Patents by Inventor Ali Unal
Ali Unal 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: 20170009325Abstract: The present invention, in some embodiments, is a method of forming an O temper or T temper product that includes obtaining a coil of a non-ferrous alloy strip as feedstock; uncoiling the coil of the feedstock; heating the feedstock to a temperature between a recrystallization temperature of the non-ferrous alloy and 10 degrees Fahrenheit below a solidus temperature of the non-ferrous alloy; and quenching the feedstock to form a heat-treated product having am O temper or T temper. The non-ferrous alloy strip used in the method excludes aluminum alloys having 0.4 weight percent silicon, less than 0.2 weight percent iron, 0.35 to 0.40 weight percent copper, 0.9 weight percent manganese, and 1 weight percent magnesium.Type: ApplicationFiled: July 7, 2015Publication date: January 12, 2017Inventors: Gavin F. Wyatt-Mair, David A. Tomes, William D. Bennon, Raymond J. Kilmer, James C. Riggs, Ali Unal, John M. Newman, Thomas N. Rouns
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Publication number: 20150191810Abstract: Systems and methods for continuously casting Al—Mg alloy sheet or plate product having a high amount of magnesium are disclosed. The Al—Mg products have 4 or 6 to 8 or 10 wt, % Mg and are resistant to both stress corrosion cracking and intergranular corrosion.Type: ApplicationFiled: January 7, 2015Publication date: July 9, 2015Inventors: Ali Unal, David A. Tomes, JR., Gavin Wyatt-Mair, David Timmons
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Publication number: 20150071816Abstract: An aluminum alloy product and method for producing the aluminum alloy product that, in some embodiments, includes an aluminum alloy strip having at least 0.8 wt. % manganese, at least 0.6 wt % iron, or at least 0.8 wt. % manganese and at least 0.6 wt % iron. A near surface of the aluminum alloy strip, in some embodiments, is substantially free of large particles having an equivalent diameter of at least 50 micrometers and includes small particles. Each small particle, in some embodiments, has a particular equivalent diameter that is less than 3 micrometers, and a quantity per unit area of the small particles having the particular equivalent diameter is at least 0.01 particles per square micrometer at the near surface of the aluminum alloy strip.Type: ApplicationFiled: September 8, 2014Publication date: March 12, 2015Inventors: Ali Unal, Gavin F. Wyatt-Mair, David A. Tomes, Thomas N. Rouns, Lynette M. Karabin
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Patent number: 8956472Abstract: Systems and methods for continuously casting Al—Mg alloy sheet or plate product having a high amount of magnesium are disclosed. The Al—Mg products have 4 or 6 to 8 or 10 wt. % Mg and are resistant to both stress corrosion cracking and intergranular corrosion.Type: GrantFiled: November 7, 2008Date of Patent: February 17, 2015Assignee: Alcoa Inc.Inventors: Ali Unal, David A. Tomes, Jr., Gavin Wyatt-Mair, David Timmons
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Patent number: 8697248Abstract: The present invention discloses an aluminum alloy product having a first outer layer, a central layer, and a second outer layer. The central layer of the aluminum alloy product has a higher concentration of particulate matter than said first or second outer layers. The particular matter has a size of at least about 30 microns. And, the aluminum alloy product has a thickness ranging from between about 0.004 inches to about 0.25 inches.Type: GrantFiled: October 28, 2010Date of Patent: April 15, 2014Assignee: Alcoa Inc.Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Patent number: 8403027Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).Type: GrantFiled: April 11, 2007Date of Patent: March 26, 2013Assignee: Alcoa Inc.Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Patent number: 8381796Abstract: A method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particulate matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product including a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.Type: GrantFiled: October 28, 2010Date of Patent: February 26, 2013Assignee: ALCOA Inc.Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Publication number: 20110042032Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particular matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.Type: ApplicationFiled: October 28, 2010Publication date: February 24, 2011Inventors: David A. Tomes, JR., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Publication number: 20110036464Abstract: The present invention discloses an aluminum alloy product having a first outer layer, a central layer, and a second outer layer. The central layer of the aluminum alloy product has a higher concentration of particulate matter than said first or second outer layers. The particular matter has a size of at least about 30 microns. And, the aluminum alloy product has a thickness ranging from between about 0.004 inches to about 0.25 inches.Type: ApplicationFiled: October 28, 2010Publication date: February 17, 2011Inventors: David A. Tomes, JR., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Patent number: 7846554Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of an inner layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces. The method yields an MMC having a central layer enriched with particulate matter and sandwiched between metallic outer layers.Type: GrantFiled: April 11, 2007Date of Patent: December 7, 2010Assignee: Alcoa Inc.Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Publication number: 20100119407Abstract: Systems and methods for continuously casting Al—Mg alloy sheet or plate product having a high amount of magnesium are disclosed. The Al—Mg products have 4 or 6 to 8 or 10 wt. % Mg and are resistant to both stress corrosion cracking and intergranular corrosion.Type: ApplicationFiled: November 7, 2008Publication date: May 13, 2010Applicant: Alcoa Inc.Inventors: Ali Unal, David A. tomes, JR., Gavin Wyatt-Mair, David Timmons
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Publication number: 20100084053Abstract: The present invention discloses a product comprising a 1xxx, 3xxx and 8xxx series aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product. The product has an O-temper tensile strength, O-temper elongation, and O-temper Mullen pressure that are at least 10% greater compared to the average values of the same alloy in O-temper cast using a slab or roll-casting process. The product is substantially free of pinholes caused by centerline segregation of intermetallic particles. In another embodiment, the present invention discloses a 8111 or 8921 aluminum alloy made by a non-ingot casting process, where the aluminum alloy has a thickness of about 5 micrometers to about 150 micrometers for a foil product.Type: ApplicationFiled: October 7, 2008Publication date: April 8, 2010Inventors: David Tomes, David W. Timmons, Gavin F. Wyatt-Mair, Ali Unal, John W. Collins, III
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Patent number: 7503377Abstract: A method and apparatus for continuous casting of metal strip, the apparatus having (i) a first endless belt supported and moved on the surfaces of a first entry pulley and a first exit pulley and (ii) a second endless belt supported and moved on the surfaces of a second entry pulley and a second exit pulley, with an entry nip defined between the first and second entry pulleys and an exit nip defined between the first and second exit pulleys. Opposing surfaces of the first and second belts progressively diverge from each other in the direction of movement thereof. The apparatus may include a cooled roll in place of the first pulley and first belt with a nip defined between the cooled roll and the second entry pulley.Type: GrantFiled: June 23, 2006Date of Patent: March 17, 2009Assignee: Alcoa Inc.Inventors: Gavin F. Wyatt-Mair, Ali Unal
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Patent number: 7503378Abstract: A method of continuous casting non-ferrous alloys which includes delivering molten non-ferrous alloy to a casting apparatus. The casting apparatus rapidly cools at least a portion of the non-ferrous alloy at a rate of at least about 100° C. thereby solidifying an outer layer of the non-ferrous alloy surrounding an inner layer of a molten component and a solid component of dendrites. The dendrites are altered to yield cast product exhibiting good resistance to cracking.Type: GrantFiled: October 13, 2006Date of Patent: March 17, 2009Assignee: Alcoa Inc.Inventor: Ali Ünal
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Publication number: 20080254309Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of an inner layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces. The method yields an MMC having a central layer enriched with particulate matter and sandwiched between metallic outer layers.Type: ApplicationFiled: April 11, 2007Publication date: October 16, 2008Applicant: Alcoa Inc.Inventors: David A. Tomes, Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Publication number: 20080251230Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).Type: ApplicationFiled: April 11, 2007Publication date: October 16, 2008Applicant: Alcoa Inc.Inventors: David A. Tomes, Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
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Publication number: 20080041277Abstract: Fluoride-containing hydraulic cements, raw mixtures for producing fluoride-containing hydraulic cements and methods of producing the same are provided. The raw mixture comprises a fluoride source, a calcium oxide source and a silicon oxide. The fluoride source may be a fluoride-containing industrial waste, such as spent pot lining, corresponding to a fluoride content of between 0.1 wt % and 15 wt % within the raw mixture. The ratio of producible calcium oxide to silicon oxide within the raw mixture may be at least about 2:1 and the ratio of producible calcium oxide to the sum of silicon oxide and aluminum oxide within the raw mixture may be at least about 1.5:1.Type: ApplicationFiled: August 7, 2007Publication date: February 21, 2008Applicant: Alcoa Inc.Inventors: Pradip, Beena Rai, Sathish Ponnurangam, Prakash Kapur, Ali Unal, Roy Cahill, Joseph Norton, Judith Stenack, Vivek Sharma
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Publication number: 20070137830Abstract: A method of continuous casting non-ferrous alloys which includes delivering molten non-ferrous alloy to a casting apparatus. The casting apparatus rapidly cools at least a portion of the non-ferrous alloy at a rate of at least about 100° C. thereby solidifying an outer layer of the non-ferrous alloy surrounding an inner layer of a molten component and a solid component of dendrites. The dendrites are altered to yield cast product exhibiting good resistance to cracking.Type: ApplicationFiled: October 13, 2006Publication date: June 21, 2007Inventor: Ali Unal
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Publication number: 20070095499Abstract: The present invention provides an apparatus for strip casting of molten metal including a pair of casting rollers adapted to receive molten metal along a horizontal axis, wherein a vertical distance separating the pair of casting rollers defines a molding zone; and an electromagnetic edge containment apparatus positioned on each side of the molding zone having an induction coil wound about a portion of a magnetic member to generate magnetic lines of force upon application of a current, wherein the poles of the magnetic member are positioned distal from to aligned to the planar sidewall of the casting rollers and the current provides magnetic lines of force perpendicular to said horizontal axis that contain the molten metal in contact to the casting rollers without substantially increasing the temperature of the molten metal.Type: ApplicationFiled: November 1, 2005Publication date: May 3, 2007Inventors: David Tomes, Ali Unal, Gavin Wyatt-Mair, David Timmons
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Patent number: 7182825Abstract: A method of making aluminum alloy sheet in a continuous in-line process is provided. A continuously-cast aluminum alloy strip is optionally quenched, hot or warm rolled, annealed or heat-treated in-line, optionally quenched, and preferably coiled, with additional hot, warm or cold rolling steps as needed to reach the desired gauge. The process can be used to make aluminum alloy sheet of T or O temper having the desired properties, in a much shorter processing time.Type: GrantFiled: February 19, 2004Date of Patent: February 27, 2007Assignee: Alcoa Inc.Inventors: Ali Ünal, Gavin Federick Wyatt-Mair, David Allen Tomes, Jr., David Wayne Timmons