Patents Assigned to Ultramet
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Publication number: 20180066366Abstract: A graphite-metal carbide-rhenium article of manufacture is provided, which is suitable for use as a component in the hot zone of a rocket motor at operating temperatures in excess of approximately 3,000 degrees Celsius. One side of the metal carbide is chemically bonded to the surface of the graphite, and the rhenium containing protective coating is mechanically bonded to the other side of the metal carbide. Rhenium forms a solid solution with carbon at elevated temperatures. The metal carbide interlayer serves as a diffusion barrier to prevent carbon from migrating into contact with the rhenium containing protective coating. The metal carbide is formed by a conversion process wherein a refractory metal carbide former is allowed to react with carbon in the surface of the graphite. This structure is lighter and less expensive than corresponding solid rhenium components.Type: ApplicationFiled: November 11, 2017Publication date: March 8, 2018Applicant: UltrametInventors: Brian Williams, Victor M. Arrieta, Arthur J. Fortini
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Patent number: 9881699Abstract: A method for fabricating a cellular tritium breeder component includes obtaining a reticulated carbon foam skeleton comprising a network of interconnected ligaments. The foam skeleton is then melt-infiltrated with a tritium breeder material, for example, lithium zirconate or lithium titanate. The foam skeleton is then removed to define a cellular breeder component having a network of interconnected tritium purge channels. In an embodiment the ligaments of the foam skeleton are enlarged by adding carbon using chemical vapor infiltration (CVI) prior to melt-infiltration. In an embodiment the foam skeleton is coated with a refractory material, for example, tungsten, prior to melt infiltration.Type: GrantFiled: September 15, 2014Date of Patent: January 30, 2018Assignees: The Regents of the University of California, UltrametInventors: Robert Shahram Shaefer, Nasr M. Ghoniem, Brian Williams
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Publication number: 20140025179Abstract: Reticulated composites are formed with a thin coating of a ductile biocompatible metal such as tantalum on a brittle biocompatible substrate such as vitreous carbon. Such composites exhibit physical properties that permit these monolithic composites to be morselized, or sized and shaped manually. Such composites exhibit surfaces with excellent ductile metal biocompatibility properties, but with strength and fracture physical properties that are more characteristic of the brittle substrate than of the ductile metal. Such composites fracture easily, and may be morselized or worked by manual sizing and shaping. Such morselization and working is accomplished by breaking or fracturing the composite, rather than plastically deforming it. Morselized or manually shaped reticulated composites exhibit excellent biocompatibility characteristics with micro- and nano-textured surfaces that promote rapid bone ingrowth and adhesion. When the composite is broken, the substrate is exposed.Type: ApplicationFiled: March 14, 2013Publication date: January 23, 2014Applicant: UltrametInventors: Arthur J. Fortini, Richard Kaplan, Gregory Borwick
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Publication number: 20120114922Abstract: A graphite-metal carbide-rhenium article of manufacture is provided, which is suitable for use as a component in the hot zone of a rocket motor at operating temperatures in excess of approximately 3,000 degrees Celsius. One side of the metal carbide is chemically bonded to the surface of the graphite, and the rhenium containing protective coating is mechanically bonded to the other side of the metal carbide. Rhenium forms a solid solution with carbon at elevated temperatures. The metal carbide interlayer serves as a diffusion barrier to prevent carbon from migrating into contact with the rhenium containing protective coating. The metal carbide is formed by a conversion process wherein a refractory metal carbide former is allowed to react with carbon in the surface of the graphite. This structure is lighter and less expensive than corresponding solid rhenium components.Type: ApplicationFiled: October 19, 2011Publication date: May 10, 2012Applicant: UltrametInventors: Brian Williams, Victor Arrieta, Arthur J. Fortini
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Patent number: 7338540Abstract: A method of decomposing an organic azide is provided and comprises allowing an organic azide to contact a catalytic metal halide, main group halide, mixed metal-main group halide, or mixture thereof. Organic azide fuel sources comprising an organic azide/catalyst combination are also provided.Type: GrantFiled: August 5, 2003Date of Patent: March 4, 2008Assignee: Ultramet IncorporatedInventors: Jason R. Babcock, Arthur J. Fortini
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Patent number: 7297368Abstract: A method of making a carbon fiber-carbon matrix reinforced ceramic composite wherein the result is a carbon fiber-carbon matrix reinforcement is embedded within a ceramic matrix. The ceramic matrix does not penetrate into the carbon fiber-carbon matrix reinforcement to any significant degree. The carbide matrix is a formed in situ solid carbide of at least one metal having a melting point above about 1850 degrees centigrade. At least when the composite is intended to operate between approximately 1500 and 2000 degrees centigrade for extended periods of time the solid carbide with the embedded reinforcement is formed first by reaction infiltration. Molten silicon is then diffused into the carbide. The molten silicon diffuses preferentially into the carbide matrix but not to any significant degree into the carbon-carbon reinforcement.Type: GrantFiled: April 15, 2004Date of Patent: November 20, 2007Assignee: UltrametInventors: Brian Williams, Robert Benander
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Patent number: 6929866Abstract: A composite rigid foam structure that has a skin or coating on at least one of its surfaces. The skin is formed in situ by thermal spray techniques. The skin is bonded substantially throughout the surface of the porous substrate to the peripheries of the pores. The skin on the average does not penetrate the surface of the substrate by more than the depth of about 2 to 5 pores. Thus, thermal spraying the skin onto the rigid foam produces a composite that is tightly and uniformly bonded together without unduly increasing the weight of the composite structure. Both thermal conductivity and bonding are excellent.Type: GrantFiled: November 16, 1999Date of Patent: August 16, 2005Assignee: UltrametInventors: Brian E. Williams, Jerry Brockmeyer, Robert H. Tuffias
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Patent number: 6921707Abstract: A process for forming metal oxides, including mixed metal oxides, in a dilute vapor phase at a temperature below approximately 350 degrees Fahrenheit. The resulting novel oxides can be formed as dense films or coatings with very high strain-to-crack values, or as nanoparticles, depending primarily upon the concentration of the reactants. The novel oxides are formed by the reaction in the vapor phase of reactive metal molecules with atomic oxygen. The reactions are instantaneous at room temperature, which permits this process to be applied to the formation of metal oxides on temperature sensitive substrates. The atomic oxygen and highly reactive metal containing molecules are generated by the application of an effective amount of ultraviolet radiation.Type: GrantFiled: May 26, 2000Date of Patent: July 26, 2005Assignee: UltrametInventors: Alfred Zinn, David Scott
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Patent number: 6298764Abstract: A muzzle flash and blast suppressor comprising a body of reticulated refractory foam generally surrounding the projectile path adjacent the muzzle of a device. One side of the body of foam is exposed to the pressure within the projectile path just behind the projectile, and the other side is exposed to the unconfined ambient pressure. The foam is required to be possessed of sufficient structural strength to permit its exterior side to be exposed without confinement to the ambient environment. Hot exhaust gasses flowing laterally of the projectile path pass through the body from the high to the low pressure side. In such passage the gasses are cooled by expansion and by contact with the interstices of the body. Debris is filtered out and the pressure is substantially reduced. Typically, the refractory foam has from approximately 30 to 100 pores per inch and is from approximately 90 to 50 percent void volume.Type: GrantFiled: January 14, 2000Date of Patent: October 9, 2001Assignee: UltrametInventors: Andrew J. Sherman, Jerry Brockmeyer, Gregory Peters, Robert H. Tuffias
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Patent number: 6206531Abstract: A high precision composite optical mirror substrate comprising a lightweight reticulated foam core which is less than about 25 percent dense, an initially separate dense or small pore size faceplate mounted to the core, and a continuous formed in situ encapsulating coating. The coating fully encapsulates the ligaments throughout the reticulated foam core, the juncture between the core and the faceplate, and the faceplate, including the exposed face of the faceplate (the mirror surface). The exposed face of the dense faceplate is shaped to about the desired mirror surface shape. The deposit of coating material on the exposed face of the faceplate is near net shape to the desired mirror surface. The physical characteristics of the composite substrate are dominated by the properties of the coating material. When the coating material is a chemical vapor deposit of silicon carbide, the interlayer is preferably graphite with a thermal expansion coefficient that closely matches that of the silicon carbide.Type: GrantFiled: May 25, 1999Date of Patent: March 27, 2001Assignees: Ultramet, Ono LabratioriesInventors: Brian E. Williams, Russell M. Ono
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Patent number: 6103149Abstract: A method of manufacturing and the resultant reticulated open cell carbon foam with a controlled aspect ratio between 0.6 to 1.2 throughout the body of the foam billet by controlling the exothermic reaction of the resin system below the decomposition temperature of the foam.Type: GrantFiled: July 12, 1996Date of Patent: August 15, 2000Assignee: UltrametInventor: Edwin P. Stankiewicz
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Patent number: 6040266Abstract: A method of producing an acoustic baffle/catalyst foam support material and the resultant material. A polyurethane open cell foam material is provided having a density between 10-100 ppi. The polyurethane foam is infiltrated with a resin material to produce an impregnated foam. The impregnated foam is pyrolized to form a carbon skeleton forming a carbon foam. The carbon foam skeleton is coated with one or more of the following group of materials to a relative density of five to thirty five (5-35) percent, the group of materials being SiC, Si.sub.3 N.sub.4, MoSi.sub.2 or high temperature metal.Type: GrantFiled: February 22, 1994Date of Patent: March 21, 2000Assignee: UltrametInventors: Thomas F. Fay, III, Raffaele La Ferla, Andrew J. Sherman, Edwin P. Stankiewicz
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Patent number: 5935351Abstract: The present invention is a metallic composite which is resistant to erosion and corrosion at the high temperatures and pressures which are encountered in gun tubes, including projectile launchers. This composite comprises a ductile layer of rhenium or a rhenium alloy containing more than 20 percent rhenium, and a layer of a lower cost high strength material such as steel, nickel, nickel alloy, cobalt, or cobalt alloy. A solid solution of the two metals is formed between the two layers making a metallurgical bond. The metallurgical bond may be enhanced through the use of a bond promoter having solubility with both metallic layers.Type: GrantFiled: November 14, 1997Date of Patent: August 10, 1999Assignee: UltrametInventors: Andrew Sherman, Victor Arrietta
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Patent number: 5928799Abstract: The present invention is a metallic composite which is resistant to erosion and corrosion at the high temperatures and pressures which are encountered in gun tubes, including projectile launchers. This composite comprises a ductile layer of rhenium or a rhenium alloy containing more than 20 percent rhenium, and a layer of a lower cost high strength material such as steel, nickel, nickel alloy, cobalt, or cobalt alloy. A solid solution of the two metals is formed between the two layers making a metallurgical bond. The metallurgical bond may be enhanced through the use of a bond promoter having solubility with both metallic layers.Type: GrantFiled: June 14, 1995Date of Patent: July 27, 1999Assignee: UltrametInventors: Andrew Sherman, Victor Arrietta
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Patent number: 5876793Abstract: The invention relates to the encapsulation of Geldhart class C substrate powders with a coating of metal, binder, or sintering aid. Encapsulation is achieved using chemical vapor deposition techniques in a recirculating fast-fluidized or turbulent fluidization flow bed reactor. Thin, smooth, generally uniform, fully encapsulating coatings are produced on the fine substrate particles. The coated Geldhart class C particles, and products made therefrom, exhibit excellent improved physical properties.Type: GrantFiled: February 21, 1996Date of Patent: March 2, 1999Assignee: UltrametInventors: Andrew Sherman, Victor Arrietta
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Patent number: 5855828Abstract: A refractory composite structure is formed which comprises a ductile refractory metallic layer with a roughened surface which is tightly bonded to a refractory composite structural shell. The roughened surface is preferably dendritic in form and produced by chemical vapor deposition techniques. The refractory composite structural shell is preferably a carbon-carbon composite formed by applying a carbon filament preform to the roughened surface, infiltrating the preform with a carbon matrix precursor, and carbonizing the precursor.Type: GrantFiled: June 7, 1995Date of Patent: January 5, 1999Assignee: UltrametInventors: Robert H. Tuffias, Brian E. Williams, Richard B. Kaplan
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Patent number: 5780157Abstract: A refractory composite structure comprising a ductile refractory metallic layer with a roughened surface which is tightly bonded to a refractory composite structural shell. The roughened surface is dendritic in form and is produced by chemical vapor deposition techniques.Type: GrantFiled: June 6, 1994Date of Patent: July 14, 1998Assignee: UltrametInventors: Robert H. Tuffias, Brian E. Williams, Richard B. Kaplan
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Patent number: 5372380Abstract: An airbag assembly including an inflatable airbag, an ignitable propellant charge for generating inflating gas and a filter between the interior of the airbag and the propellant charge. The filter comprising a porous carbon foam substrate coated substantially throughout with a thermally and structurally stable material which has been formed in situ by chemical vapor deposition techniques.Type: GrantFiled: May 20, 1993Date of Patent: December 13, 1994Assignee: UltrametInventors: Andrew J. Duffy, Richard B. Kaplan, Stanley A. Racik, Edwin P. Stankiewicz, Robert H. Tuffias, Brian E. Williams
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Patent number: 5283109Abstract: A high temperature resistant structure which is capable of withstanding temperatures well in excess of 2500 degrees Fahrenheit in oxidizing environments for periods of at least several hours. A high temperature resistant substrate such as carbon carbon composite is coated in situ with very thin alternate layers of silicon carbide and a carbide formed from hafnium or zirconium. The coating is preferably formed using chemical vapor deposition procedures.Type: GrantFiled: April 15, 1991Date of Patent: February 1, 1994Assignee: UltrametInventors: Richard B. Kaplan, Hugh O. Pierson, J. Grady Sheek, Robert H. Tuffias, Brian E. Williams
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Patent number: 5282861Abstract: A tantalum open cell structure is formed by chemical vapor deposition onto a reticulated carbon foam substrate. Tantalum has a long history of use as an implant material, in both bone and soft tissue. This lightweight, strong, porous structure, mimicking the microstructure of natural cancellous bone, acts as a matrix for the incorporation of bone, providing optimal permeability and a high surface area to encourage new bone ingrowth.Type: GrantFiled: March 11, 1992Date of Patent: February 1, 1994Assignee: UltrametInventor: Richard B. Kaplan