Patents by Inventor Michael S. KESLER
Michael S. KESLER 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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Patent number: 11718898Abstract: An alloy includes aluminum, a rare earth element, and an alloying element selected from the following: Si, Cu, Mg, Fe, Ti, Zn, Zr, Mn, Ni, Sr, B, Ca, and a combination thereof. The aluminum (Al), the rare earth element (RE), and the alloying element are characterized by forming at least one form of an intermetallic compound. An amount of the rare earth element in the alloy is in a range of about 1 wt. % to about 12 wt. %, and an amount of the alloying element in the alloy is greater than an amount of the alloying element present in the intermetallic compound.Type: GrantFiled: July 13, 2020Date of Patent: August 8, 2023Assignees: Lawrence Livermore National Security, LLC, University of Tennessee Research Foundation, Iowa State University Research Foundation, Inc., UT-Battelle, LLC, Eck Industries, Inc.Inventors: Emily E. Moore, Hunter B. Henderson, Aurelien Perron, Scott K. McCall, Orlando Rios, Zachary C. Sims, Michael S. Kesler, David Weiss, Patrice E. A. Turchi, Ryan T. Ott
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Patent number: 11667996Abstract: A solid aluminum-fiber composite comprising: (i) an aluminum-containing matrix comprising elemental aluminum; (ii) coated or uncoated fibers embedded within said aluminum-containing matrix, wherein said fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said fibers embedded therein; and (iii) an intermetallic layer present as an interface between each of said fibers and the aluminum-containing matrix, wherein said intermetallic layer has a composition different from said aluminum-containing matrix and said fibers, and said intermetallic layer contains at least one element that is also present in the aluminum-containing matrix and at least one element present in the fibers, whether from the coated or interior portion of the fibers. Methods of producing the above-described composite are also described.Type: GrantFiled: November 29, 2018Date of Patent: June 6, 2023Assignees: UT-Battelle, LLC, Eck Industries, Inc.Inventors: Orlando Rios, Michael S. Kesler, Zachary C. Sims, Edgar Lara-Curzio, David Weiss
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Patent number: 11565318Abstract: A reactive matrix infiltration process is described herein, which includes contacting a surface of a preform comprising reinforcement material particles with a molten infiltrant comprising a matrix material, the matrix material comprising an Al—Ce alloy, whereby the infiltrant at least partially fills spaces between the reinforcement material particles by capillary action and reacts with the reinforcement material particles to form a composite material form, the composite material comprising the matrix material, at least one intermetallic phase, and, optionally, reinforcement material particles. A composite material form also is described, which includes a plurality of reinforcement material particles comprising a metal alloy or a ceramic, a matrix material at least partially filling spaces between the reinforcement material particles; and at least one intermetallic phase surrounding at least some of the reinforcement material particles.Type: GrantFiled: September 3, 2020Date of Patent: January 31, 2023Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation, Eck Industries IncorporatedInventors: Orlando Rios, Craig A. Bridges, Amelia M. Elliott, Hunter B. Henderson, Michael S. Kesler, Zachary Sims, David Weiss
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Patent number: 11535912Abstract: An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.Type: GrantFiled: June 29, 2021Date of Patent: December 27, 2022Assignees: UT-Battelle, LLC, Eck Industries, Inc.Inventors: Orlando Rios, David Weiss, Zachary C. Sims, William G. Carter, Michael S. Kesler
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Patent number: 11365463Abstract: The disclosure concerns methods for making a composition comprising a light metal and an intermetallic comprising the light metal and a light rare earth element. The composition also may include a plurality of nanoparticles comprising an oxide of the light metal. The method includes directly reducing a light rare earth element precursor compound in a melt of the light metal, thereby forming the light rare earth element and nanoparticles of the light metal oxide.Type: GrantFiled: February 4, 2020Date of Patent: June 21, 2022Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation, Eck Industries Incorporated, Iowa State University Research Foundation, Inc., Colorado School of Mines, Lawrence Livermore National Security, LLCInventors: Orlando Rios, Hunter B. Henderson, Michael S. Kesler, Bruce A. Moyer, Zachary Sims, David Weiss, Ryan Ott, Corby Anderson, Hao Cui, Scott McCall
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Publication number: 20220145486Abstract: A product includes an aluminum alloy having an anodized layer. The alloy has a bulk composition including at least 1 wt. % of one or more rare earth elements (REEs). A product includes microstructures extending across a boundary defined between an anodized layer and an unoxidized alloy. Each microstructure includes an intermetallic phase transitioning to an oxidized intermetallic phase across the boundary. A product includes an anodized layer where up to 90% of a thickness of the layer includes voids resulting at least in part from dissolution of a rare earth element oxidized intermetallic phase. The voids are in a morphology of the dissolved oxidized intermetallic phase.Type: ApplicationFiled: November 9, 2021Publication date: May 12, 2022Inventors: Scott K. McCall, David Weiss, Michael S. Kesler, Michael J. Thompson, Orlando Rios, Hunter B. Henderson, Zachary Cole Sims, Ryan T. Ott
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Publication number: 20210355565Abstract: The disclosure concerns methods for making a composition comprising a light metal and an intermetallic comprising the light metal and a light rare earth element. The composition also may include a plurality of nanoparticles comprising an oxide of the light metal. The method includes directly reducing a light rare earth element precursor compound in a melt of the light metal, thereby forming the light rare earth element and nanoparticles of the light metal oxide.Type: ApplicationFiled: February 4, 2020Publication date: November 18, 2021Inventors: Orlando Rios, Hunter B. Henderson, Michael S. Kesler, Bruce A. Moyer, Zachary Sims, David Weiss, Ryan Ott, Corby Anderson, Hao Cui
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Publication number: 20210324500Abstract: An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.Type: ApplicationFiled: June 29, 2021Publication date: October 21, 2021Applicants: UT-Battelle, LLC, Eck Industries, Inc.Inventors: Orlando RIOS, David WEISS, Zachary C. SIMS, William G. CARTER, Michael S. KESLER
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Publication number: 20210108292Abstract: An alloy includes aluminum, a rare earth element, and an alloying element selected from the following: Si, Cu, Mg, Fe, Ti, Zn, Zr, Mn, Ni, Sr, B, Ca, and a combination thereof. The aluminum (Al), the rare earth element (RE), and the alloying element are characterized by forming at least one form of an intermetallic compound. An amount of the rare earth element in the alloy is in a range of about 1 wt. % to about 12 wt. %, and an amount of the alloying element in the alloy is greater than an amount of the alloying element present in the intermetallic compound.Type: ApplicationFiled: July 13, 2020Publication date: April 15, 2021Inventors: Emily E. Moore, Hunter B. Henderson, Aurelien Perron, Scott K. McCall, Orlando Rios, Zachary C. Sims, Michael S. Kesler, David Weiss, Patrice E. A. Turchi, Ryan T. Ott
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Publication number: 20210060652Abstract: A reactive matrix infiltration process is described herein, which includes contacting a surface of a preform comprising reinforcement material particles with a molten infiltrant comprising a matrix material, the matrix material comprising an Al—Ce alloy, whereby the infiltrant at least partially fills spaces between the reinforcement material particles by capillary action and reacts with the reinforcement material particles to form a composite material form, the composite material comprising the matrix material, at least one intermetallic phase, and, optionally, reinforcement material particles. A composite material form also is described, which includes a plurality of reinforcement material particles comprising a metal alloy or a ceramic, a matrix material at least partially filling spaces between the reinforcement material particles; and at least one intermetallic phase surrounding at least some of the reinforcement material particles.Type: ApplicationFiled: September 3, 2020Publication date: March 4, 2021Inventors: Orlando Rios, Craig A. Bridges, Amelia M. Elliott, Hunter B. Henderson, Michael S. Kesler, Zachary Sims, David Weiss
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Patent number: 10782193Abstract: An example apparatus can comprise an emitter to emit radio frequency radiation, an absorber that changes temperature based on emissions from the emitter, and one or more sensors to measure a temperature difference between a sample and a reference coupled to the absorber.Type: GrantFiled: September 1, 2017Date of Patent: September 22, 2020Assignees: UT-Battelle, LLC, Iowa State University Research Foundation, Inc.Inventors: Tom Byvank, Benjamin S. Conner, Roger A. Kisner, Michael A. McGuire, Orlando Rios, Michael S. Kesler, Gerard M. Ludtka, Boyd Evans, Cajetan Ikenna Niebedim, Ralph William McCallum
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Publication number: 20190169725Abstract: A solid aluminum-fiber composite comprising: (i) an aluminum-containing matrix comprising elemental aluminum; (ii) coated or uncoated fibers embedded within said aluminum-containing matrix, wherein said fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said fibers embedded therein; and (iii) an intermetallic layer present as an interface between each of said fibers and the aluminum-containing matrix, wherein said intermetallic layer has a composition different from said aluminum-containing matrix and said fibers, and said intermetallic layer contains at least one element that is also present in the aluminum-containing matrix and at least one element present in the fibers, whether from the coated or interior portion of the fibers. Methods of producing the above-described composite are also described.Type: ApplicationFiled: November 29, 2018Publication date: June 6, 2019Inventors: Orlando RIOS, Michael S. KESLER, Zachary C. SIMS, Edgar LARA-CURZIO, David WEISS
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Publication number: 20170362687Abstract: An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.Type: ApplicationFiled: June 16, 2017Publication date: December 21, 2017Inventors: Orlando RIOS, David WEISS, Zachary C. SIMS, William G. CARTER, Michael S. KESLER