Iowa State University Research Foundation Inc.

University of Massachusetts

Indium Corporation of America

Safi-Tech, Inc.

Martin Thuo

Ian Tevis

Boyce S Chang

Christophe Frankiewicz

Andrew Martin

Peter C Collins

Chuanshen Du

Jacob Sporrer

Jiahao Chen

Paul Ramon Gregory

Winnie M Kiarie

Thomas Ales

Aaron J Rossini

Stephanie Oyola-Reynoso

Darin Heisterkamp

Chris Frankiewicz

Julia Jinling Chang

Thomas Ward, Iii

Dana Drochner

Various embodiments relate to forming particles using undercooled metal particles in response to focused low power laser light. Particle growth can be initiated by utilizing the metastable and liquid nature of the particles, allowing for surface instability promoted by the laser light to induce liquid flow to translate to a neighboring particle. This event can cascade radially leading to accumulation of the liquid metal at the epicenter. The grown solidified particle size can be varied by using different power, exposure time, or working distance. Once the liquid has accumulated into a single region, it eventually solidifies either through homogeneous or heterogeneous nucleation to give a solid particle of larger size than the original. Such a method can be used to print patterns on a surface in four dimensions, where the fourth dimension (4D) is attained through gradient in size of the particles made. Additional systems and methods are disclosed.

Mask-free photolithography using metastable undercooled metal particles

A method of direct printing or writing of a metallic material involves depositing, with a printing device or writing device, an ink comprising of at least undercooled liquid metallic particles dispersed in a carrier fluid. The ink is deposited on any substrate surface to deposit the undercooled liquid metal particles thereon as one or more layers that can form a desired pattern or layered structure.

Direct printing and writing using undercooled metallic core-shell particles

A material includes a plurality of supercooled micro-capsules each including a metallic core in a liquid state at a temperature below a solidification temperature of the metallic core and further includes a metallic shell surrounding each respective metallic core. A plurality of alloyed metallic particles and flux are mixed with the plurality of supercooled micro-capsules to form a solder paste. Upon heating the solder paste, the plurality of alloyed particles melt. As the metallic shells destabilize, the liquid metallic cores interdiffuse with the melted alloyed particles forming a new alloy that has a higher melting temperature than the melting temperature of the alloyed metallic particles.

Solder materials including supercooled micro-capsules and alloyed particles

One or more techniques and/or systems are disclosed for a dry-type lubricant for use in a dry product hopper to help improve dry product flow and to improve anti-jamming properties of the dry product. The example lubricant can comprise a hydrophilic fiber, such as cellulose, having a width to length aspect ratio that provides a thin fiber. A plurality of hydrophobic particles are deposited on the surface of the fiber, resulting in a fiber surface exhibiting amphiphobic properties. Further, the fiber can operably absorb water, and then releases the absorbed water to the surface of the fiber under mechanical stress, such as when mixed with a product in a hopper. This can result in the water being disposed on the surface of the fiber, to provide lubrication to a product in a hopper to improve flow and anti-jamming characteristics of the product in the hopper.

Solid dry-type lubricant

A droplet comprises a core including an alloy comprising a majority of a first metallic element and a minority of a second element, wherein the core is in a liquid state below a solidus temperature of the alloy. A shell is arranged to enclose the core and includes an exterior surface comprising a majority of the second element and a minority of the first metallic element, wherein the shell is in a solid state below the solidus temperature of the alloy. The alloy can comprise a solder material that can be used to form solder connections below a solidus temperature of the alloy.

Undercooled liquid metallic droplets having a protective shell

Textured particles and methods of making the same. A textured particle includes an inner core and a spherical solid outer shell including an outer surface. The inner core is inside the outer shell. The outer surface includes a first tier texture including a first metal, wherein the first metal is greater than 50 atomic % of a total atomic content of all metals in the first tier texture; a second tier texture including the second metal, wherein the second metal is greater than 50 atomic % of a total atomic content of all metals in the second tier texture; and a third tier texture including the third metal, wherein the third metal is greater than 50 atomic % of a total atomic content of all metals in the third tier texture. The first metal, second metal, and third metals are different metals.

Textured particles

Coated irregular surfaces, replicas made therefrom, and methods of making the same. A particle-coated substrate includes a coating including undercooled liquid metallic particles. The particles include a solid shell comprising a metal oxide, and a liquid metallic core that is below the melting point of the liquid metallic core. The particle-coated substrate also includes a substrate including an irregular surface, wherein the coating is on the irregular surface.

Coated irregular surfaces

Undercooled liquid metallic core-shell particles, whose core is stable against solidification at ambient conditions, i.e. under near ambient temperature and pressure conditions, are used to join or repair metallic non-particulate components. The undercooled-shell particles in the form of nano-size or micro-size particles comprise an undercooled stable liquid metallic core encapsulated inside an outer shell, which can comprise an oxide or other stabilizer shell typically formed in-situ on the undercooled liquid metallic core. The shell is ruptured to release the liquid phase core material to join or repair a component(s).

Stable undercooled metallic particles for filling a void

A system and method are presented for producing metallic core-shell particles. The system includes the housing having a hollow interior configured to receive and hold a molten metal input, a carrier fluid, and one or more reagents. The system also includes a shearing assembly positioned within the hollow interior of the housing. The shearing assembly is configured to, when the molten metal input, carrier fluid, and one or more reagents are held withing hollow interior and sealed within housing, shear the molten metal input into particles of an effective size so that a shell created on a surface of the particles via reaction with the one or more reagents prevents a core of the particles from solidifying when the particles are cooled to a temperature below a freezing temperature of the molten metal input.

System and method for manufacture of undercooled metallic core-shell particles

A system and method are presented for producing solder paste having undercooled metallic core-shell particles. In one or more arrangements, the system includes a reconstitution assembly, a dispenser assembly, and a mixer, among other components. The reconstitution assembly is configured to place the cores of the solid core metallic core-shell particles into an undercooled liquid state to form a plurality of undercooled metallic core-shell particles. The dispenser assembly is configured to dispense one or more of a set of available flux components. The mixer assembly is configured to mix the one or more of the set of flux components dispensed by the dispenser assembly with the plurality of undercooled metallic core-shell particles formed by the reconstitution assembly to form a solder paste.

Solder paste on demand apparatus

One or more techniques and/or systems are disclosed for a dry-type lubricant for use in a dry product hopper to help improve dry product flow and to improve anti jamming properties of the dry product. The example lubricant can comprise a hydrophilic fiber, such as cellulose, having a width to length aspect ratio that provides a thin fiber. A plurality of hydrophobic particles are deposited on the surface of the fiber, resulting in a fiber surface exhibiting amphiphobic properties. Further, the fiber can operably absorb water, and then releases the absorbed water to the surface of the fiber under mechanical stress, such as when mixed with a product in a hopper. This can result in the water being disposed on the surface of the fiber, to provide lubrication to a product in a hopper to improve flow and anti jamming characteristics of the product in the hopper.

Stable undercooled metallic particles for engineering at ambient conditions

Various embodiments relate to additive manufacturing in which the Langmuir equation can be used to predict composition in the processing. This equation can be integrated into a model with knowledge of elemental solubility and relative reactivity of relevant elements in the additive manufacturing processing. Use of thermodynamic principles can be programmed into a finite element modeling strategy integrating the Langmuir equation, coupling the thermal fields of additive manufacturing and the surrounding environments with the rules and/or equations to predict solute pickup and/or solute loss. The modeling strategy can be implemented to identify the elements in relative concentrations to be used in the additive manufacturing processing to provide for the controlled loss of certain elements to prevent absorption of unwanted elements into molten material, formed by additive manufacturing, from the atmosphere around the molten material. Additional systems and methods are disclosed.

Interstitial control during additive manufacturing

A physical and chemical method is provided for de-mixing (e.g. extracting, separating, purifying and/or enriching) the metal constituents of an alloy or mixed material into different droplet or solid particle products that are highly enriched in the respective phases of the metal. The method involves for instance but is not limited to, shearing, separating and segregating metallic droplets and particles in a carrier fluid to form other droplets or particles that are each separately highly enriched in one of some, if not of all, of the constituent phases of the alloy or mixed material.

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Apex, NC, United States of America

Martin Thuo