,  B33Y80/00 ,  H01F7/02 ,  H01F1/057 ,  H01F13/00 ,  H01F41/02

CPC classification number: H01F1/055 ,  B33Y80/00 ,  C22C38/005 ,  C22C38/06 ,  C22C38/08 ,  C22C38/105 ,  C22C38/30 ,  H01F1/0577 ,  H01F7/021 ,  H01F7/0278 ,  H01F13/003 ,  H01F41/0266 ,  H01F41/0273 ,  C22C2202/02

Abstract: Some variations provide a permanent-magnet structure comprising: a region having a plurality of magnetic domains and a region-average magnetic axis, wherein each of the magnetic domains has a domain magnetic axis that is substantially aligned with the region-average magnetic axis, and wherein the plurality of magnetic domains is characterized by an average magnetic domain size. Within the region, there is a plurality of metal-containing grains characterized by an average grain size, and each of the magnetic domains has a domain easy axis that is dictated by a crystallographic texture of the metal-containing grains. The region has a region-average easy axis based on the average value of the domain easy axis within that region. The region-average magnetic axis and the region-average easy axis form a region-average alignment angle that has a standard deviation less than 30° within the plurality of magnetic domains. Many permanent-magnet structures are disclosed herein.

公开(公告)号：US12023759B2

公开(公告)日：2024-07-02

申请号：US18102905

申请日：2023-01-30

Applicant: HRL Laboratories, LLC

Inventor： Amber Sucich ,  Eric Clough ,  Brennan Yahata ,  Darby Laplant

IPC: B23K26/342 ,  B22F10/28 ,  B33Y10/00 ,  H01F1/147

CPC classification number: B23K26/342 ,  B22F10/28 ,  B33Y10/00 ,  H01F1/147 ,  B22F2998/10

Abstract: Some variations provide a method of tailoring the surface of a soft magnet, comprising: depositing an austenite-phase-stabilizing donor material on one or more first surface regions of a ferromagnetic receiver material; not depositing the austenite-phase-stabilizing donor material on one or more second surface regions of the ferromagnetic receiver material; laser melting the austenite-phase-stabilizing donor material into the first surface regions; and solidifying the molten austenite-phase-stabilizing donor material within the first surface regions, thereby selectively alloying the ferromagnetic receiver material in the first surface regions. Laser ablation may be utilized instead of laser melting. The first surface regions have a significantly higher magnetic permeability, following the selective alloying of the donor material, compared to the second surface regions. Soft magnets with surface-tailored magnetic permeability are provided by this technology, which is demonstrated using several examples. One commercial application is selectively alloyed soft magnets for a rotor in an electric motor.

公开(公告)号：US11862653B2

公开(公告)日：2024-01-02

申请号：US17111108

申请日：2020-12-03

Applicant: HRL LABORATORIES, LLC

Inventor： Mark O'Masta ,  Jacob Hundley ,  Eric Clough ,  Christopher Roper ,  Geoffrey McKnight

IPC: H01L27/146

CPC classification number: H01L27/14632 ,  H01L27/1462 ,  H01L27/14687

Abstract: An imaging sensor package includes: an imaging sensor; and an architected substrate coupled to a bottom surface of the imaging sensor. The architected substrate has local stiffness variations along an in-plane direction of the architected substrate, and the imaging sensor and the architected substrate are curved.

公开(公告)号：US11721458B2

公开(公告)日：2023-08-08

申请号：US17359557

申请日：2021-06-26

Applicant: HRL Laboratories, LLC

Inventor： Brennan Yahata ,  Eric Clough ,  Christopher Henry ,  Amber Sucich ,  Darby Laplant ,  Tobias Schaedler

IPC: H01F41/02 ,  H01F13/00 ,  H01F7/02 ,  H01F1/057 ,  H01F1/055 ,  C22C38/00 ,  C22C38/30 ,  C22C38/08 ,  C22C38/10 ,  C22C38/06 ,  B33Y80/00

CPC classification number: H01F1/055 ,  B33Y80/00 ,  C22C38/005 ,  C22C38/06 ,  C22C38/08 ,  C22C38/105 ,  C22C38/30 ,  H01F1/0577 ,  H01F7/021 ,  H01F7/0278 ,  H01F13/003 ,  H01F41/0266 ,  H01F41/0273 ,  C22C2202/02

Abstract: This invention provides methods for fabricating a hard or soft magnet with tailorable magnetic and crystallographic orientations. Methods are disclosed to individually tailor three-dimensional voxels for selected crystallographic orientations and, independently, selected magnetic orientations with location specificity throughout a magnet. Some variations provide a method of making a magnet, comprising: providing a feedstock composition containing magnetic or magnetically susceptible materials; exposing the feedstock composition to an energy source for melting, thereby generating a first melt layer; solidifying the first melt layer in the presence of an externally applied magnetic field, thereby generating a magnetic metal layer containing a plurality of individual voxels; optionally repeating to generate a plurality of solid layers; and recovering a magnet comprising the magnetic metal layer(s), wherein the externally applied magnetic field has a magnetic-field orientation that is selected to control a magnetic axis and a crystallographic texture within the magnetic metal layer(s).

公开(公告)号：US20210313374A1

公开(公告)日：2021-10-07

申请号：US17111108

申请日：2020-12-03

Applicant: HRL LABORATORIES, LLC

Inventor： Mark O'Masta ,  Jacob Hundley ,  Eric Clough ,  Christopher Roper ,  Geoffrey McKnight

IPC: H01L27/146

Abstract: An imaging sensor package includes: an imaging sensor; and an architected substrate coupled to a bottom surface of the imaging sensor. The architected substrate has local stiffness variations along an in-plane direction of the architected substrate, and the imaging sensor and the architected substrate are curved.