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    ADDITIVE MANUFACTURING WITH NANOFUNCTIONALIZED PRECURSORS
    1.
    发明申请
    ADDITIVE MANUFACTURING WITH NANOFUNCTIONALIZED PRECURSORS 审中-公开

    公开(公告)号：WO2018144324A4

    公开(公告)日：2018-08-09

    申请号：PCT/US2018/015341

    申请日：2018-01-26

    Applicant: HRL LABORATORIES, LLC

    Inventor： MARTIN, John ,  YAHATA, Brennan ,  SCHAEDLER, Tobias ,  HUNDLEY, Jacob

    IPC: B22F3/105 ,  B33Y10/00 ,  B33Y70/00

    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.

    FUNCTIONALIZED ASPHERICAL POWDER FEEDSTOCKS AND METHODS OF MAKING THE SAME
    2.
    发明申请
    FUNCTIONALIZED ASPHERICAL POWDER FEEDSTOCKS AND METHODS OF MAKING THE SAME 审中-公开

    公开(公告)号：WO2021101621A1

    公开(公告)日：2021-05-27

    申请号：PCT/US2020/051699

    申请日：2020-09-20

    Applicant: HRL LABORATORIES, LLC

    Inventor： HUNDLEY, Jacob ,  YAHATA, Brennan ,  MARTIN, John ,  SCHAEDLER, Tobias

    IPC: B22F1/00 ,  B22F9/04

    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.

    FORMULATIONS WITH ACTIVE FUNCTIONAL ADDITIVES FOR 3D PRINTING OF PRECERAMIC POLYMERS, AND METHODS OF 3D-PRINTING THE FORMULATIONS
    3.
    发明申请
    FORMULATIONS WITH ACTIVE FUNCTIONAL ADDITIVES FOR 3D PRINTING OF PRECERAMIC POLYMERS, AND METHODS OF 3D-PRINTING THE FORMULATIONS 审中-公开

    公开(公告)号：WO2018160241A3

    公开(公告)日：2018-09-07

    申请号：PCT/US2017/063211

    申请日：2017-11-27

    Applicant: HRL LABORATORIES, LLC

    Inventor： ECKEL, Zak ,  SCHAEDLER, Tobias ,  MARTIN, John ,  CANTE, Kenneth

    IPC: C04B35/571 ,  C04B35/56 ,  B33Y70/00 ,  B33Y10/00

    Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

    FORMULATIONS WITH ACTIVE FUNCTIONAL ADDITIVES FOR 3D PRINTING OF PRECERAMIC POLYMERS, AND METHODS OF 3D-PRINTING THE FORMULATIONS
    4.
    发明申请
    FORMULATIONS WITH ACTIVE FUNCTIONAL ADDITIVES FOR 3D PRINTING OF PRECERAMIC POLYMERS, AND METHODS OF 3D-PRINTING THE FORMULATIONS 审中-公开

    公开(公告)号：WO2018160241A2

    公开(公告)日：2018-09-07

    申请号：PCT/US2017/063211

    申请日：2017-11-27

    Applicant: HRL LABORATORIES, LLC

    Inventor： ECKEL, Zak ,  SCHAEDLER, Tobias ,  MARTIN, John ,  CANTE, Kenneth

    IPC: C04B35/571 ,  C04B35/56 ,  B33Y70/00 ,  B33Y10/00

    Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

    PRECERAMIC 3D-PRINTING MONOMER AND POLYMER FORMULATIONS
    5.
    发明申请
    PRECERAMIC 3D-PRINTING MONOMER AND POLYMER FORMULATIONS 审中-公开

    公开(公告)号：WO2021246997A1

    公开(公告)日：2021-12-09

    申请号：PCT/US2020/035481

    申请日：2020-05-31

    Applicant: HRL LABORATORIES, LLC

    Inventor： ECKEL, Zak ,  NOWAK, Andrew ,  DUSTIN, Ashley ,  RODRIGUEZ, April ,  BUI, Phuong ,  SCHAEDLER, Tobias

    IPC: C04B35/571 ,  B33Y70/00 ,  B33Y80/00 ,  C08G77/50 ,  B28B1/00

    Abstract: This disclosure provides resin formulations which may be used for 3D printing and thermally treating to produce a ceramic material. The disclosure provides direct, free-form 3D printing of a preceramic polymer, followed by converting the preceramic polymer to a 3D-printed ceramic composite with potentially complex 3D shapes. A wide variety of chemical compositions is disclosed, and several experimental examples are included to demonstrate reduction to practice. For example, preceramic resin formulations may contain a carbosilane in which there is at least one functional group selected from vinyl, allyl, ethynyl, unsubstituted or substituted alkyl, ester group, amine, hydroxyl, vinyl ether, vinyl ester, glycidyl, glycidyl ether, vinyl glycidyl ether, vinyl amide, vinyl triazine, vinyl isocyanurate, acrylate, methacrylate, alkacrylate, alkyl alkacrylate, phenyl, halide, thiol, cyano, cyanate, or thiocyanate. The resin formulations may contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material.

    OMNIDIRECTIONAL AND THERMALLY DURABLE INFRARED REFLECTORS, AND METHODS FOR MAKING THE SAME
    6.
    发明申请
    OMNIDIRECTIONAL AND THERMALLY DURABLE INFRARED REFLECTORS, AND METHODS FOR MAKING THE SAME 审中-公开

    公开(公告)号：WO2021108000A1

    公开(公告)日：2021-06-03

    申请号：PCT/US2020/045834

    申请日：2020-08-12

    Applicant: HRL LABORATORIES, LLC

    Inventor： CUI, Shanying ,  MEENEHAN, Sean ,  SCHAEDLER, Tobias ,  BUI, Phuong

    IPC: G02B6/122 ,  G02B6/12

    Abstract: The disclosed structure is configured such that it does not support electromagnetic waves having frequencies within a selected band gap; those electromagnetic waves are thus reflected. Some variations provide an omnidirectional infrared reflector comprising a three-dimensional photonic crystal containing: rods of a first material that has a first refractive index, wherein the rods are arranged to form a plurality of lattice periods in three dimensions, and wherein the rods are connected at a plurality of nodes; and a second material that has a refractive index that is lower than the first refractive index, wherein the rods are embedded in the second material. The lattice spacing and the rod radius or width are selected to produce a photonic band gap within a selected band of the infrared spectrum. Methods of making and using the three-dimensional photonic crystal are described. Applications include thermal barrier coatings and blackbody emission signature control.

    ADDITIVELY MANUFACTURED HIGH-TEMPERATURE ALUMINUM ALLOYS, AND FEEDSTOCKS FOR MAKING THE SAME
    7.
    发明申请
    ADDITIVELY MANUFACTURED HIGH-TEMPERATURE ALUMINUM ALLOYS, AND FEEDSTOCKS FOR MAKING THE SAME 审中-公开

    公开(公告)号：WO2020139427A2

    公开(公告)日：2020-07-02

    申请号：PCT/US2019/050542

    申请日：2019-09-11

    Applicant: HRL LABORATORIES, LLC

    Inventor： SCHAEDLER, Tobias ,  HUNDLEY, Jacob ,  MARTIN, John ,  MILLER, Julie

    IPC: C22C21/00

    Abstract: Some variations provide an aluminum alloy comprising aluminum and from 0.5 wt% to 60 wt% of an alloy element X selected from the group consisting of Zr, Ti, Hf, V, Ta, Nb, Cr, Mo, W, Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and combinations or alloys thereof, wherein the alloy element X is present as an intermetallic precipitate containing Al and X. An exemplary intermetallic precipitate is Al 3 Zr. Some variations provide a feedstock powder comprising: from 80 wt% to 99 wt% of an aluminum-containing base powder with an average particle size from 10 microns to 500 microns; and, intimately mixed with the base powder, from 1 wt% to 20 wt% of an alloying powder with average particle size from 0.01 microns to 90 microns, containing an alloy element X or a hydride, carbide, oxide, nitride, boride, or sulfide thereof.

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