Patents Assigned to Ultramet
  • Publication number: 20180066366
    Abstract: 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: Application
    Filed: November 11, 2017
    Publication date: March 8, 2018
    Applicant: Ultramet
    Inventors: Brian Williams, Victor M. Arrieta, Arthur J. Fortini
  • Patent number: 9881699
    Abstract: 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: Grant
    Filed: September 15, 2014
    Date of Patent: January 30, 2018
    Assignees: The Regents of the University of California, Ultramet
    Inventors: Robert Shahram Shaefer, Nasr M. Ghoniem, Brian Williams
  • Publication number: 20140025179
    Abstract: 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: Application
    Filed: March 14, 2013
    Publication date: January 23, 2014
    Applicant: Ultramet
    Inventors: Arthur J. Fortini, Richard Kaplan, Gregory Borwick
  • Publication number: 20120114922
    Abstract: 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: Application
    Filed: October 19, 2011
    Publication date: May 10, 2012
    Applicant: Ultramet
    Inventors: Brian Williams, Victor Arrieta, Arthur J. Fortini
  • Patent number: 7338540
    Abstract: 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: Grant
    Filed: August 5, 2003
    Date of Patent: March 4, 2008
    Assignee: Ultramet Incorporated
    Inventors: Jason R. Babcock, Arthur J. Fortini
  • Patent number: 7297368
    Abstract: 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: Grant
    Filed: April 15, 2004
    Date of Patent: November 20, 2007
    Assignee: Ultramet
    Inventors: Brian Williams, Robert Benander
  • Patent number: 6929866
    Abstract: 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: Grant
    Filed: November 16, 1999
    Date of Patent: August 16, 2005
    Assignee: Ultramet
    Inventors: Brian E. Williams, Jerry Brockmeyer, Robert H. Tuffias
  • Patent number: 6921707
    Abstract: 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: Grant
    Filed: May 26, 2000
    Date of Patent: July 26, 2005
    Assignee: Ultramet
    Inventors: Alfred Zinn, David Scott
  • Patent number: 6298764
    Abstract: 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: Grant
    Filed: January 14, 2000
    Date of Patent: October 9, 2001
    Assignee: Ultramet
    Inventors: Andrew J. Sherman, Jerry Brockmeyer, Gregory Peters, Robert H. Tuffias
  • Patent number: 6206531
    Abstract: 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: Grant
    Filed: May 25, 1999
    Date of Patent: March 27, 2001
    Assignees: Ultramet, Ono Labratiories
    Inventors: Brian E. Williams, Russell M. Ono
  • Patent number: 6103149
    Abstract: 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: Grant
    Filed: July 12, 1996
    Date of Patent: August 15, 2000
    Assignee: Ultramet
    Inventor: Edwin P. Stankiewicz
  • Patent number: 6040266
    Abstract: 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: Grant
    Filed: February 22, 1994
    Date of Patent: March 21, 2000
    Assignee: Ultramet
    Inventors: Thomas F. Fay, III, Raffaele La Ferla, Andrew J. Sherman, Edwin P. Stankiewicz
  • Patent number: 5935351
    Abstract: 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: Grant
    Filed: November 14, 1997
    Date of Patent: August 10, 1999
    Assignee: Ultramet
    Inventors: Andrew Sherman, Victor Arrietta
  • Patent number: 5928799
    Abstract: 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: Grant
    Filed: June 14, 1995
    Date of Patent: July 27, 1999
    Assignee: Ultramet
    Inventors: Andrew Sherman, Victor Arrietta
  • Patent number: 5876793
    Abstract: 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: Grant
    Filed: February 21, 1996
    Date of Patent: March 2, 1999
    Assignee: Ultramet
    Inventors: Andrew Sherman, Victor Arrietta
  • Patent number: 5855828
    Abstract: 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: Grant
    Filed: June 7, 1995
    Date of Patent: January 5, 1999
    Assignee: Ultramet
    Inventors: Robert H. Tuffias, Brian E. Williams, Richard B. Kaplan
  • Patent number: 5780157
    Abstract: 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: Grant
    Filed: June 6, 1994
    Date of Patent: July 14, 1998
    Assignee: Ultramet
    Inventors: Robert H. Tuffias, Brian E. Williams, Richard B. Kaplan
  • Patent number: 5372380
    Abstract: 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: Grant
    Filed: May 20, 1993
    Date of Patent: December 13, 1994
    Assignee: Ultramet
    Inventors: Andrew J. Duffy, Richard B. Kaplan, Stanley A. Racik, Edwin P. Stankiewicz, Robert H. Tuffias, Brian E. Williams
  • Patent number: 5283109
    Abstract: 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: Grant
    Filed: April 15, 1991
    Date of Patent: February 1, 1994
    Assignee: Ultramet
    Inventors: Richard B. Kaplan, Hugh O. Pierson, J. Grady Sheek, Robert H. Tuffias, Brian E. Williams
  • Patent number: 5282861
    Abstract: 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: Grant
    Filed: March 11, 1992
    Date of Patent: February 1, 1994
    Assignee: Ultramet
    Inventor: Richard B. Kaplan