Patents by Inventor Brennan YAHATA
Brennan YAHATA has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240087780Abstract: Some variations provide a permanent-magnet structure comprising: a region having a plurality of magnetic domains and a region-average magnetic axis, wherein each of the magnetic domains has a domain magnetic axis that is substantially aligned with the region-average magnetic axis, and wherein the plurality of magnetic domains is characterized by an average magnetic domain size. Within the region, there is a plurality of metal-containing grains characterized by an average grain size, and each of the magnetic domains has a domain easy axis that is dictated by a crystallographic texture of the metal-containing grains. The region has a region-average easy axis based on the average value of the domain easy axis within that region. The region-average magnetic axis and the region-average easy axis form a region-average alignment angle that has a standard deviation less than 30° within the plurality of magnetic domains. Many permanent-magnet structures are disclosed herein.Type: ApplicationFiled: November 15, 2023Publication date: March 14, 2024Inventors: Brennan YAHATA, Eric CLOUGH, Christopher HENRY, Amber SUCICH, Darby LAPLANT, Tobias SCHAEDLER
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Publication number: 20240082913Abstract: 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.Type: ApplicationFiled: November 22, 2023Publication date: March 14, 2024Inventors: John H. MARTIN, Brennan YAHATA, Tobias A. SCHAEDLER, Jacob M. HUNDLEY
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Patent number: 11919085Abstract: 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.Type: GrantFiled: May 27, 2021Date of Patent: March 5, 2024Assignee: HRL Laboratories, LLCInventors: John H. Martin, Brennan Yahata, Tobias A. Schaedler, Jacob M. Hundley
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Patent number: 11862369Abstract: Some variations provide a permanent-magnet structure comprising: a region having a plurality of magnetic domains and a region-average magnetic axis, wherein each of the magnetic domains has a domain magnetic axis that is substantially aligned with the region-average magnetic axis, and wherein the plurality of magnetic domains is characterized by an average magnetic domain size. Within the region, there is a plurality of metal-containing grains characterized by an average grain size, and each of the magnetic domains has a domain easy axis that is dictated by a crystallographic texture of the metal-containing grains. The region has a region-average easy axis based on the average value of the domain easy axis within that region. The region-average magnetic axis and the region-average easy axis form a region-average alignment angle that has a standard deviation less than 30° within the plurality of magnetic domains. Many permanent-magnet structures are disclosed herein.Type: GrantFiled: June 26, 2021Date of Patent: January 2, 2024Assignee: HRL Laboratories, LLCInventors: Brennan Yahata, Eric Clough, Christopher Henry, Amber Sucich, Darby Laplant, Tobias Schaedler
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Publication number: 20230398604Abstract: Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.Type: ApplicationFiled: June 1, 2023Publication date: December 14, 2023Inventors: John H. MARTIN, Brennan YAHATA, Adam F. GROSS
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METHODS FOR TAILORING THE MAGNETIC PERMEABILITY OF SOFT MAGNETS, AND SOFT MAGNETS OBTAINED THEREFROM
Publication number: 20230321757Abstract: Some variations provide a method of tailoring the surface of a soft magnet, comprising: depositing an austenite-phase-stabilizing donor material on one or more first surface regions of a ferromagnetic receiver material; not depositing the austenite-phase-stabilizing donor material on one or more second surface regions of the ferromagnetic receiver material; laser melting the austenite-phase-stabilizing donor material into the first surface regions; and solidifying the molten austenite-phase-stabilizing donor material within the first surface regions, thereby selectively alloying the ferromagnetic receiver material in the first surface regions. Laser ablation may be utilized instead of laser melting. The first surface regions have a significantly higher magnetic permeability, following the selective alloying of the donor material, compared to the second surface regions. Soft magnets with surface-tailored magnetic permeability are provided by this technology, which is demonstrated using several examples.Type: ApplicationFiled: January 30, 2023Publication date: October 12, 2023Inventors: Amber SUCICH, Eric CLOUGH, Brennan YAHATA, Darby LAPLANT -
Publication number: 20230326637Abstract: This invention provides methods for fabricating a hard or soft magnet with tailorable magnetic and crystallographic orientations. Methods are disclosed to individually tailor three-dimensional voxels for selected crystallographic orientations and, independently, selected magnetic orientations with location specificity throughout a magnet.Type: ApplicationFiled: June 14, 2023Publication date: October 12, 2023Inventors: Brennan YAHATA, Eric CLOUGH, Christopher HENRY, Amber SUCICH, Darby LAPLANT, Tobias SCHAEDLER
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Publication number: 20230282398Abstract: The disclosed technology provides a nanofunctionalized magnetic material feedstock comprising: from 50 wt % to 99.5 wt % of magnetic microparticles having an average microparticle effective diameter from 1 micron to 500 microns; from 0.4 wt % to 40 wt % of one or more rare earth elements; and from 0.1 wt % to 10 wt % of metal-containing inoculant nanoparticles, wherein at least 1 wt % of the inoculant nanoparticles are chemically and/or physically disposed on surfaces of the magnetic microparticles. The nanofunctionalized magnetic material feedstock is processed using high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.Type: ApplicationFiled: February 24, 2023Publication date: September 7, 2023Inventors: Brennan YAHATA, Adam GROSS, Christopher HENRY, Darby LAPLANT, Amber SUCICH, Raymond NGUYEN, Christine KIM
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Publication number: 20230282397Abstract: The disclosed technology provides a cladded permanent magnet comprising: a core magnet region containing a core magnetic material; and a magnet cladding containing a shell magnetic material comprising (i) a magnetic compound that is chemically the same as the core magnetic material, (ii) one or more rare earth elements, and (iii) metal-containing inoculant nanoparticles, wherein the magnet cladding is disposed on the core magnet region, wherein the magnet cladding has at least 10% higher ambient-temperature magnetic coercivity compared to the core magnet region. The cladded permanent magnet is made via high-throughput laser-based additive manufacturing to optimize the architecture of NdFeB or other magnets, generating site-specific, demagnetization-resistant microstructures. This disclosure teaches a rapid, single-step laser-based process to tailor the easy axis alignment, grain size, and microstructure of a permanent magnet at corners and edges to resist demagnetization.Type: ApplicationFiled: February 24, 2023Publication date: September 7, 2023Inventors: Brennan YAHATA, Adam GROSS, Christopher HENRY, Darby LAPLANT, Amber SUCICH, Raymond NGUYEN, Christine KIM
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Patent number: 11721458Abstract: This invention provides methods for fabricating a hard or soft magnet with tailorable magnetic and crystallographic orientations. Methods are disclosed to individually tailor three-dimensional voxels for selected crystallographic orientations and, independently, selected magnetic orientations with location specificity throughout a magnet.Type: GrantFiled: June 26, 2021Date of Patent: August 8, 2023Assignee: HRL Laboratories, LLCInventors: Brennan Yahata, Eric Clough, Christopher Henry, Amber Sucich, Darby Laplant, Tobias Schaedler
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Patent number: 11701709Abstract: Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.Type: GrantFiled: April 2, 2021Date of Patent: July 18, 2023Assignee: HRL Laboratories, LLCInventors: John H. Martin, Brennan Yahata, Adam F. Gross
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Patent number: 11608548Abstract: Provided are maraging steel alloys having improved microstructures. Some variations provide maraging steel alloys including a base maraging steel alloy, a grain refiner, and optionally, a strengthening element. The base maraging steel alloy is surface-functionalized with the grain refiner. Other variations provide a method of method of manufacturing maraging steel including mixing a base maraging steel alloy with a grain refiner resulting in a maraging steel mixture, melting the maraging steel mixture, and solidifying the maraging steel mixture forming an equiaxed microstructure.Type: GrantFiled: October 1, 2019Date of Patent: March 21, 2023Assignee: THE BOEING COMPANYInventors: Brennan Yahata, Julie Miller, John H. Martin
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Publication number: 20220314316Abstract: Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail.Type: ApplicationFiled: June 10, 2022Publication date: October 6, 2022Inventors: John H. MARTIN, Tobias A. SCHAEDLER, Brennan YAHATA, Jacob M. HUNDLEY, Jason A. GRAETZ, Adam F. GROSS, William CARTER
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Patent number: 11446735Abstract: Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail.Type: GrantFiled: May 8, 2020Date of Patent: September 20, 2022Assignee: HRL Laboratories, LLCInventors: John H. Martin, Tobias A. Schaedler, Brennan Yahata, Jacob M. Hundley, Jason A. Graetz, Adam F. Gross, William Carter
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Patent number: 11286543Abstract: Some variations provide an additively manufactured aluminum alloy comprising from 84.5 wt % to 92.1 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 1.8 wt % to 2.9 wt % magnesium; from 4.5 wt % to 6.1 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium. The additively manufactured aluminum alloy is in the form of a three-dimensional component. The zirconium functions as a grain-refiner element within the additively manufactured aluminum alloy. The additively manufactured aluminum alloy may be characterized by an average grain size of less than 10 microns. The additively manufactured aluminum alloy may have a substantially crack-free microstructure with equiaxed grains.Type: GrantFiled: January 30, 2019Date of Patent: March 29, 2022Assignee: HRL Laboratories, LLCInventors: John H. Martin, Brennan Yahata
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Publication number: 20220044870Abstract: This invention provides methods for fabricating a hard or soft magnet with tailorable magnetic and crystallographic orientations. Methods are disclosed to individually tailor three-dimensional voxels for selected crystallographic orientations and, independently, selected magnetic orientations with location specificity throughout a magnet.Type: ApplicationFiled: June 26, 2021Publication date: February 10, 2022Inventors: Brennan YAHATA, Eric CLOUGH, Christopher HENRY, Amber SUCICH, Darby LAPLANT, Tobias SCHAEDLER
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Publication number: 20220044851Abstract: Some variations provide a permanent-magnet structure comprising: a region having a plurality of magnetic domains and a region-average magnetic axis, wherein each of the magnetic domains has a domain magnetic axis that is substantially aligned with the region-average magnetic axis, and wherein the plurality of magnetic domains is characterized by an average magnetic domain size. Within the region, there is a plurality of metal-containing grains characterized by an average grain size, and each of the magnetic domains has a domain easy axis that is dictated by a crystallographic texture of the metal-containing grains. The region has a region-average easy axis based on the average value of the domain easy axis within that region. The region-average magnetic axis and the region-average easy axis form a region-average alignment angle that has a standard deviation less than 30° within the plurality of magnetic domains. Many permanent-magnet structures are disclosed herein.Type: ApplicationFiled: June 26, 2021Publication date: February 10, 2022Inventors: Brennan YAHATA, Eric CLOUGH, Christopher HENRY, Amber SUCICH, Darby LAPLANT, Tobias SCHAEDLER
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Publication number: 20210283689Abstract: 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.Type: ApplicationFiled: May 27, 2021Publication date: September 16, 2021Inventors: John H. MARTIN, Brennan YAHATA, Tobias A. SCHAEDLER, Jacob M. HUNDLEY
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Patent number: 11117193Abstract: 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.Type: GrantFiled: January 25, 2018Date of Patent: September 14, 2021Assignee: HRL Laboratories, LLCInventors: John H. Martin, Brennan Yahata, Tobias A. Schaedler, Jacob M. Hundley
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Publication number: 20210220909Abstract: Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.Type: ApplicationFiled: April 2, 2021Publication date: July 22, 2021Inventors: John H. MARTIN, Brennan YAHATA, Adam F. GROSS