Abstract: Some variations provide a process for additive manufacturing of a nanofunctionalized metal alloy, comprising: providing a nanofunctionalized metal precursor containing metals and grain-refining nanoparticles; exposing a first amount of the nanofunctionalized metal precursor to an energy source for melting the precursor, thereby generating a first melt layer; solidifying the first melt layer, thereby generating a first solid layer; and repeating many times to generate a plurality of solid layers in an additive-manufacturing build direction. The additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains.

Abstract: Some variations provide a process for additive manufacturing of a nanofunctionalized metal alloy, comprising: providing a nanofunctionalized metal precursor containing metals and grain-refining nanoparticles; exposing a first amount of the nanofunctionalized metal precursor to an energy source for melting the precursor, thereby generating a first melt layer; solidifying the first melt layer, thereby generating a first solid layer; and repeating many times to generate a plurality of solid layers in an additive-manufacturing build direction. The additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains.

Abstract: An electromechanical lock can have a bezel along an exterior surface. A touch of a human finger upon the bezel can be determined and used to adjust a deadbolt between a lock state and an unlock state.

Abstract: Some variations provide a method of making an additively manufactured single-crystal metallic component, comprising: providing a feedstock comprising a first metal or metal alloy; providing a build plate comprising a single crystal of a second metal or metal alloy; exposing the feedstock to an energy source for melting the feedstock, generating a melt layer on the build plate; and solidifying the melt layer, generating a solid layer (on the build plate) of a metal component. The solid layer is also a single crystal of the first metal or metal alloy. The method may be repeated many times to build the part. Some variations provide a single-crystal metallic component comprising a plurality of solid layers in an additive-manufacturing build direction, wherein the plurality of solid layers forms a single crystal of a metal or metal alloy with a continuous crystallographic texture. The crystal orientation may vary along the additive-manufacturing build direction.

Abstract: Some variations provide a system for producing a functionalized powder, comprising: an agitated pressure vessel; first particles and second particles contained within the agitated pressure vessel; a fluid contained within the agitated pressure vessel; an exhaust line for releasing the fluid from the agitated pressure vessel; and a means for recovering a functionalized powder containing the second particles disposed onto surfaces of the first particles. A preferred fluid is carbon dioxide in liquefied or supercritical form. The carbon dioxide may be initially loaded into the pressure vessel as solid carbon dioxide. The pressure vessel may be batch or continuous and is operated under reaction conditions to functionalize the first particles with the second particles, thereby producing a functionalized powder, such as nanofunctionalized metal particles in which nanoparticles act as grain refiners for a component ultimately produced from the nanofunctionalized metal particles.

Abstract: Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.

Abstract: Some variations provide a method of making an additively manufactured single-crystal metallic component, comprising: providing a feedstock comprising a first metal or metal alloy; providing a build plate comprising a single crystal of a second metal or metal alloy; exposing the feedstock to an energy source for melting the feedstock, generating a melt layer on the build plate; and solidifying the melt layer, generating a solid layer (on the build plate) of a metal component. The solid layer is also a single crystal of the first metal or metal alloy. The method may be repeated many times to build the part. Some variations provide a single-crystal metallic component comprising a plurality of solid layers in an additive-manufacturing build direction, wherein the plurality of solid layers forms a single crystal of a metal or metal alloy with a continuous crystallographic texture. The crystal orientation may vary along the additive-manufacturing build direction.

Abstract: Some variations provide a system for producing a functionalized powder, comprising: an agitated pressure vessel; first particles and second particles contained within the agitated pressure vessel; a fluid contained within the agitated pressure vessel; an exhaust line for releasing the fluid from the agitated pressure vessel; and a means for recovering a functionalized powder containing the second particles disposed onto surfaces of the first particles. A preferred fluid is carbon dioxide in liquefied or supercritical form. The carbon dioxide may be initially loaded into the pressure vessel as solid carbon dioxide. The pressure vessel may be batch or continuous and is operated under reaction conditions to functionalize the first particles with the second particles, thereby producing a functionalized powder, such as nanofunctionalized metal particles in which nanoparticles act as grain refiners for a component ultimately produced from the nanofunctionalized metal particles.

Abstract: A smart door lock includes a main housing configured to be disposed interior of a standard bore hole of a door. An outer housing is disposed exterior of a secure environment and electrically and mechanically connected to the main housing via conductive prongs. An inner housing is disposed interior of the secure environment. A rotating member is magnetically attached to the inner housing. A deadbolt within a bolt housing transitions between a locked position and an unlocked position in response to the door lock detecting a user device within a wireless communication range, detecting a touch on a sensor of the outer housing, or rotation of the rotating member. The outer housing includes leakage regions to facilitate transmission of wireless signals to the main housing.

Abstract: Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.

Abstract: Some variations provide an aluminum alloy feedstock for additive manufacturing, the aluminum alloy feedstock comprising from 81.5 wt % to 88.8 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 3.0 wt % to 4.6 wt % magnesium; and from 7.1 wt % to 9.0 wt % zinc. The aluminum alloy feedstock may be in the form of a free-flowing powder or a feedstock ingot, for example. In some variations, the aluminum alloy feedstock comprises from 84.9 wt % to 88.3 wt % aluminum; from 1.2 wt % to 2.0 wt % copper; from 3.2 wt % to 4.4 wt % magnesium; and from 7.3 wt % to 8.7 wt % zinc.

Abstract: A thin-walled metal part, and a method to fabricate such a part out of various alloys. A plurality of layers are formed, each of the layers being formed on a polymer template or on a previously formed layer. A homogenizing heat treatment is used to cause chemical elements in the layers to interdiffuse, to form a single continuous layer with a substantially uniform alloy composition.

Abstract: Disclosed are embodiments of a tapered bolt receiver for a door lock to accommodate misalignment, between a deadbolt mounted to a door, and an opposing jamb. The tapered bolt receiver can be configured to accommodate misalignment for a deadbolt having a non-tapered bolt, such as for an electromechanical smart lock having a battery stored within a battery compartment that is integrated with an enhanced bolt. Also disclosed are embodiments of a deadbolt plate pivot assembly that is pivotably mountable to a corresponding deadbolt assembly to define a plate pivot system, to accommodate a beveled door edge. An illustrative embodiment of the deadbolt plate pivot assembly includes opposing plate that captures a hinge assembly, which can include plastic plate hinges, which serve to locate the deadbolt plate pivot assembly with respect to a corresponding bolt housing, and can provide a spring force and/or constant torque when mounted to a beveled door.

Abstract: Provided are maraging steel alloys having improved microstructures. Some variations provide maraging steel alloys including a base maraging steel alloy, a grain refiner, and optionally, a strengthening element. The base maraging steel alloy is surface-functionalized with the grain refiner. Other variations provide a method of method of manufacturing maraging steel including mixing a base maraging steel alloy with a grain refiner resulting in a maraging steel mixture, melting the maraging steel mixture, and solidifying the maraging steel mixture forming an equiaxed microstructure.

Abstract: Some variations provide a composition for additive manufacturing (3D printing) of metals, comprising: from 10 vol % to 70 vol % of a photocurable liquid resin; from 10 vol % to 70 vol % of metal or metal alloy particles, optionally configured with a photoreflective surface; and from 0.01 vol % to 10 vol % of a photoinitiator. Other variations provide a composition for additive manufacturing of metals, comprising: from 1 vol % to 70 vol % of a photocurable liquid resin; from 0.1 vol % to 98 vol % of an organometallic compound containing a first metal; from 1 vol % to 70 vol % of metal or metal alloy particles containing a second metal (which may be the same as or different than the first metal); and from 0.01 vol % to 10 vol % of a photoinitiator. Many examples of metals, photocurable resins, organometallic compounds, photoinitiators, and optional additives are disclosed, and methods of making and using the composition are described.

Abstract: Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure.

Abstract: Some variations provide an aluminum alloy feedstock for additive manufacturing, the aluminum alloy feedstock comprising from 79.8 wt % to 88.3 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 3.0 wt % to 4.6 wt % magnesium; from 7.1 wt % to 9.0 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium as a grain-refiner element. The aluminum alloy feedstock may be in the form of an ingot powder. In some variations, the aluminum alloy feedstock comprises from 81.3 wt % to about 87.8 wt % aluminum; from 1.2 wt % to 2.0 wt % copper; from 3.2 wt % to 4.4 wt % magnesium; from 7.3 wt % to 8.7 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium.

Abstract: Certain aspects of the technology disclosed herein include an apparatus and method for storing energy in a electromechanical lock. The electromechanical lock can include a main housing and a deadbolt. The main housing can be configured to extend a deadbolt along a path to lock and/or unlock a door. The deadbolt can have a hollow inner region configured to receive an energy storage device. The energy storage device within the deadbolt can be electrically connected to the main housing. The energy storage device can be used to power an actuator and/or accelerometer in the main housing.

Abstract: The disclosed process is capable of depositing thin layers of a wide variety of metals onto powders of magnesium, aluminum, and their alloys. A material is provided that comprises particles containing a reactive metal coated with a noble metal that has a less-negative standard reduction potential than the reactive metal. The coating has a thickness from 1 nanometer to 100 microns, for example. A method of forming an immersion deposit on a reactive metal comprises: combining a reactive metal, an ionic liquid, and a noble metal salt; depositing the noble metal on the reactive metal by a surface-displacement reaction, thereby generating the immersion deposit on the reactive metal; and removing the ionic liquid from the immersion deposit. The material may be present in an article or object (e.g., a sintered part) containing from 0.25 wt % to 100 wt % of a coated reactive metal as disclosed herein.

Abstract: Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail.