公开(公告)号：US12116653B2

公开(公告)日：2024-10-15

申请号：US17026218

申请日：2020-09-19

Applicant: HRL Laboratories, LLC

Inventor： Jacob M. Hundley ,  Brennan D. Yahata ,  John H. Martin ,  Tobias A. Schaedler

IPC: B22F1/16 ,  B22F1/05 ,  B22F1/054 ,  B22F1/062 ,  B22F1/068 ,  B22F1/145 ,  B22F1/17 ,  B22F9/04 ,  C22C1/05

CPC classification number: 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

Abstract: 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.

公开(公告)号：US12037669B1

公开(公告)日：2024-07-16

申请号：US16784890

申请日：2020-02-07

Applicant: HRL Laboratories, LLC

Inventor： John H. Martin ,  Julie Miller ,  Brennan D. Yahata ,  Jacob M. Hundley

IPC: C22C9/00 ,  B22F9/02 ,  B23K26/342 ,  B33Y70/00 ,  C22C5/02 ,  C22C5/06 ,  C22C11/00 ,  C22C12/00 ,  C22C13/00 ,  C22C14/00 ,  C22C16/00 ,  C22C18/00 ,  C22C19/03 ,  C22C19/07 ,  C22C21/00 ,  C22C22/00 ,  C22C27/00 ,  C22C27/02 ,  C22C27/04 ,  C22C27/06 ,  C22C28/00 ,  C22C38/00 ,  C22C49/14 ,  B33Y10/00

CPC classification number: C22C9/00 ,  B22F9/02 ,  B23K26/342 ,  B33Y70/00 ,  C22C5/02 ,  C22C5/06 ,  C22C11/00 ,  C22C12/00 ,  C22C13/00 ,  C22C14/00 ,  C22C16/00 ,  C22C18/00 ,  C22C19/03 ,  C22C19/07 ,  C22C21/00 ,  C22C22/00 ,  C22C27/00 ,  C22C27/02 ,  C22C27/04 ,  C22C27/06 ,  C22C28/00 ,  C22C38/00 ,  C22C49/14 ,  B22F2304/10 ,  B33Y10/00

Abstract: Some variations provide a metal-alloy biphasic system containing a first metal M1 and a second metal M2, wherein a second metal phase has a melting temperature lower than that of a first metal phase, and wherein the metal-alloy biphasic system has a hierarchical microstructure containing a second length scale that is at least one order of magnitude smaller than a first length scale. Some variations provide a metal-alloy biphasic system containing a first metal M1 and a second metal M2, wherein a second metal phase has a melting temperature lower than that of a first metal phase, and wherein the first metal phase forms a continuous network. Other variations provide a metal-alloy biphasic powder containing at least a first metal and a second metal, wherein the solubility of first metal in second metal is less than 5%. Methods of making and using the powders and biphasic system are disclosed.

公开(公告)号：US20200341171A1

公开(公告)日：2020-10-29

申请号：US16926478

申请日：2020-07-10

Applicant: HRL LABORATORIES, LLC

Inventor： Jacob M. Hundley ,  Zak C. Eckel ,  Sophia S. Yang ,  Alan J. Jacobsen ,  William Carter

IPC: G02B1/12 ,  G02B1/14 ,  G02B6/138

Abstract: Methods of manufacturing a structure having at least one plated region and at least one unplated region. The method includes plating a metal on a polymer structure having a first region accepting the metal and a second region unreceptive to the metal plating. The first region may include fully-cured polymer optical waveguides and the second region may include partially-cured polymer optical waveguides. The first region may include a first polymer composition and the second region may include a second polymer composition different than the first polymer composition.

公开(公告)号：US10590042B2

公开(公告)日：2020-03-17

申请号：US15946680

申请日：2018-04-05

Applicant: HRL Laboratories, LLC

Inventor： Zak C. Eckel ,  Jacob M. Hundley ,  Robert Mone

IPC: C04B35/589 ,  C04B35/524 ,  B28B1/00 ,  C04B35/571 ,  C04B35/597 ,  C04B35/583 ,  C08L83/08 ,  C04B35/634 ,  C08L83/04 ,  B33Y70/00 ,  C01B21/064 ,  C08L83/02 ,  C08G77/20 ,  C08G77/28

Abstract: Resins for 3D printing of a preceramic composition loaded with a solid polymer filler, followed by converting the preceramic composition to a 3D-printed ceramic material, are described. Some variations provide a preceramic composition containing a radiation-curable liquid resin formulation and a solid polymer filler dispersed within the liquid resin formulation. The liquid resin formulation is compatible with stereolithography, UV curing, and/or 3D printing. The solid polymer filler may be an organic polymer, an inorganic polymer, or a combination thereof. The solid polymer filler may itself be an inorganic preceramic polymer, which may have the same composition as a polymerized variant of the liquid resin formulation, or a different composition. Many compositions are disclosed as options for the liquid resin formulation and the solid polymer filler.

公开(公告)号：US10427375B2

公开(公告)日：2019-10-01

申请号：US15622518

申请日：2017-06-14

Applicant: HRL LABORATORIES, LLC

Inventor： Jacob M. Hundley ,  Tobias A. Schaedler ,  Sophia S. Yang ,  Alan J. Jacobsen

IPC: B32B3/12 ,  B29C33/38 ,  B29C33/42 ,  B32B9/00 ,  B32B15/04 ,  B32B27/06 ,  B32B27/30 ,  B32B27/32 ,  B32B27/34 ,  B32B27/36 ,  B32B3/26 ,  B32B7/00 ,  B32B7/02 ,  B32B7/04 ,  B32B7/12 ,  B32B9/04 ,  B32B15/00 ,  B32B27/00 ,  B32B27/28 ,  B32B3/00 ,  B32B3/02 ,  B32B3/14 ,  B32B3/18 ,  B32B3/20 ,  B32B3/28 ,  B32B3/30 ,  B29C64/124 ,  B29C64/135 ,  B29C64/129 ,  B29C64/40 ,  B29C35/08 ,  B33Y10/00 ,  B33Y80/00

Abstract: A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

公开(公告)号：US20180214949A1

公开(公告)日：2018-08-02

申请号：US15880488

申请日：2018-01-25

Applicant: HRL Laboratories, LLC

Inventor： John H. Martin ,  Brennan Yahata ,  Tobias A. Schaedler ,  Jacob M. Hundley

IPC: B22F3/105 ,  B22F1/00 ,  B22F5/12 ,  B33Y70/00 ,  B22F7/04

CPC classification number: B22F3/1055 ,  B22F1/0018 ,  B22F5/12 ,  B22F2007/042 ,  B22F2301/052 ,  B22F2301/054 ,  B22F2301/058 ,  B22F2301/10 ,  B22F2301/15 ,  B22F2301/205 ,  B22F2301/255 ,  B22F2301/30 ,  B22F2304/05 ,  B22F2999/00 ,  B33Y10/00 ,  B33Y70/00 ,  C22C1/05 ,  Y02P10/295

Abstract: Some variations provide a process for additive manufacturing of a nanofunctionalized metal alloy, comprising: providing a nanofunctionalized metal precursor containing metals and grain-refining nanoparticles; exposing a first amount of the nanofunctionalized metal precursor to an energy source for melting the precursor, thereby generating a first melt layer; solidifying the first melt layer, thereby generating a first solid layer; and repeating many times to generate a plurality of solid layers in an additive-manufacturing build direction. The additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains. Other variations provide an additively manufactured, nanofunctionalized metal alloy comprising metals selected from aluminum, iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; and grain-refining nanoparticles selected from zirconium, tantalum, niobium, titanium, or oxides, nitrides, hydrides, carbides, or borides thereof, wherein the additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains.

公开(公告)号：US09919489B2

公开(公告)日：2018-03-20

申请号：US15204204

申请日：2016-07-07

Applicant: HRL LABORATORIES, LLC

Inventor： Jacob M. Hundley ,  Eric C. Clough ,  Alan J. Jacobsen

IPC: B32B3/06 ,  E04C2/292 ,  E04C2/296 ,  B32B27/08 ,  B32B27/36 ,  B32B3/26 ,  B32B5/20 ,  C08J3/28 ,  B33Y10/00 ,  B33Y80/00 ,  B32B7/08 ,  B29C64/129 ,  B29K105/00 ,  B29L9/00 ,  B29L11/00

CPC classification number: B32B3/06 ,  B29C64/129 ,  B29K2105/0002 ,  B29K2105/0058 ,  B29L2009/00 ,  B29L2011/0075 ,  B32B3/266 ,  B32B5/20 ,  B32B7/08 ,  B32B27/08 ,  B32B27/36 ,  B32B2250/02 ,  B32B2250/40 ,  B32B2255/26 ,  B32B2307/518 ,  B32B2605/00 ,  B33Y10/00 ,  B33Y80/00 ,  C08J3/28 ,  E04C2/292 ,  E04C2/296

Abstract: A sandwich structure including at least one fastener attached to a first facesheet, an ordered three-dimensional microstructure core defined by a series of interconnected polymer waveguides around the at least one fastener and attached to the first facesheet, and a second facesheet attached to the ordered three-dimensional microstructure core. The ordered three-dimensional microstructure core is sandwiched between the first facesheet and the second facesheet.

公开(公告)号：US09738013B1

公开(公告)日：2017-08-22

申请号：US14462521

申请日：2014-08-18

Applicant: HRL LABORATORIES, LLC

Inventor： Sophia S. Yang ,  Alan J. Jacobsen ,  Zak C. Eckel ,  Jacob M. Hundley ,  William Carter

IPC: B32B7/02 ,  B32B3/00 ,  B32B3/26 ,  B29C35/08 ,  B32B3/12 ,  G03F7/20 ,  G03F7/26

CPC classification number: B29C35/0805 ,  B29C35/0894 ,  B29C2035/0827 ,  B29C2035/0838 ,  B32B3/12 ,  G03F7/0037 ,  G03F7/20 ,  G03F7/201 ,  G03F7/2012 ,  G03F7/26

Abstract: A multi-chemistry structure includes: a plurality of interconnected polymer struts arranged in a lattice; a first layer of the lattice including a first array of first unit cells; a second layer of the lattice including a second array of second unit cells; at least one region of the lattice being formed of a first polymer; and at least one region of the lattice being formed of a second polymer different from the first polymer.

公开(公告)号：US09731471B2

公开(公告)日：2017-08-15

申请号：US14970521

申请日：2015-12-15

Applicant: HRL Laboratories, LLC

Inventor： Tobias A. Schaedler ,  Jacob M. Hundley ,  John H. Martin ,  Christopher S. Roper ,  Eric C. Clough

IPC: B32B3/20 ,  B32B3/12 ,  B33Y10/00 ,  B29C45/00 ,  B29C67/00 ,  C23F1/00 ,  B33Y80/00 ,  B32B15/20 ,  C25D3/12 ,  C25D3/56 ,  B29L7/00

CPC classification number: B32B3/12 ,  B29C45/0053 ,  B29C64/00 ,  B29C64/135 ,  B29C2045/0079 ,  B29L2007/002 ,  B32B15/01 ,  B32B15/20 ,  B32B2307/304 ,  B32B2307/306 ,  B32B2607/00 ,  B33Y10/00 ,  B33Y80/00 ,  C23C10/32 ,  C23C10/48 ,  C23C18/1653 ,  C23C28/02 ,  C23C28/023 ,  C23F1/00 ,  C25D3/12 ,  C25D3/562

Abstract: A lightweight sandwich panel structure with a complex shape and curvature, and a method to fabricate such a panel out of high temperature alloys. Embodiments of a micro-truss core structure that offer high specific strength and stiffness while allowing for curvature, and methods for depositing multiple layers of metals that can be interdiffused into complex alloys, are provided. A core of a panel may be fabricated from a polymer template, which may be shaped, e.g., curved, and coated with metal layers, which may then be heat treated to cause the layers of metal to interdiffuse, to form an alloy.

公开(公告)号：US20160250820A1

公开(公告)日：2016-09-01

申请号：US15151324

申请日：2016-05-10

Applicant: HRL LABORATORIES, LLC

Inventor： Jacob M. Hundley ,  Tobias A. Schaedler ,  Sophia S. Yang ,  Alan J. Jacobsen

IPC: B32B3/12 ,  B29C67/00 ,  B32B27/06 ,  G03F7/20 ,  B32B9/00 ,  B32B15/04

CPC classification number: B32B3/12 ,  B29C33/3835 ,  B29C33/3842 ,  B29C33/424 ,  B29C64/124 ,  B29C64/129 ,  B29C64/135 ,  B29C64/40 ,  B29C67/0062 ,  B29C67/0066 ,  B29C67/007 ,  B29C67/0092 ,  B29C2035/0827 ,  B32B3/00 ,  B32B3/02 ,  B32B3/14 ,  B32B3/18 ,  B32B3/20 ,  B32B3/26 ,  B32B3/266 ,  B32B3/28 ,  B32B3/30 ,  B32B7/00 ,  B32B7/02 ,  B32B7/04 ,  B32B7/12 ,  B32B9/00 ,  B32B9/005 ,  B32B9/04 ,  B32B15/00 ,  B32B15/04 ,  B32B27/00 ,  B32B27/06 ,  B32B27/28 ,  B32B27/30 ,  B32B27/302 ,  B32B27/308 ,  B32B27/32 ,  B32B27/34 ,  B32B27/365 ,  B32B2250/00 ,  B32B2250/40 ,  B32B2264/00 ,  B32B2264/107 ,  B32B2307/40 ,  B32B2307/558 ,  B32B2307/56 ,  B32B2307/718 ,  B32B2307/728 ,  B32B2307/73 ,  B32B2307/732 ,  B32B2419/00 ,  B32B2605/00 ,  B33Y10/00 ,  B33Y80/00 ,  Y10T29/49826 ,  Y10T428/24149

Abstract: A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

Abstract translation: 具有厚度层级的三维晶格结构包括彼此隔开的第一表面和第二表面，其间限定三维晶格结构的厚度; 沿所述第一表面和所述第二表面之间的多个方向延伸的多个成角度的支柱; 多个节点将多个成角度的支柱彼此连接，形成多个单位单元。 多个倾斜支柱的至少一部分沿着格子结构的厚度方向内部终止，并且向晶格结构的第一或第二表面提供多个内部自由度。