公开(公告)号：US20240087780A1

公开(公告)日：2024-03-14

申请号：US18509479

申请日：2023-11-15

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: 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：US20230321757A1

公开(公告)日：2023-10-12

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 ,  H01F1/147 ,  B22F10/28 ,  B33Y10/00

CPC classification number: B23K26/342 ,  H01F1/147 ,  B22F10/28 ,  B33Y10/00 ,  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：US20240399457A1

公开(公告)日：2024-12-05

申请号：US18799082

申请日：2024-08-09

Applicant: HRL Laboratories, LLC

Inventor： John H. MARTIN ,  Brennan YAHATA ,  Darby LAPLANT ,  Christopher ROPER

IPC: B22F10/20 ,  B28B1/00 ,  B29C64/141 ,  B33Y10/00 ,  B33Y80/00

Abstract: Some variations provide an additively manufactured article comprising a first region and a second region, wherein the first region is a solid region or a porous region, wherein the second region has a pore size larger than the first-region pore size, and wherein the first-region average permeability is lower than the second-region average permeability. Some variations provide a co-sintering method of making an architected material with regions having different permeabilities, in which different additive-manufacturing process parameters are applied to distinct regions of the structure. Other variations provide a wall-pinning method of making an architected material with regions having different permeabilities, in which additive-manufacturing process parameters are selected to sinter pinned feedstock powder between solid walls. Engineered structures with controlled permeability, integrated manifolds, and arbitrary geometries are disclosed, without the requirement of complex manufacturing. Many uses are described for the disclosed additively manufactured articles.

公开(公告)号：US20230326637A1

公开(公告)日：2023-10-12

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 ,  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 ,  C22C38/005 ,  C22C38/30 ,  C22C38/08 ,  C22C38/105 ,  C22C38/06 ,  B33Y80/00 ,  H01F7/021 ,  H01F7/0278 ,  H01F1/0577 ,  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：US20230282397A1

公开(公告)日：2023-09-07

申请号：US18114202

申请日：2023-02-24

Applicant: HRL Laboratories, LLC

Inventor： Brennan YAHATA ,  Adam GROSS ,  Christopher HENRY ,  Darby LAPLANT ,  Amber SUCICH ,  Raymond NGUYEN ,  Christine KIM

IPC: H01F1/053 ,  H01F1/00 ,  H01F7/02

CPC classification number: H01F1/0536 ,  H01F1/0045 ,  H01F7/021 ,  H01F7/0221 ,  H01F41/0253

Abstract: The disclosed technology provides a cladded permanent magnet comprising: a core magnet region containing a core magnetic material; and a magnet cladding containing a shell magnetic material comprising (i) a magnetic compound that is chemically the same as the core magnetic material, (ii) one or more rare earth elements, and (iii) metal-containing inoculant nanoparticles, wherein the magnet cladding is disposed on the core magnet region, wherein the magnet cladding has at least 10% higher ambient-temperature magnetic coercivity compared to the core magnet region. The cladded permanent magnet is made via high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.

公开(公告)号：US20220282357A1

公开(公告)日：2022-09-08

申请号：US17751650

申请日：2022-05-23

Applicant: HRL Laboratories, LLC

Inventor： John H. MARTIN ,  Darby LAPLANT ,  Julie MILLER

IPC: C22C21/00

Abstract: Some variations provide an aluminum (Al) alloy containing at least 0.1 at % zirconium (Zr) and/or at least 0.1 at % chromium (Cr), wherein the aluminum alloy is in the form of an additively manufactured object. Other variations provide an aluminum-containing powder comprising Al particles, Cr particles, and Zr particles, wherein at least some of the Cr particles as well as at least some of the Zr particles are physically and/or chemically assembled on surfaces of the Al particles, and wherein the aluminum-containing powder contains at least 0.1 at % Zr and at least 0.1 at % Cr. In this invention, the combination of surface functionalization and additive manufacturing has fundamentally created a new composition space of valuable aluminum alloys. The disclosed Al alloys are strong, thermally stable, and corrosion-resistant.

公开(公告)号：US20240308002A1

公开(公告)日：2024-09-19

申请号：US18673653

申请日：2024-05-24

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：US20230282398A1

公开(公告)日：2023-09-07

申请号：US18114199

申请日：2023-02-24

Applicant: HRL Laboratories, LLC

Inventor： Brennan YAHATA ,  Adam GROSS ,  Christopher HENRY ,  Darby LAPLANT ,  Amber SUCICH ,  Raymond NGUYEN ,  Christine KIM

IPC: H01F1/055

CPC classification number: H01F1/0551 ,  B82Y25/00

Abstract: The disclosed technology provides a nanofunctionalized magnetic material feedstock comprising: from 50 wt % to 99.5 wt % of magnetic microparticles having an average microparticle effective diameter from 1 micron to 500 microns; from 0.4 wt % to 40 wt % of one or more rare earth elements; and from 0.1 wt % to 10 wt % of metal-containing inoculant nanoparticles, wherein at least 1 wt % of the inoculant nanoparticles are chemically and/or physically disposed on surfaces of the magnetic microparticles. The nanofunctionalized magnetic material feedstock is processed using high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.

公开(公告)号：US20210102276A1

公开(公告)日：2021-04-08

申请号：US17121601

申请日：2020-12-14

Applicant: HRL Laboratories, LLC

Inventor： John H. MARTIN ,  Darby LAPLANT ,  Julie MILLER

IPC: C22C21/00

Abstract: Some variations provide an aluminum (Al) alloy containing at least 0.1 at % zirconium (Zr) and/or at least 0.1 at % chromium (Cr), wherein the aluminum alloy is in the form of an additively manufactured object. Other variations provide an aluminum-containing powder comprising Al particles, Cr particles, and Zr particles, wherein at least some of the Cr particles as well as at least some of the Zr particles are physically and/or chemically assembled on surfaces of the Al particles, and wherein the aluminum-containing powder contains at least 0.1 at % Zr and at least 0.1 at % Cr. In this invention, the combination of surface functionalization and additive manufacturing has fundamentally created a new composition space of valuable aluminum alloys. The disclosed Al alloys are strong, thermally stable, and corrosion-resistant.