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1.发明授权公开(公告)号：US12012646B1
公开(公告)日：2024-06-18
申请号：US16209036
申请日：2018-12-04
IPC分类号： C22C19/05 , B22F1/054 , B23K26/342 , B33Y70/00 , B33Y80/00
CPC分类号： C22C19/057 , B22F1/054 , B23K26/342 , B33Y70/00 , B33Y80/00 , B22F2301/15
摘要： Some variations provide an additively manufactured metal-containing component comprising (i) nickel, (ii) aluminum and/or titanium, and (iii) nanoparticles, wherein the sum of aluminum weight percentage and one-half of titanium weight percentage is at least 3 on a nanoparticle-free basis, and wherein the additively manufactured metal-containing component has a microstructure that is substantially crack-free with equiaxed grains. A feedstock composition is also provided, comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, wherein the microparticles comprise (i) nickel and (ii) aluminum and/or titanium, and wherein the sum of aluminum weight percentage and one-half of titanium weight percentage is at least 3 on a nanoparticle-free basis. The nanoparticles may be selected from metals; ceramics; cermets; intermetallic alloys; oxides, carbides, nitrides, borides, or hydrides thereof; polymers; and/or carbon. Successful nanofunctionalization of MAR-M-247 nickel superalloy is demonstrated, creating a crack-free additively manufactured microstructure.
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公开(公告)号：US10927434B2
公开(公告)日：2021-02-23
申请号：US15808878
申请日：2017-11-09
发明人： Brennan D. Yahata , John H. Martin
摘要： Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.
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公开(公告)号：US11779894B2
公开(公告)日：2023-10-10
申请号：US15996439
申请日：2018-06-02
发明人： John H. Martin , Brennan D. Yahata , Robert Mone
IPC分类号： B22F1/054 , B01J3/02 , B22F9/04 , B01J3/04 , B22F9/02 , B22F1/052 , B01F33/40 , B01F35/60 , B01F35/71 , B01F35/221 , B01F35/75 , B82Y30/00 , B82Y40/00 , B22F1/17 , B22F1/102 , B22F1/18
CPC分类号： B01J3/02 , B01F33/401 , B01F35/2213 , B01F35/2215 , B01F35/22161 , B01F35/602 , B01F35/711 , B01F35/7543 , B01J3/04 , B22F1/052 , B22F1/054 , B22F1/056 , B22F9/02 , B22F9/04 , B22F1/102 , B22F1/17 , B22F1/18 , B22F2201/04 , B22F2201/30 , B22F2202/01 , B22F2202/03 , B22F2202/15 , B22F2301/052 , B22F2301/058 , B22F2301/10 , B22F2301/15 , B22F2301/205 , B22F2301/255 , B22F2301/30 , B22F2301/35 , B22F2301/40 , B22F2302/05 , B22F2302/10 , B22F2302/20 , B22F2302/256 , B22F2303/20 , B22F2998/10 , B22F2999/00 , B82Y30/00 , B82Y40/00 , B22F1/102 , B22F2999/00 , B22F1/102 , B22F2202/15 , B22F9/02 , B22F2999/00 , B22F1/17 , B22F1/18 , B22F2202/15 , B22F9/02 , B22F2999/00 , B22F9/02 , B22F2202/15 , B22F1/17 , B22F1/18 , B22F2999/00 , B22F1/17 , B22F1/18 , B22F1/054 , B22F1/056 , B22F2998/10 , B22F1/05 , B22F2202/15 , B22F1/102 , B22F2998/10 , B22F1/17 , B22F1/18 , B22F2202/15 , B22F1/05 , B22F2998/10 , B22F1/05 , B22F2202/15 , B22F1/17 , B22F1/18
摘要： Some variations provide a system for producing a functionalized powder, comprising: an agitated pressure vessel; first particles and second particles contained within the agitated pressure vessel; a fluid contained within the agitated pressure vessel; an exhaust line for releasing the fluid from the agitated pressure vessel; and a means for recovering a functionalized powder containing the second particles disposed onto surfaces of the first particles. A preferred fluid is carbon dioxide in liquefied or supercritical form. The carbon dioxide may be initially loaded into the pressure vessel as solid carbon dioxide. The pressure vessel may be batch or continuous and is operated under reaction conditions to functionalize the first particles with the second particles, thereby producing a functionalized powder, such as nanofunctionalized metal particles in which nanoparticles act as grain refiners for a component ultimately produced from the nanofunctionalized metal particles. Methods for making the functionalized powder are also disclosed.
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4.发明授权公开(公告)号：US12076818B2
公开(公告)日：2024-09-03
申请号：US18106333
申请日：2023-02-06
IPC分类号： C30B13/06 , B22F3/10 , B22F10/10 , B23K9/04 , B23K26/06 , B23K26/073 , B23K26/342 , B33Y80/00 , C30B13/24 , C30B13/32 , C30B19/08 , C30B29/00 , C30B29/52 , C30B29/68 , B33Y10/00 , B33Y30/00 , B33Y70/00
CPC分类号： B23K26/342 , B22F3/1028 , B22F10/10 , B23K9/044 , B23K26/0604 , B23K26/0734 , B33Y80/00 , C30B13/06 , C30B13/24 , C30B13/32 , C30B19/08 , C30B29/00 , C30B29/52 , C30B29/68 , B22F2999/00 , B33Y10/00 , B33Y30/00 , B33Y70/00
摘要： Some variations provide a method of making an additively manufactured single-crystal metallic component, comprising: providing a feedstock comprising a first metal or metal alloy; providing a build plate comprising a single crystal of a second metal or metal alloy; exposing the feedstock to an energy source for melting the feedstock, generating a melt layer on the build plate; and solidifying the melt layer, generating a solid layer (on the build plate) of a metal component. The solid layer is also a single crystal of the first metal or metal alloy. The method may be repeated many times to build the part. Some variations provide a single-crystal metallic component comprising a plurality of solid layers in an additive-manufacturing build direction, wherein the plurality of solid layers forms a single crystal of a metal or metal alloy with a continuous crystallographic texture. The crystal orientation may vary along the additive-manufacturing build direction.
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5.发明授权公开(公告)号：US11865641B1
公开(公告)日：2024-01-09
申请号：US16442614
申请日：2019-06-17
IPC分类号： C30B29/52 , B23K26/342 , B23K9/04 , B23K26/06 , B23K26/073 , C30B13/32 , C30B19/08 , C30B13/24 , C30B13/06 , C30B29/68 , B22F3/10 , B22F10/10 , B33Y80/00 , C30B29/00 , B33Y70/00 , B33Y10/00 , B33Y30/00
CPC分类号： B23K26/342 , B22F3/1028 , B22F10/10 , B23K9/044 , B23K26/0604 , B23K26/0734 , B33Y80/00 , C30B13/06 , C30B13/24 , C30B13/32 , C30B19/08 , C30B29/00 , C30B29/52 , C30B29/68 , B22F2999/00 , B33Y10/00 , B33Y30/00 , B33Y70/00
摘要： Some variations provide a method of making an additively manufactured single-crystal metallic component, comprising: providing a feedstock comprising a first metal or metal alloy; providing a build plate comprising a single crystal of a second metal or metal alloy; exposing the feedstock to an energy source for melting the feedstock, generating a melt layer on the build plate; and solidifying the melt layer, generating a solid layer (on the build plate) of a metal component. The solid layer is also a single crystal of the first metal or metal alloy. The method may be repeated many times to build the part. Some variations provide a single-crystal metallic component comprising a plurality of solid layers in an additive-manufacturing build direction, wherein the plurality of solid layers forms a single crystal of a metal or metal alloy with a continuous crystallographic texture. The crystal orientation may vary along the additive-manufacturing build direction.
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公开(公告)号：US11591671B2
公开(公告)日：2023-02-28
申请号：US17010902
申请日：2020-09-03
发明人： Brennan D. Yahata , John H. Martin
摘要： Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.
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公开(公告)号：US11434546B2
公开(公告)日：2022-09-06
申请号：US17089853
申请日：2020-11-05
发明人： Brennan D. Yahata , John H. Martin
摘要： Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.
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公开(公告)号：US10857735B1
公开(公告)日：2020-12-08
申请号：US15958676
申请日：2018-04-20
发明人： John H. Martin , Brennan D. Yahata , Eric Clough
IPC分类号： B29C64/386 , G01N29/12 , G01N29/46 , B33Y10/00 , B33Y30/00 , B29C64/153 , B29C64/194 , B29C64/20 , B29C64/188 , B29C64/393 , B33Y50/02
摘要： 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.
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公开(公告)号：US10808297B2
公开(公告)日：2020-10-20
申请号：US15808872
申请日：2017-11-09
发明人： Brennan D. Yahata , John H. Martin
摘要： Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.
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公开(公告)号：US12116653B2
公开(公告)日：2024-10-15
申请号：US17026218
申请日：2020-09-19
IPC分类号： B22F1/16 , B22F1/05 , B22F1/054 , B22F1/062 , B22F1/068 , B22F1/145 , B22F1/17 , B22F9/04 , C22C1/05
CPC分类号： C22C1/05 , B22F1/05 , B22F1/054 , B22F1/062 , B22F1/068 , B22F1/145 , B22F1/16 , B22F1/17 , B22F9/04 , B22F2009/043 , B22F2009/045 , B22F2304/05 , B22F2304/10 , B22F2304/15 , B22F2998/10 , B22F2999/00 , B22F1/06 , B22F1/05 , C22C1/05 , B22F2009/043 , B22F1/062
摘要： This disclosure provides an improvement over the state of the art by teaching a low-cost method to produce feedstock powder, without undergoing a phase change, from industrially relevant wrought alloys that are widely available at low cost. The surfaces of aspherical particles are functionalized with particulates having a different size and composition than the particles, to control the solidification response of the feedstock. Some variations provide a metal-containing functionalized material comprising: a plurality of aspherical particles comprising a metal or a metal alloy; and a plurality of metal-containing or ceramic particulates that are assembled on surfaces of the aspherical particles, wherein the particulates are compositionally different than the aspherical particles. Methods of making and using the metal-containing functionalized materials are described. The invention provides an economic advantage over traditional gas-atomized or water-atomized metal powder feedstocks for powder-based metal additive manufacturing or other powder metallurgy processes.
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