Iowa State University Research Foundation, Inc.

United States of America, As Represented by the Secretary of the Navy

U.S. Department of Energy

California Institute of Technology

Sandia Corporation

National Technology & Engineering Solutions of Sandia, LLC

Los Alamos National Security, LLC

Iver E Anderson

Robert L Terpstra

Barbara K Lograsso

Joel R Rieken

Kevin W Dennis

Andrew J Heidloff

David J Byrd

R William McCallum

Daniel J Sordelet

Emma Marie Hamilton White

Jason Ting

Thomas J Barton

Timothy W Ellis

Sina Ijadi-Maghsoodi

Joel Lee Harringa

Andrew Douglas Steinmetz

Matthew J Kramer

Richard S Figliola

Aaron G Kassen

Ozer Unal

Mohammad Nosrati

Jack D Ayers

Bruce Allan Cook

Alan Mark Russell

Joshua U Otaigbe

Matthew Frank Besser

Jeffrey A Moore

Jon M McAvoy

Adam J Boesenberg

Holly M Molnar

Jia Mi

Mary Anne Alvin

Vitalij K Pecharsky

Ratnakumar V Bugga

Bruce G McMordie

John D Verhoeven

Edwin D Gibson

Brent T Fultz

Nicolas Argibay

Jeffrey S Hansen

Andrew Benjamin Kustas

Paul Chandler Turner

Liangfa Hu

Michael E Chandross

Edward R Argetsinger

Frederick G Yost

Duane D Johnson

Alan D Hartman

Robert C Bowman

Charles K Witham

Stephen N Paglieri

John F Smith

Jack I Paige

Raymond Vernon Puckett

Jeffrey E Shield

William A Spitzig

Suleyman B Biner

Matthew G Osborne

Eric J Deaton

Emma H White

Dave Byrd

Bo Kong

Timothy E Prost

Trevor M Riedemann

Jordan A Tiarks

Ross Anderson

Franz Hugolino Hernandez Gaitan

Andy Heidlof

Emma White

Hyong J Kim

Andrew E Freichs

Kathlene Nicole Reeve

S Bulent Biner

Jeffery A Moore

Alan I Goldman

Chad M Miller

Refractory-reinforced multiphase high entropy alloys (RHEAs) advantageously providing high strength and fracture toughness in an as-AM deposited condition and other conditions are described.

Ultra-high strength multphase high-entropy alloys

A method for gas atomization of a titanium alloy, nickel alloy, or other alumina (AlO)-forming alloy wherein the atomized particles are exposed as they solidify and cool in a very short time to multiple gaseous reactive agents for the in-situ formation of a passivation reaction film on the atomized particles wherein the reaction film retains a precursor halogen alloying element that is subsequently introduced into a microstructure formed by subsequent thermally processing of the atomized particles to improve oxidation resistance.

Passivation and alloying element retention in gas atomized powders

The broad applicability of at least certain aspects of the present invention derives from the ability to determine the critical location where secondary satellite formation occurs for any atomization system or design and allows for the rapid assessment of the effectiveness of various satellite reduction strategies, including but not limited to several embodiments detailed herein. Aspects of this invention can be utilized during initial atomization system design in order to evaluate effective chamber geometries and enabling strategies which reduce/eliminate satelliting, or can be retrofit to existing systems and allows for economic evaluation of effectiveness based off of initial capital expenditures versus increased operating requirements/expenses.

Powder satellite-reduction apparatus and method for gas atomization process

Improved manufacturing processes and resulting anisotropic permanent magnets, such as for example alnico permanent magnets, having highly controlled and aligned microstructure in the solid state are provided. A certain process embodiment involves applying a particular orientation and strength of magnetic field to loose, binder-coated magnet alloy powder particles in a compact-forming device as they are being formed into a compact in order to preferentially align the magnet alloy powder particles in the compact. The preferential alignment of the magnet alloy powder particle is locked in place in the compact by the binder after compact forming is complete. After removal from the device, the compact can be subjected to a subsequent sintering or other heat treating operation.

Heat treatable magnets having improved alignment through application of external magnetic field during binder-assisted molding

Magnet microstructure manipulation in the solid state by controlled application of a sufficient stress in a direction during high temperature annealing in a single-phase region of heat-treatable magnet alloys, e.g., alnico-type magnets is followed by magnetic annealing and draw annealing to improve coercivity and saturation magnetization properties. The solid-state process can be termed highly controlled abnormal grain growth (hereafter AGG) and will make aligned sintered anisotropic magnets that meet or exceed the magnetic properties of cast versions of the same alloy types.

Solid state grain alignment of permanent magnets in near-final shape

A concentric ring gas atomization nozzle with isolated gas supply manifolds is provided for manipulating the close-coupled atomization gas structure to improve the yield of atomized powders.

Atomizer for improved ultra-fine powder production

A method for gas atomization of oxygen-reactive reactive metals and alloys wherein the atomized particles are exposed as they solidify and cool in a very short time to multiple gaseous reactive agents for the in-situ formation of a protective reaction film on the atomized particles. The present invention is especially useful for making highly pyrophoric reactive metal or alloy atomized powders, such as atomized magnesium and magnesium alloy powders. The gaseous reactive species (agents) are introduced into the atomization spray chamber at locations downstream of a gas atomizing nozzle as determined by the desired powder or particle temperature for the reactions and the desired thickness of the reaction film.

Stability of gas atomized reactive powders through multiple step in-situ passivation

A solder alloy includes Sn, optional Ag, Cu, and Al wherein the solder alloy composition together with the solder alloy superheat temperature and rapid cooling rate from the superheat temperature are controlled to provide a dispersion of fine hard Cu&#x2014;Al intermetallic particles in an as-solidified solder alloy microstructure wherein the particles are retained even after multiple solder reflow cycles often used in modern electronic assembly procedures to provide a particle strengthening to the solder joint microstructure as well as exert a grain refining effect on the solder joint microstructure, providing a strong, impact- and thermal aging-resistant solder joint that has beneficial microstructural features and is substantially devoid of AgSn blades.

Rapidly solidifying Pb-free Sn-Ag-Cu-Al or Sn-Cu-Al solder

A solder alloy includes Sn, optional Ag, Cu, and Al wherein the alloy composition is controlled to provide a strong, impact-and thermal aging-resistant solder joint that has beneficial microstructural features and is substantially devoid of AgSn blades.

Pb-free Sn&#x2014;Ag&#x2014;Cu&#x2014;Al or Sn&#x2014;Cu&#x2014;Al solder

The present invention relates to CuAlalloys and CuAl-based bulk alloys and coatings that exhibit significantly increased hardness characteristics compared to traditional copper-aluminum alloys.

Hard and super-hard metal alloys and methods for making the same

A method of making dispersion-strengthened alloy particles involves melting an alloy having a corrosion and/or oxidation resistance-imparting alloying element, a dispersoid-forming element, and a matrix metal wherein the dispersoid-forming element exhibits a greater tendency to react with a reactive species acquired from an atomizing gas than does the alloying element. The melted alloy is atomized with the atomizing gas including the reactive species to form atomized particles so that the reactive species is (a) dissolved in solid solution to a depth below the surface of atomized particles and/or (b) reacted with the dispersoid-forming element to form dispersoids in the atomized particles to a depth below the surface of said atomized particles. The atomized alloy particles are solidified as solidified alloy particles or as a solidified deposit of alloy particles. Bodies made from the dispersion strengthened alloy particles, deposit thereof, exhibit enhanced fatigue and creep resistance and reduced wear as well as enhanced corrosion and/or oxidation resistance at high temperatures by virtue of the presence of the corrosion and/or oxidation resistance imparting alloying element in solid solution in the particle alloy matrix.

Dispersoid reinforced alloy powder and method of making

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Ames, IA, United States of America

Iver E Anderson