Patents by Inventor Kristopher A. Darling
Kristopher A. Darling 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: 11975385Abstract: A nano-structured alloy material includes a nanoparticle; a matrix phase surrounding the nanoparticle; and an alkali/alkali Earth metal to alter (i) a material property of the nanoparticle, (ii) a material property of the matrix phase, and (iii) an interaction of the nanoparticle with the matrix phase.Type: GrantFiled: March 22, 2022Date of Patent: May 7, 2024Assignee: The United States of America as represented by the Secretary of the ArmyInventors: Kristopher A. Darling, Billy C. Hornbuckle, Blake P. Fullenwider, Albert M. Ostlind, Anthony J. Roberts, Anit K. Giri
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Publication number: 20230302531Abstract: A nano-structured alloy material includes a nanoparticle; a matrix phase surrounding the nanoparticle; and an alkali/alkali Earth metal to alter (i) a material property of the nanoparticle, (ii) a material property of the matrix phase, and (iii) an interaction of the nanoparticle with the matrix phase.Type: ApplicationFiled: March 22, 2022Publication date: September 28, 2023Inventors: Kristopher A. Darling, Billy C. Hornbuckle, Blake P. Fullenwider, Albert M. Ostlind, Anthony J. Roberts, Anit K. Giri
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Publication number: 20230279525Abstract: A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25% of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa?m.Type: ApplicationFiled: August 12, 2022Publication date: September 7, 2023Inventors: John J. PITTARI, III, Steven M. Kilczewski, Jeffrey J. Swab, Kristopher A. Darling, Billy C. Hornbuckle, Heather A. Murdoch, Robert J. Dowding
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Publication number: 20230279565Abstract: A dissolvable engineered component fabricated using an aluminum-based nanogalvanic alloy and a method of manufacturing such a dissolvable engineered component.Type: ApplicationFiled: March 2, 2022Publication date: September 7, 2023Inventors: THOMAS L. LUCKENBAUGH, Anthony J. Roberts, Billy C. Hornbuckle, Anit K. Giri, Kristopher A. Darling
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Publication number: 20230272539Abstract: A method and apparatus for generating hydrogen gas by reacting a nanogalvanic alloy with water vapor. The apparatus comprises a water vapor source for supplying water vapor to a reaction chamber containing a nanogalvanic alloy. The nanogalvanic alloy reacts with the water vapor to produce hydrogen.Type: ApplicationFiled: February 28, 2022Publication date: August 31, 2023Inventors: Anthony J. Roberts, Anit K. Giri, Billy C. Hornbuckle, Kristopher A. Darling
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Patent number: 11725262Abstract: A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25% of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa?m.Type: GrantFiled: August 12, 2022Date of Patent: August 15, 2023Assignee: The United States of America as represented by the Secretary of the ArmyInventors: John J. Pittari, III, Steven M. Kilczewski, Jeffrey J. Swab, Kristopher A. Darling, Billy C. Hornbuckle, Heather A. Murdoch, Robert J. Dowding
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Publication number: 20230160042Abstract: A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25% of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa?m.Type: ApplicationFiled: August 12, 2022Publication date: May 25, 2023Inventors: John J. PITTARI, III, Steven M. Kilczewski, Jeffrey J. Swab, Kristopher A. Darling, Billy C. Hornbuckle, Heather A. Murdoch, Robert J. Dowding
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Publication number: 20230002857Abstract: Alloys comprised of a refined microstructure, ultrafine or nano scaled, that when reacted with water or any liquid containing water will spontaneously and rapidly produce hydrogen at ambient or elevated temperature are described. These metals, termed here as aluminum based nanogalvanic alloys will have applications that include but are not limited to energy generation on demand. The alloys may be composed of primarily aluminum and other metals e.g., tin bismuth, indium, gallium, lead, etc. and/or carbon, and mixtures and alloys thereof. The alloys may be processed by ball milling for the purpose of synthesizing powder feed stocks, in which each powder particle will have the above-mentioned characteristics. These powders can be used in their inherent form or consolidated using commercially available techniques for the purpose of manufacturing useful functional components.Type: ApplicationFiled: September 7, 2022Publication date: January 5, 2023Inventors: Billy C. Hornbuckle, Anthony J. Roberts, Thomas L. Luckenbaugh, Anit K. Giri, Kristopher A. Darling
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Patent number: 11434549Abstract: A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25% of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa?m.Type: GrantFiled: November 9, 2017Date of Patent: September 6, 2022Assignee: The United States of America as represented by the Secretary of the ArmyInventors: John J. Pittari, III, Steven M. Kilczewski, Jeffrey J. Swab, Kristopher A. Darling, Billy C. Hornbuckle, Heather A. Murdoch, Robert J. Dowding
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Patent number: 11386243Abstract: A method for screening a large design space of compositions with possible application as binders in cermet and powder metallurgy applications allows rapid elimination of large portions of the design space from contention so that resource intensive procedures, such as computationally intensive modeling techniques and experimental testing, can be focused on potential binder compositions with a high likelihood of being used successfully. The method relies on parameters such as surface tension, contact angle, viscosity, a special capillary metric that is used to characterize capillary behavior, and melting point, which are relatively easy to calculate or determine, to screen out large portions of the design space. Exemplary binder compositions are obtained using the method.Type: GrantFiled: March 12, 2019Date of Patent: July 12, 2022Assignee: The United States of America as represented by the Secretary of the ArmyInventors: Heather A. Murdoch, Kristopher A. Darling
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Patent number: 11198923Abstract: Alloys comprised of a refined microstructure, ultrafine or nano scaled, that when reacted with water or any liquid containing water will spontaneously and rapidly produce hydrogen at ambient or elevated temperature are described. These metals, termed here as aluminum based nanogalvanic alloys will have applications that include but are not limited to energy generation on demand. The alloys may be composed of primarily aluminum and other metals e.g. tin bismuth, indium, gallium, lead, etc. and/or carbon, and mixtures and alloys thereof. The alloys may be processed by ball milling for the purpose of synthesizing powder feed stocks, in which each powder particle will have the above mentioned characteristics. These powders can be used in their inherent form or consolidated using commercially available techniques for the purpose of manufacturing useful functional components.Type: GrantFiled: July 23, 2018Date of Patent: December 14, 2021Assignee: The United States of America as represented by the Secretary of the ArmyInventors: Anit K. Giri, Anthony J. Roberts, Billy C. Hornbuckle, Scott M. Grendahl, Kristopher A. Darling
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Publication number: 20200293624Abstract: A method for screening a large design space of compositions with possible application as binders in cermet and powder metallurgy applications allows rapid elimination of large portions of the design space from contention so that resource intensive procedures, such as computationally intensive modeling techniques and experimental testing, can be focused on potential binder compositions with a high likelihood of being used successfully. The method relies on parameters such as surface tension, contact angle, viscosity, a special capillary metric that is used to characterize capillary behavior, and melting point, which are relatively easy to calculate or determine, to screen out large portions of the design space. Exemplary binder compositions are obtained using the method.Type: ApplicationFiled: March 12, 2019Publication date: September 17, 2020Inventors: Heather A. Murdoch, Kristopher A. Darling
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Patent number: 10766071Abstract: Novel metallic systems and methods for their fabrication provide an extreme creep-resistant nano-crystalline metallic material. The material comprises a matrix formed of a solvent metal with crystalline grains having diameters of no more than about 500 nm, and a plurality of dispersed metallic particles formed on the basis of a solute metal in the solvent metal matrix and having diameters of no more than about 200 nm. The particle density along the grain boundary of the matrix is as high as about 2 nm2 of grain boundary area per particle so as to substantially block grain boundary motion and rotation and limit creep at temperatures above 35% of the melting point of the material.Type: GrantFiled: February 14, 2018Date of Patent: September 8, 2020Assignee: The United States of America as represented by the Secretary of the ArmyInventors: Laszlo J. Kecskes, Kristopher A. Darling, Rajiv S. Mishra, Yuri Mishin, Kiran N. Solanki, Mansa Rajagopalan
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Publication number: 20200024702Abstract: A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25% of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa?m.Type: ApplicationFiled: September 30, 2019Publication date: January 23, 2020Inventors: John J. Pittari, III, Steven M. Kilczewski, Jeffrey J. Swab, Kristopher A. Darling, Billy C. Hornbuckle, Heather A. Murdoch, Robert J. Dowding
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Publication number: 20200024689Abstract: Alloys comprised of a refined microstructure, ultrafine or nano scaled, that when reacted with water or any liquid containing water will spontaneously and rapidly produce hydrogen at ambient or elevated temperature are described. These metals, termed here as aluminum based nanogalvanic alloys will have applications that include but are not limited to energy generation on demand. The alloys may be composed of primarily aluminum and other metals e.g. tin bismuth, indium, gallium, lead, etc. and/or carbon, and mixtures and alloys thereof. The alloys may be processed by ball milling for the purpose of synthesizing powder feed stocks, in which each powder particle will have the above mentioned characteristics. These powders can be used in their inherent form or consolidated using commercially available techniques for the purpose of manufacturing useful functional components.Type: ApplicationFiled: September 23, 2019Publication date: January 23, 2020Inventors: Anit K. Giri, Anthony J. Roberts, Billy C. Hornbuckle, Scott M. Grendahl, Kristopher A. Darling
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Patent number: 10487375Abstract: High-density thermodynamically stable nanostructured copper-based metallic systems, and methods of making, are presented herein. A ternary high-density thermodynamically stable nanostructured copper-based metallic system includes: a solvent of copper (Cu) metal; that comprises 50 to 95 atomic percent (at. %) of the metallic system; a first solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system; and a second solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system. The internal grain size of the solvent is suppressed to no more than 250 nm at 98% of the melting point temperature of the solvent and the solute metals remain uniformly dispersed in the solvent at that temperature. Processes for forming these metallic systems include: subjecting powder metals to a high-energy milling process, and consolidating the resultant powder metal subjected to the milling to form a bulk material.Type: GrantFiled: April 7, 2016Date of Patent: November 26, 2019Assignee: The United States of America as represented by the Secretary of the ArmyInventors: Laszlo J. Kecskes, Micah J. Gallagher, Anthony J. Roberts, Kristopher A. Darling, Brady G. Butler
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Publication number: 20190024216Abstract: Alloys comprised of a refined microstructure, ultrafine or nano scaled, that when reacted with water or any liquid containing water will spontaneously and rapidly produce hydrogen at ambient or elevated temperature are described. These metals, termed here as aluminum based nanogalvanic alloys will have applications that include but are not limited to energy generation on demand. The alloys may be composed of primarily aluminum and other metals e.g. tin bismuth, indium, gallium, lead, etc. and/or carbon, and mixtures and alloys thereof. The alloys may be processed by ball milling for the purpose of synthesizing powder feed stocks, in which each powder particle will have the above mentioned characteristics. These powders can be used in their inherent form or consolidated using commercially available techniques for the purpose of manufacturing useful functional components.Type: ApplicationFiled: July 23, 2018Publication date: January 24, 2019Inventors: Anit K. Giri, Anthony J. Roberts, Billy C. Hornbuckle, Scott M. Grendahl, Kristopher A. Darling
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Publication number: 20180229308Abstract: Novel metallic systems and methods for their fabrication provide an extreme creep-resistant nano-crystalline metallic material. The material comprises a matrix formed of a solvent metal with crystalline grains having diameters of no more than about 500 nm, and a plurality of dispersed metallic particles formed on the basis of a solute metal in the solvent metal matrix and having diameters of no more than about 200 nm. The particle density along the grain boundary of the matrix is as high as about 2 nm2 of grain boundary area per particle so as to substantially block grain boundary motion and rotation and limit creep at temperatures above 35% of the melting point of the material.Type: ApplicationFiled: February 14, 2018Publication date: August 16, 2018Inventors: Laszlo J. Kecskes, Kristopher A. Darling, Rajiv S. Mishra, Yuri Mishin, Kiran N. Solanki, Mansa Rajagopalan
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Publication number: 20180142331Abstract: A sintered cemented carbide body including tungsten carbide, and a substantially cobalt-free binder including an iron-based alloy sintered with the tungsten carbide. The iron-based alloy is approximately 2-25 % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may be approximately 90 wt % and the iron-based alloy may be approximately 10 wt % of the overall weight percentage of the sintered tungsten carbide and iron-based alloy. The tungsten carbide may comprise a substantially same size before and after undergoing sintering. The iron-based alloy may be sintered with the tungsten carbide using a uniaxial hot pressing process, a spark plasma sintering process, or a pressureless sintering process. The sintered tungsten carbide and iron-based alloy has a hardness value of at least 15 GPa and a fracture toughness value of at least 11 MPa?m.Type: ApplicationFiled: November 9, 2017Publication date: May 24, 2018Inventors: John J. Pittari, III, Steven M. Kilczewski, Jeffrey J. Swab, Kristopher A. Darling, Billy C. Hornbuckle, Heather A. Murdoch, Robert J. Dowding
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Patent number: 9822430Abstract: High-density thermodynamically stable nanostructured copper-based metallic systems, and methods of making, are presented herein. A ternary high-density thermodynamically stable nanostructured copper-based metallic system includes: a solvent of copper (Cu) metal; that comprises 50 to 95 atomic percent (at. %) of the metallic system; a first solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system; and a second solute metal dispersed in the solvent that comprises 0.01 to 50 at. % of the metallic system. The internal grain size of the solvent is suppressed to no more than 250 nm at 98% of the melting point temperature of the solvent and the solute metals remain uniformly dispersed in the solvent at that temperature. Processes for forming these metallic systems include: subjecting powder metals to a high-energy milling process, and consolidating the resultant powder metal subjected to the milling to form a bulk material.Type: GrantFiled: September 6, 2013Date of Patent: November 21, 2017Assignee: The United States of America as represented by the Secretary of the ArmyInventors: Laszlo J. Kecskes, Micah J. Gallagher, Anthony J. Roberts, Kristopher A. Darling