Patents by Inventor Raymond F. Decker
Raymond F. Decker 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: 9017602Abstract: A method of forming a wrought material having a refined grain structure is provided. The method comprises providing a metal alloy material having a depressed solidus temperature and a low temperature eutectic phase transformation. The metal alloy material is molded and rapidly solidified to form a fine grain precursor that has fine grains surrounded by a eutectic phase with fine dendritic arm spacing. The fine grain precursor is plastic deformed at a high strain rate to cause recrystallization without substantial shear banding to form a fine grain structural wrought form. The wrought form is then thermally treated to precipitate the eutectic phase into nanometer sized dispersoids within the fine grains and grain boundaries and to define a thermally treated fine grain structure wrought form having grains finer than the fine grains and the fine dendritic arm spacing of the fine grain precursor.Type: GrantFiled: February 4, 2011Date of Patent: April 28, 2015Assignee: Thixomat, Inc.Inventors: Raymond F. Decker, Jack Huang, Sanjay G. Kulkarni, Stephen E. Lebeau, Ralph E. Vining
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Publication number: 20130126295Abstract: A currency coin and method of making a currency coin. The currency coin includes a planchet coated with Ni derived from carbonyl Ni. During production of the currency coin, a planchet of one a variety of materials is provided and Ni is derived from Ni containing material utilizing the carbonyl process. In short, Ni is derived from carbonyl Ni. The Ni derived from carbonyl Ni is then deposited on the planchet forming a Ni coated coin.Type: ApplicationFiled: November 16, 2012Publication date: May 23, 2013Inventor: Raymond F. Decker
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Publication number: 20120305145Abstract: A method of forming a wrought material having a refined grain structure is provided. The method comprises providing a metal alloy material having a depressed solidus temperature and a low temperature eutectic phase transformation. The metal alloy material is molded and rapidly solidified to form a fine grain precursor that has fine grains surrounded by a eutectic phase with fine dendritic arm spacing. The fine grain precursor is plastic deformed at a high strain rate to cause recrystallization without substantial shear banding to form a fine grain structural wrought form. The wrought form is then thermally treated to precipitate the eutectic phase into nanometer sized dispersoids within the fine grains and grain boundaries and to define a thermally treated fine grain structure wrought form having grains finer than the fine grains and the fine dendritic arm spacing of the fine grain precursor.Type: ApplicationFiled: February 4, 2011Publication date: December 6, 2012Inventors: Raymond F. Decker, Jack Huang, Sanjay G. Kulkarni, Stephen E. Lebeau, Ralph E. Vining
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Publication number: 20090087681Abstract: An impact resistant composite member is for at least one of armor plate and an impact resistant structure. The member comprises a body in plate form and a reinforcement structure located within the body. The body includes a metal alloy having a fine grain size of about 5 microns or less.Type: ApplicationFiled: June 13, 2008Publication date: April 2, 2009Inventors: Raymond F. Decker, Sanjay Kulkarni, Joseph R. Pickens
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Patent number: 7028746Abstract: An apparatus for molding a metal material. The apparatus includes a vessel with portions defining a passageway through the vessel. An inlet is located toward one end and a member or agitation means is located within the passageway. A plurality of heaters are located a length of the vessel. The first of the heaters is located immediately downstream of the inlet and is a low frequency induction coil heater whereby the temperature gradient through the vessel's sidewall is minimized.Type: GrantFiled: October 14, 2003Date of Patent: April 18, 2006Assignee: Thixomat, Inc.Inventors: Ron Akers, Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker, Chris Pedder
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Patent number: 6736188Abstract: A vessel for processing feed stock material into molten or semi-molten state. The vessel includes a body defining an interior surface, an inlet, for receiving the feed stock material and an outlet discharging the material. The sidewall of the body comprises three layers, referred to as the shell, an intermediate layer and a liner. The intermediate layer is disposed between the shell and the liner and is formed of material softer than the materials forming the shell and the liner. The presence of the intermediate layer minimizes the thermal gradient along the thickness of the barrel.Type: GrantFiled: June 28, 2002Date of Patent: May 18, 2004Assignee: Thixomat, Inc.Inventors: Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker
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Publication number: 20040084171Abstract: An apparatus for molding a metal material. The apparatus includes a vessel with portions defining a passageway through the vessel. An inlet is located toward one end and a member or agitation means is located within the passageway. A plurality of heaters are located a length of the vessel. The first of the heaters is located immediately downstream of the inlet and is a low frequency induction coil heater whereby the temperature gradient through the vessel's sidewall is minimized.Type: ApplicationFiled: October 14, 2003Publication date: May 6, 2004Applicant: Thixomat, Inc.Inventors: Ron Akers, Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker, Chris Pedder
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Publication number: 20040003911Abstract: A vessel for processing feed stock material into molten or semi-molten state. The vessel includes a body defining an interior surface, an inlet, for receiving the feed stock material and an outlet discharging the material. The sidewall of the body comprises three layers, referred to as the shell, an intermediate layer and a liner. The intermediate layer is disposed between the shell and the liner and is formed of a material softer than the materials forming the shell and the liner. The presence of the intermediate layer minimizes the thermal gradient along the thickness of the barrel.Type: ApplicationFiled: June 28, 2002Publication date: January 8, 2004Applicant: Thixomat, Inc.Inventors: Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker
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Patent number: 6514308Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.Type: GrantFiled: August 17, 2001Date of Patent: February 4, 2003Assignee: Thixomat, Inc.Inventors: Stephen E. LeBeau, D. Matthew Walukas, Raymond F. Decker
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Patent number: 6514309Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.Type: GrantFiled: August 17, 2001Date of Patent: February 4, 2003Assignee: Thixomat, Inc.Inventors: Stephen E. LeBeau, D. Matthew Walukas, Raymond F. Decker
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Publication number: 20020170696Abstract: An apparatus for molding a metal material. The apparatus includes a vessel with portions defining a passageway through the vessel. An inlet is located toward one end and a member or agitation means is located within the passageway. A plurality of heaters are located a length of the vessel. The first of the heaters is located immediately downstream of the inlet and is a low frequency induction coil heater whereby the temperature gradient through the vessel's sidewall is minimized.Type: ApplicationFiled: May 18, 2001Publication date: November 21, 2002Inventors: Ron Akers, Ralph E. Vining, D. Matthew Walukas, Raymond F. Decker, Chris Pedder
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Publication number: 20020029658Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.Type: ApplicationFiled: August 17, 2001Publication date: March 14, 2002Inventors: Stephen E. LeBeau, D. Matthew Walukas, Raymond F. Decker
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Publication number: 20020017165Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.Type: ApplicationFiled: August 17, 2001Publication date: February 14, 2002Inventors: Stephen E. LeBeau, D. Matthew Walukas, Raymond F. Decker
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Patent number: 6299665Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.Type: GrantFiled: July 6, 1999Date of Patent: October 9, 2001Assignee: Thixomat, Inc.Inventors: Stephen E. LeBeau, D. Matthew Walukas, Raymond F. Decker
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Patent number: 6059012Abstract: An apparatus for processing feed stock into a thixotropic state. The apparatus includes a barrel with first, second and nozzle sections. The first, second and nozzle sections are connected together and include surfaces that cooperatively defining a central passageway through the barrel. The first section is constructed of a first material, the second end section is constructed of a second material and the nozzle is constructed of a third material. The first material exhibits a greater resistance to thermal fatigue and thermal shock than the second material while the nozzle section includes a bushing which inhibits heat transfer to the die, precluding excessive molding pressures and cycle times. The apparatus also includes a preheater for preheating the feed stock before entry into the barrel, a thermal gradient monitoring system, a novel robust nozzle construction, and a two-stage embodiment of the apparatus.Type: GrantFiled: June 3, 1999Date of Patent: May 9, 2000Assignee: Thixomat, Inc.Inventors: Ralph Vining, Raymond F. Decker, Robert D. Carnahan, D. Matthew Walukas, Robert Kilbert, Charles VanSchilt, Rich Newman
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Patent number: 5996679Abstract: A fully dense powder metal cobalt-base article having high resistance to semi-solid metal wear and corrosion. The article has a constituent composition of C in an amount of about 0.65 to less than about 1%, W in an amount of about 3 to about 5%, Cr in an amount of about 25 to about 30%, Co in an amount principally comprising the balance of the article. The article has a hardness of greater than 42HRC and more preferably 45HRC, a bend fracture strength of greater than 330 ksi and substantial dimensional and mechanical property stability during exposure to temperatures in range of about 1100.degree. F. to 1500.degree. F.Type: GrantFiled: November 4, 1996Date of Patent: December 7, 1999Assignee: Thixomat, Inc.Inventors: Kenneth E. Pinnow, Raymond F. Decker
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Patent number: 5983978Abstract: An apparatus for processing feed stock into a thixotropic state. The apparatus includes a barrel with first, second and nozzle sections. The first, second and nozzle sections are connected together and include surfaces that cooperatively defining a central passageway through the barrel. The first section is constructed of a first material, the second end section is constructed of a second material and the nozzle is constructed of a third material. The first material exhibits a greater resistance to thermal fatigue and thermal shock than the second material while the nozzle section includes a bushing which inhibits heat transfer to the die, precluding excessive molding pressures and cycle times. The apparatus also includes a preheater for preheating the feed stock before entry into the barrel, a thermal gradient monitoring system, a novel robust nozzle construction, and a two-stage embodiment of the apparatus.Type: GrantFiled: September 30, 1997Date of Patent: November 16, 1999Assignee: Thixomat, Inc.Inventors: Ralph Vining, Raymond F. Decker, Robert D. Carnahan, D. Matthew Walukas, Robert Kilbert, Charles VanSchilt, Rich Newman
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Patent number: 5819839Abstract: An apparatus for processing materials which are highly corrosive while in a thixotropic state, for example aluminum. The apparatus includes a barrel which is adapted to receive the material through an inlet. In the barrel, the material is heated and subjected to shearing, forming a highly corrosive, semi-solid slurry which is discharged from the barrel through a nozzle. The barrel is constructed with an outer layer of a first material and an inner layer of a Nb-based alloy which is bonded to the outer layer. Positioned within the passageway of the barrel is a screw, the rotation of which operates to subject the material to shearing and move the material through the barrel. The screw is constructed with an outer layer of the Nb-based alloy that is molecularly bonded to an inner core of a different material. The Nb-based alloy is resistant to the corrosive effects of the material being processed.Type: GrantFiled: July 2, 1997Date of Patent: October 13, 1998Assignee: Thixomat, Inc.Inventors: John Mihelich, Raymond F. Decker
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Patent number: 5711366Abstract: An apparatus for processing materials which are highly corrosive while in a thixotropic state, for example aluminum. The apparatus includes a barrel which is adapted to receive the material through an inlet. In the barrel, the material is heated and subjected to shearing, forming a highly corrosive, semi-solid slurry which is discharged from the barrel through a nozzle. The barrel is constructed with an outer layer of a first material and an inner layer of an Nb-based alloy which is bonded to the outer layer. Positioned within the passageway of the barrel is a screw, the rotation of which operates to subject the material to shearing and move the material through the barrel. The screw is constructed with an outer layer of the Nb-based alloy that is molecularly bonded to an inner core of a different material. The Nb-based alloy is resistant to the corrosive effects of the material being processed.Type: GrantFiled: May 31, 1996Date of Patent: January 27, 1998Assignee: Thixomat, Inc.Inventors: John Mihelich, Raymond F. Decker
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Patent number: 5242479Abstract: This invention relates to a method and apparatus for developing a metallic carbide coating on a substrate. The invention involves providing an enclosed chamber with sources of carbon in the form of a blank and an ingot of a metal material taken from the group including titanium, boron and silicon. Electron beam guns are employed to heat the carbon source causing a carbon vapor flow within the vessel. In accordance with this invention, the metal ingot is subjected to two distinct heating steps. A first heating step preferably using an electron beam gun, melts the ingot and the molten material flows onto a refractory surface where it is subjected to a second heating step, preferably also using an electron beam gun. The plural heating approach of this invention has been found to produce significant increases in metal vaporization rate, thus permitting a higher rate of formation of metallic carbide to be provided on the substrate.Type: GrantFiled: May 26, 1992Date of Patent: September 7, 1993Assignee: Paton Tek, Inc.Inventors: Boris A. Movchan, Alexander A. Chevychelov, Raymond F. Decker