Patents by Inventor Daniel E. Bullard
Daniel E. Bullard 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: 11261516Abstract: The present disclosure provides systems and methods for depositing a metal layer adjacent to or on a substrate. Substrates may comprise, for example, one or more of iron, chromium, nickel, silicon, vanadium, titanium, boron, tungsten, aluminum, molybdenum, cobalt, manganese, zirconium, and niobium, oxides thereof, nitrides thereof, sulfides thereof, or any combination thereof. A substrate may be a steel substrate. A metal layer may be deposited via, for example, roll coating, vapor deposition, slurry deposition, or electrochemical deposition.Type: GrantFiled: November 16, 2018Date of Patent: March 1, 2022Assignee: PUBLIC JOINT STOCK COMPANY “SEVERSTAL”Inventors: Zachary M. Detweiler, Joseph E. McDermott, Adam G. Thomas, Daniel E. Bullard, Martin Janousek
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Publication number: 20190217336Abstract: The present disclosure provides methods forming a stainless steel part. A method for forming a stainless steel part may comprise providing a substrate comprising stainless steel and at least one depression that projects into at least a portion of the substrate. The at least one depression may be in accordance with a depression pattern. A coating material may be provided on at least a portion of the surface having at least one depression.Type: ApplicationFiled: January 11, 2019Publication date: July 18, 2019Inventors: Daniel E. Bullard, David Keifer, Zachary M. Detweiler
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Publication number: 20190153581Abstract: The present disclosure provides systems and methods for depositing a metal layer adjacent to or on a substrate. Substrates may comprise, for example, one or more of iron, chromium, nickel, silicon, vanadium, titanium, boron, tungsten, aluminum, molybdenum, cobalt, manganese, zirconium, and niobium, oxides thereof, nitrides thereof, sulfides thereof, or any combination thereof. A substrate may be a steel substrate. A metal layer may be deposited via, for example, roll coating, vapor deposition, slurry deposition, or electrochemical deposition.Type: ApplicationFiled: November 16, 2018Publication date: May 23, 2019Inventors: Zachary M. DETWEILER, Joseph E. MCDERMOTT, Adam G. THOMAS, Daniel E. BULLARD, Martin JANOUSEK
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Patent number: 9333727Abstract: A steel manufacturing process can include forming an iron oxide layer on a hot band during hot rolling; reducing the iron oxide layer on the hot band to form a sponge iron layer that includes pores; the sponge-iron layer having a thickness in a range of about 0.05 ?m to about 1000 ?m, about 0.1 ?m to about 100 ?m, or about 5 ?m to about 25 ?m; and depositing an alloying element into the pores of the sponge iron layer to form an impregnated sponge-iron layer. The process can further include annealing the impregnated sponge-iron layer to produce an iron alloy layer carried by the substrate.Type: GrantFiled: October 31, 2013Date of Patent: May 10, 2016Assignee: Arcanum Alloy Design Inc.Inventor: Daniel E. Bullard
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Publication number: 20160010170Abstract: Herein is described a process for preparing an alloy that includes defining a product composition, thickness, and homogeneity; providing a base that has a thickness less than the product thickness and has a base composition; depositing an alloying material onto at least one surface of the base to yield a coated base that has a composition equal the product composition but has a different homogeneity; and then full thickness annealing the base and the alloying material to provide the product homogeneity. The process can be used to provide ultrathin foils, for example, ultrathin foils of ferrous or aluminum alloys.Type: ApplicationFiled: March 4, 2014Publication date: January 14, 2016Applicant: ARCANUM ALLOY DESIGN INC.Inventors: Adam G. Thomas, Daniel E. Bullard, Joseph E. McDermott
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Publication number: 20150345041Abstract: The present disclosure provides materials that include a stainless steel layer with a consistent or substantially consistent composition diffusion bonded to a carbon steel substrate. The material can have the corrosion resistance associated with the explosively welded stainless steel and the deep diffusion bonding observed typical of chromizing applications. In some embodiments, the disclosure provides materials having metal layers deposited onto a chromium surface and methods for depositing metal layers onto chromium surfaces. The present disclosure recognizes certain advantages to depositing metal layers onto chromium, such as more rapid diffusion of metals when heated to provide a stainless steel layer.Type: ApplicationFiled: May 19, 2015Publication date: December 3, 2015Inventors: Ersan Ilgar, Daniel E. Bullard
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Publication number: 20150167131Abstract: The disclosure provides a material that includes a stainless steel layer with a consistent composition diffusion bonded to a carbon steel substrate. The material can have the corrosion resistance associated with the explosively welded stainless steel and the deep diffusion bonding observed typical of chromizing applications.Type: ApplicationFiled: December 9, 2014Publication date: June 18, 2015Inventors: Daniel E. Bullard, Joseph E. McDermott, Adam Thomas
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Patent number: 8795447Abstract: A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: GrantFiled: October 12, 2013Date of Patent: August 5, 2014Assignee: Arcanum Alloy Design IncInventors: Daniel E. Bullard, Joseph E. McDermott
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Patent number: 8790790Abstract: A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: GrantFiled: October 12, 2013Date of Patent: July 29, 2014Assignee: Arcanum Alloy Design, Inc.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Patent number: 8784997Abstract: A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: GrantFiled: October 12, 2013Date of Patent: July 22, 2014Assignee: Arcanum Alloy Design, Inc.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Publication number: 20140079958Abstract: A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: ApplicationFiled: October 12, 2013Publication date: March 20, 2014Applicant: ARCANUM ALLOY DESIGN INC.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Publication number: 20140050937Abstract: A steel manufacturing process can include forming an iron oxide layer on a hot band during hot rolling; reducing the iron oxide layer on the hot band to form a sponge iron layer that includes pores; the sponge-iron layer having a thickness in a range of about 0.05 ?m to about 1000 ?m, about 0.1 ?m to about 100 ?m, or about 5 ?m to about 25 ?m; and depositing an alloying element into the pores of the sponge iron layer to form an impregnated sponge-iron layer. The process can further include annealing the impregnated sponge-iron layer to produce an iron alloy layer carried by the substrate.Type: ApplicationFiled: October 31, 2013Publication date: February 20, 2014Applicant: Arcanum Alloy Design Inc.Inventor: Daniel E. Bullard
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Publication number: 20140037987Abstract: A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: ApplicationFiled: October 12, 2013Publication date: February 6, 2014Applicant: Arcanum Alloy Design Inc.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Publication number: 20140037852Abstract: A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: ApplicationFiled: October 12, 2013Publication date: February 6, 2014Applicant: ARCANUM ALLOY DESIGN INC.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Patent number: 8628861Abstract: Herein are disclosed steel forms having stainless steel exteriors that pass a 0T-bend Advanced T-bend Test. One steel form has a stainless steel exterior; the steel form includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition can include an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: GrantFiled: March 13, 2013Date of Patent: January 14, 2014Assignee: Arcanum Alloy Design Inc.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Patent number: 8608875Abstract: A steel manufacturing process can include forming an iron oxide layer on a hot band during hot rolling; reducing the iron oxide layer on the hot band to form a sponge iron layer that includes pores; the sponge-iron layer having a thickness in a range of about 0.05 ?m to about 1000 ?m, about 0.1 ?m to about 100 ?m, or about 5 ?m to about 25 ?m; and depositing an alloying element into the pores of the sponge iron layer to form an impregnated sponge-iron layer. The process can further include annealing the impregnated sponge-iron layer to produce an iron alloy layer carried by the substrate.Type: GrantFiled: February 26, 2013Date of Patent: December 17, 2013Assignee: Arcanum Alloy Design Inc.Inventor: Daniel E. Bullard
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Publication number: 20130309410Abstract: A metal customization process that provides an alloy metal product which meets predefined product specifications which are typically based on whole thickness materials. The metal customization process can be used with any commercially available substrates (e.g., aluminum bar, aluminum coil, steel bar, steel coil, and alloys thereof) but, preferably, the substrate is made of steel (e.g., carbon steel, low carbon steel or steel alloys). This process can include receiving a product specification that can include performance or composition criteria; converting the product specification to a surface specification and a core specification; then treating a substrate with a deposition composition, for example, at a temperature below an annealing temperature, thereby depositing at least one alloying element onto the substrate to form a coating composition that is carried by the substrate; and then annealing the coated substrate to provide a product that meets the product specification.Type: ApplicationFiled: March 13, 2013Publication date: November 21, 2013Applicant: Arcanum Alloy Design Inc.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Patent number: 8557397Abstract: A steel form having a stainless steel exterior; the steel form includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: GrantFiled: September 28, 2012Date of Patent: October 15, 2013Assignee: Arcanum Alloy Design Inc.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Publication number: 20130252022Abstract: Herein are disclosed steel forms having stainless steel exteriors that pass a 0T-bend Advanced T-bend Test. One steel form has a stainless steel exterior; the steel form includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 ?m to about 250 ?m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition can include an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 ?m and less than the thickness of the stainless steel region, and has a bonding composition.Type: ApplicationFiled: March 13, 2013Publication date: September 26, 2013Applicant: ARCANUM ALLOY DESIGN INC.Inventors: Daniel E. Bullard, Joseph E. McDermott
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Patent number: 7291252Abstract: Steel cabinet parts and other steel objects are electrocoated in a cationic resin-containing bath. The steel objects are chromium-coated, free of phosphate and preferably free of chromium oxide. The products are not significantly subject to filiform corrosion, and the process is economically beneficial because throwpower is more easily controlled than in previous processes.Type: GrantFiled: November 25, 2002Date of Patent: November 6, 2007Assignee: United States Steel CorporationInventors: Jian X. Li, Daniel E. Bullard, Chyang J. Wu