Patents by Inventor Denis B. Christopherson, JR.
Denis B. Christopherson, JR. 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: 11685982Abstract: An improved atomized powder metal material containing an increased amount of free graphite after heat treatment and/or sintering is provided. The powder metal material is typically a ferrous alloy and includes carbon in an amount of 1.0 wt. % to 6.5 wt. % and silicon in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal material. The powder metal material can also include various other alloying elements, for example at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).Type: GrantFiled: October 16, 2017Date of Patent: June 27, 2023Assignees: Tenneco Inc., Le Corporation de L'Ecole Polytechnique De MontrealInventors: Mathieu Boisvert, Gilles L'Esperance, Philippe Beaulieu, Denis B. Christopherson, Jr.
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Publication number: 20230037455Abstract: An improved atomized powder metal material containing an increased amount of free graphite after heat treatment and/or sintering is provided. The powder metal material is typically a ferrous alloy and includes carbon in an amount of 1.0 wt. % to 6.5 wt. % and silicon in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal material. The powder metal material can also include various other alloying elements, for example at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).Type: ApplicationFiled: September 30, 2022Publication date: February 9, 2023Inventors: Mathieu Boisvert, Gilles L'Esperance, Philippe Beaulieu, Denis B. Christopherson, JR.
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Patent number: 10926334Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: January 27, 2020Date of Patent: February 23, 2021Assignee: Tenneco Inc.Inventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Patent number: 10837087Abstract: A sintered material for use in an internal combustion engine, such as a valve seat insert, is provided. The material includes a pressed base powder metal mixture and a Cu-rich phase infiltrated in pores of the base powder metal mixture. The base powder metal mixture includes at least one of Mo and W, and at least one additive, such as B, N, and/or C. The amount of the Mo and/or W is 50 wt. % to 85 wt. %, based on the total weight of the material. The at least one additive is present in a total amount of 0.2 to 25 wt. %, based on the total weight of the material, and the Cu-rich phase is present in an amount of 15 wt. % to 50 wt. %, based on the total weight of the material. The material also has a thermal conductivity of at least 70 W/mK.Type: GrantFiled: August 3, 2017Date of Patent: November 17, 2020Assignee: Tenneco Inc.Inventors: Philippe Beaulieu, Denis B. Christopherson, Jr.
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Publication number: 20200216935Abstract: A powder metal material and sintered component formed of the powder metal material is provided. The powder metal material comprises a plurality of particles including copper in an amount of 10 wt. % to 50 wt. %, based on the total weight of the particles. The particles also include at least one of iron, nickel, an cobalt. The particles further include at least one of boron, carbon, chromium, manganese, molybdenum, nitrogen, niobium, phosphorous, sulfur, aluminum, bismuth, silicon, tin, tantalum, titanium, vanadium, tungsten, hafnium, and zirconium. The particles are formed by atomizing and optionally heat treating. The particles consist of a first area and a second area, wherein the first area is copper-rich and the second area includes hard phases. The hard phases being present in an amount of at least 33 wt. %, based on the total weight of the second area.Type: ApplicationFiled: January 2, 2020Publication date: July 9, 2020Inventors: Philippe Beaulieu, Mathieu Boisvert, Denis B. Christopherson, JR.
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Publication number: 20200156156Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: ApplicationFiled: January 27, 2020Publication date: May 21, 2020Inventors: Philippe BEAULIEU, Denis B. Christopherson, JR., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Patent number: 10543535Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: September 13, 2017Date of Patent: January 28, 2020Assignees: Tenneco Inc., Corporation de L'Ecole Polytechnique De MontrealInventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Espérance
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Patent number: 10124411Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: September 16, 2015Date of Patent: November 13, 2018Assignees: Federal-Mogul LLC, La Corporation de l'Ecole Polytechnique de MontrealInventors: Philippe Beaulieu, Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance
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Publication number: 20180169751Abstract: A thermometric powder metal material for testing to replicate an actual powder material during use of the actual powder metal material in an internal combustion engine is provided. The thermometric powder metal material includes pores and has a decrease in hardness as a function of temperature according to the following equation: D Hardness/D Temperature=>0.5 HV/° C. The properties of the actual powder metal material, when the actual powder metal is used in an internal combustion engine, can be estimated using the thermometric powder metal material by first adjusting the thermal conductivity of the thermometric powder metal material or controlling the porosity of the thermometric powder metal material to replicate the actual powder metal material, and then subjecting thermometric powder metal material to an engine test. For example, the thermal conductivity can be adjusted by infiltrating the thermometric powder metal material with copper.Type: ApplicationFiled: December 15, 2017Publication date: June 21, 2018Inventors: Philippe BEAULIEU, Denis B. CHRISTOPHERSON, JR., Leslie John FARTHING, Gilles L'ESPERANCE, Olivier SIOUI-LATULIPPE
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Publication number: 20180104745Abstract: An improved method of manufacturing a powder metal material by water, gas, plasma, or rotating disk atomization is provided. The method includes adding at least one additive to a melted metal material before or during the atomization process. The at least one additive forms a protective gas atmosphere surrounding the melted metal material which is at least three times greater than the volume of melt to be treated. The protective atmosphere prevents introduction or re-introduction of contaminants, such as sulfur (S) and oxygen (O2), into the material. The atomized particles produced include at least one of the following advantages: median circularity of at least 0.60, median roundness of at least 0.60, less internal pores, less internal oxides, and an increased sphericity of the microstructural phases and/or constituents.Type: ApplicationFiled: October 17, 2016Publication date: April 19, 2018Inventors: Gilles L'ESPERANCE, Mathieu BOISVERT, Denis B. CHRISTOPHERSON, JR., Philippe BEAULIEU
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Publication number: 20180104746Abstract: An improved method of manufacturing a cast part by sand casting, permanent mold casting, investment casting, lost foam casting, die casting, or centrifugal casting, or a powder metal material by water, gas, plasma, ultrasonic, or rotating disk atomization is provided. The method includes adding at least one additive to a melted metal material before or during the casting or atomization process. The at least one additive forms a protective gas atmosphere surrounding the melted metal material which is at least three times greater than the volume of melt to be treated. The protective atmosphere prevents introduction or re-introduction of contaminants, such as sulfur (S) and oxygen (O2), into the material. The cast parts or atomized particles produced include at least one of the following advantages: less internal pores, less internal oxides, median circularity of at least 0.60, median roundness of at least 0.60 and increased sphericity of microstructural phases and/or constituents.Type: ApplicationFiled: September 1, 2017Publication date: April 19, 2018Inventors: Mathieu Boisvert, Gilles L'Esperance, Philippe Beaulieu, Denis B. Christopherson, JR.
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Publication number: 20180105906Abstract: An improved atomized powder metal material containing an increased amount of free graphite after heat treatment and/or sintering is provided. The powder metal material is typically a ferrous alloy and includes carbon in an amount of 1.0 wt. % to 6.5 wt. % and silicon in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal material. The powder metal material can also include various other alloying elements, for example at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).Type: ApplicationFiled: October 16, 2017Publication date: April 19, 2018Inventors: Mathieu Boisvert, Gilles L'Esperance, Philippe Beaulieu, Denis B. Christopherson, JR.
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Publication number: 20180087135Abstract: A sintered material for use in an internal combustion engine, such as a valve seat insert, is provided. The material includes a pressed base powder metal mixture and a Cu-rich phase infiltrated in pores of the base powder metal mixture. The base powder metal mixture includes at least one of Mo and W, and at least one additive, such as B, N, and/or C. The amount of the Mo and/or W is 50 wt. % to 85 wt. %, based on the total weight of the material. The at least one additive is present in a total amount of 0.2 to 25 wt. %, based on the total weight of the material, and the Cu-rich phase is present in an amount of 15 wt. % to 50 wt. %, based on the total weight of the material. The material also has a thermal conductivity of at least 70 W/mK.Type: ApplicationFiled: August 3, 2017Publication date: March 29, 2018Inventors: Philippe BEAULIEU, Denis B. CHRISTOPHERSON, JR.
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Publication number: 20180001387Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: ApplicationFiled: September 13, 2017Publication date: January 4, 2018Inventors: Philippe BEAULIEU, Denis B. CHRISTOPHERSON, JR., Leslie John FARTHING, Todd SCHOENWETTER, Gilles L'ESPERANCE
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Publication number: 20170129016Abstract: A powder metal steel alloy composition for high wear and temperature applications is made by water atomizing a molten steel alloy composition containing C in an amount of at least 3.0 wt %; at least one carbide-forming alloy element selected from the group consisting of: Cr, V, Mo or W; an O content less than about 0.5 wt %, and the balance comprising essentially Fe apart from incidental impurities. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming element(s) to oxidize during water atomization. The alloy elements are thus not tied up as oxides and are available to rapidly and readily form carbides in a subsequent sintering stage. The carbon, present in excess, is also available for diffusing into one or more other admixed powders that may be added to the prealloyed powder during sintering to control microstructure and properties of the final part.Type: ApplicationFiled: January 13, 2017Publication date: May 11, 2017Inventors: DENIS B. CHRISTOPHERSON, JR., LESLIE JOHN FARTHING, TODD SCHOENWETTER, GILLES L'ESPERANCE, PHILIPPE BEAULIEU
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Patent number: 9624568Abstract: A thermal spray powder is provided for use in a thermal spray technique, such as flame spraying, plasma spraying, cold spraying, and high velocity oxygen fuel spraying (HVOF). The thermal spray powder is formed by water or gas atomization and comprises 3.0 to 7.0 wt. % carbon, 10.0 to 25.0 wt. % chromium, 1.0 to 5.0 wt. % tungsten, 3.5 to 7.0 wt. % vanadium, 1.0 to 5.0 wt. % molybdenum, not greater than 0.5 wt. % oxygen, and at least 40.0 wt. % iron, based on the total weight of the thermal spray powder. The thermal spray powder can be applied to a metal body, such as a piston or piston ring, to form a coating. The thermal spray powder can also provide a spray-formed part.Type: GrantFiled: March 8, 2013Date of Patent: April 18, 2017Assignees: Federal-Mogul CorporationInventors: Denis B. Christopherson, Jr., Gilles L'Esperance, Jeremy Koth, Philippe Beaulieu, Leslie John Farthing, Todd Schoenwetter
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Patent number: 9546412Abstract: A powder metal steel alloy composition for high wear and temperature applications is made by water atomizing a molten steel alloy composition containing C in an amount of at least 3.0 wt %; at least one carbide-forming alloy element selected from the group consisting of: Cr, V, Mo or W; an O content less than about 0.5 wt %, and the balance comprising essentially Fe apart from incidental impurities. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming element(s) to oxidixe during water atomization. The alloy elements are thus not tied up as oxides and are available to rapidly and readily form carbides in a subsequent sintering stage. The carbon, present in excess, is also available for diffusing into one or more other admixed powders that may be added to the prealloyed powder during sintering to control microstructure and properties of the final part.Type: GrantFiled: April 7, 2009Date of Patent: January 17, 2017Assignee: Federal-Mogul CorporationInventors: Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance, Philippe Beaulieu
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Publication number: 20160001369Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: ApplicationFiled: September 16, 2015Publication date: January 7, 2016Inventors: Philippe Beaulieu, Denis B. Christopherson, JR., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance
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Patent number: 9162285Abstract: A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.Type: GrantFiled: March 15, 2013Date of Patent: October 20, 2015Assignees: Federal-Mogul Corporation, La Corporation De L'Ecole Polytechnique De MontrealInventors: Denis B. Christopherson, Jr., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance, Philippe Beaulieu
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Publication number: 20090252636Abstract: A powder metal steel alloy composition for high wear and temperature applications is made by water atomizing a molten steel alloy composition containing C in an amount of at least 3.0 wt %; at least one carbide-forming alloy element selected from the group consisting of: Cr, V, Mo or W; an O content less than about 0.5 wt %, and the balance comprising essentially Fe apart from incidental impurities. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming element(s) to oxidixe during water atomization. The alloy elements are thus not tied up as oxides and are available to rapidly and readily form carbides in a subsequent sintering stage. The carbon, present in excess, is also available for diffusing into one or more other admixed powders that may be added to the prealloyed powder during sintering to control microstructure and properties of the final part.Type: ApplicationFiled: April 7, 2009Publication date: October 8, 2009Inventors: Denis B. Christopherson, JR., Leslie John Farthing, Todd Schoenwetter, Gilles L'Esperance, Phillipe Beaulieu