Patents by Inventor Samuel J. Kernion

Samuel J. Kernion 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).

  • Patent number: 11634803
    Abstract: A quench and temper steel alloy is disclosed having the following composition in weight percent. C 0.1-0.4 Mn 0.1-1.0 Si 0.1-1.2 Cr 9.0-12.5 Ni 3.0-4.3 Mo ??1-2 Cu 0.1-1.0 Co ??1-4 W ?0.2 max. V 0.1-0.6 Ti ?0.1 max. Nb up to 0.01 Ta up to 0.01 Al ??0-0.25 N 0.1-0.35 Ce 0.006 max. La 0.006 max. The balance of the alloy is iron and the usual impurities found in similar grades of quench and temper steels intended for similar use or service, including not more than about 0.01% phosphorus and not more than about 0.010% sulfur. A quenched and tempered steel article made from this alloy is also disclosed. Further disclosed is a method of making the alloy.
    Type: Grant
    Filed: October 29, 2019
    Date of Patent: April 25, 2023
    Assignee: CRS HOLDINGS, LLC
    Inventors: David E. Wert, Samuel J. Kernion, Shane Para, Karl Heck
  • Patent number: 11609281
    Abstract: A method includes producing an amorphous precursor to a nanocomposite, the amorphous precursor comprising a material that is substantially without crystals not exceeding 20% volume fraction; performing devitrification of the amorphous precursor, wherein the devitrification comprises a process of crystallization; forming, based on the devitrification, the nanocomposite with nano-crystals that contains an induced magnetic anisotropy; tuning, based on one or more of composition, temperature, configuration, and magnitude of stress applied during annealing and modification, the magnetic anisotropy of the nanocomposite; and adjusting, based on the tuned magnetic anisotropy, a magnetic permeability of the nanocomposite.
    Type: Grant
    Filed: November 14, 2018
    Date of Patent: March 21, 2023
    Assignee: Carnegie Mellon University
    Inventors: Alex M. Leary, Paul R. Ohodnicki, Michael E. McHenry, Vladimir Keylin, Joseph Huth, Samuel J. Kernion
  • Publication number: 20220349032
    Abstract: A nickel base superalloy powder for additive manufacturing applications is disclosed. The alloy powder has the following broad weight percent composition: C ??0-0.1 Mn 0.5 max. Si ??0-0.03 Cr ?4-16 Fe ??0-1.5 Mo 0-6 W 0-8 Co ?0-15 Ti 0-2 Al 0.5-5.5 Nb 0-6 Ta ?7.5-14.5 Hf ??0-2.0 Zr ??0-0.1 Re 0-6 Ru 0-3 B ??0-0.03 The balance of the alloy is at least 50% nickel and the usual impurities. An article of manufacture made from the alloy is also disclosed.
    Type: Application
    Filed: May 17, 2022
    Publication date: November 3, 2022
    Inventors: Ning Zhou, Kyle B. Stritch, Tao Wang, Stephane A.J. Forsik, Gian A. Colombo, Samuel J. Kernion, Mario E. Epler, Austin Dicus
  • Publication number: 20210350961
    Abstract: A soft magnetic alloy having a good combination of formability and magnetic properties is disclosed. The alloy has the formula Fe100-a-b-c-d-e-fSiaMbLcM?dM?eRf wherein M is Cr and/or Mo; L is Co and/or Ni; M? is one or more of Al, Mn, Cu, Ge, Ga; M? is one or more of Ti, V, Hf, Nb, W; and R is one or more of B, Zr, Mg, P, Ce. The elements Si, M, L, M?, M?, and R have the following ranges in weight percent: Si ??4-7 M 0.1-7 L 0.1-10 M? up to 7 M? up to 7 R up to 1 The balance of the alloy is iron and usual impurities. A thin-gauge article made from the alloy and a method of making the thin-gauge article are also disclosed.
    Type: Application
    Filed: July 26, 2021
    Publication date: November 11, 2021
    Inventors: Chins Chinnasamy, Samuel J. Kernion, Eric Fitterling, Alberto Polar-Rosas, Tao Wang
  • Publication number: 20210180158
    Abstract: A nickel base superalloy powder for additive manufacturing applications is disclosed. The alloy powder has the following broad weight percent composition: C ?0-0.1 Mn 0.5 max. Si ??0-0.03 Cr ?4-16 Fe ?0-1.5 Mo 0-6 W 0-8 Co ?0-15 Ti 0-2 Al 0.5-5.5 Nb 0-6 Ta ?7.5-14.5 Hf ?0-2.0 Zr ?0-0.1 Re 0-6 Ru 0-3 B ??0-0.03 The balance of the alloy is at least 50% nickel and the usual impurities. An article of manufacture made from the alloy is also disclosed.
    Type: Application
    Filed: January 23, 2020
    Publication date: June 17, 2021
    Inventors: Ning Zhou, Kyle B. Stritch, Tao Wang, Stephane A.J. Forsik, Gian A. Colombo, Samuel J. Kernion, Mario E. Epler, Austin Dicus
  • Publication number: 20210166848
    Abstract: An Fe-base, soft magnetic alloy is disclosed. The alloy has the general formula Fe100-a-b-c-d-x-y MaM?bM?cM??d Px Mny where M is Co and/or Ni, M? is one or more of Zr, Nb, Cr, Mo, Hf, Sc, Ti, V, W, and Ta, M? is one or more of B, C, Si, and Al, and M?? is selected from the group consisting of Cu, Pt, Ir, Zn, Au, and Ag. The subscripts a, b, c, d, x, and y represent the atomic proportions of the elements and have the following atomic percent ranges: 0?a?10, 0?b?7, 5?c?20, 0?d?5, 0.1?x?15, and 0.1?y?5. The balance of the alloy is iron and usual impurities. Alloy powder, a magnetic article made therefrom, and an amorphous metal article made from the alloy are also disclosed.
    Type: Application
    Filed: February 4, 2021
    Publication date: June 3, 2021
    Inventors: Chins Chinnasamy, Samuel J. Kernion, James F. Scanlon
  • Patent number: 10837091
    Abstract: A nickel-base alloy is disclosed that has the following weight percent composition. C about 0.005 to about 0.06 Cr about 13 to about 17 Fe about 4 to about 20 Mo about 3 to about 9 W up to about 8 Co up to about 12 Al about 1 to about 3 Ti about 0.6 to about 3 Nb up to about 5.5 B about 0.001 to about 0.012 Mg about 0.0010 to about 0.0020 Zr about 0.01 to about 0.08 Si up to about 0.7 P up to about 0.05 and the balance is nickel, usual impurities, and minor amounts of other elements as residuals from alloying additions during melting. The alloy provides a combination of high strength, good creep resistance, and good resistance to crack growth. A method of heat treating a nickel base superalloy to improve the tensile ductility of the alloy is also disclosed. An article of manufacture made from the nickel base superalloy described herein is also disclosed.
    Type: Grant
    Filed: April 1, 2019
    Date of Patent: November 17, 2020
    Assignee: CRS HOLDINGS, INC.
    Inventors: Karl A. Heck, Samuel J. Kernion
  • Publication number: 20200063247
    Abstract: A quench and temper steel alloy is disclosed having the following composition in weight percent. C 0.1-0.4 Mn 0.1-1.0 Si 0.1-1.2 Cr 9.0-12.5 Ni 3.0-4.3 Mo ??1-2 Cu 0.1-1.0 Co ??1-4 W ?0.2 max. V 0.1-0.6 Ti ?0.1 max. Nb up to 0.01 Ta up to 0.01 Al ??0-0.25 N 0.1-0.35 Ce 0.006 max. La 0.006 max. The balance of the alloy is iron and the usual impurities found in similar grades of quench and temper steels intended for similar use or service, including not more than about 0.01% phosphorus and not more than about 0.010% sulfur. A quenched and tempered steel article made from this alloy is also disclosed. Further disclosed is a method of making the alloy.
    Type: Application
    Filed: October 29, 2019
    Publication date: February 27, 2020
    Inventors: David E. Wert, Samuel J. Kernion, Shane Para, Karl Heck
  • Publication number: 20190226072
    Abstract: A nickel-base alloy is disclosed that has the following weight percent composition. C about 0.005 to about 0.06 Cr about 13 to about 17 Fe about 4 to about 20 Mo about 3 to about 9 W up to about 8 Co up to about 12 Al about 1 to about 3 Ti about 0.6 to about 3 Nb up to about 5.5 B about 0.001 to about 0.012 Mg about 0.0010 to about 0.0020 Zr about 0.01 to about 0.08 Si up to about 0.7 P up to about 0.05 and the balance is nickel, usual impurities, and minor amounts of other elements as residuals from alloying additions during melting. The alloy provides a combination of high strength, good creep resistance, and good resistance to crack growth. A method of heat treating a nickel base superalloy to improve the tensile ductility of the alloy is also disclosed. An article of manufacture made from the nickel base superalloy described herein is also disclosed.
    Type: Application
    Filed: April 1, 2019
    Publication date: July 25, 2019
    Inventors: Karl A. Heck, Samuel J. Kernion
  • Publication number: 20190154765
    Abstract: A method includes producing an amorphous precursor to a nanocomposite, the amorphous precursor comprising a material that is substantially without crystals not exceeding 20% volume fraction; performing devitrification of the amorphous precursor, wherein the devitrification comprises a process of crystallization; forming, based on the devitrification, the nanocomposite with nano-crystals that contains an induced magnetic anisotropy; tuning, based on one or more of composition, temperature, configuration, and magnitude of stress applied during annealing and modification, the magnetic anisotropy of the nanocomposite; and adjusting, based on the tuned magnetic anisotropy, a magnetic permeability of the nanocomposite.
    Type: Application
    Filed: November 14, 2018
    Publication date: May 23, 2019
    Inventors: Alex M. Leary, Paul R. Ohodnicki, Michael E. McHenry, Vladimir Keylin, Joseph Huth, Samuel J. Kernion
  • Patent number: 10280498
    Abstract: A nickel-base alloy is disclosed that has the following weight percent composition. C about 0.005 to about 0.06 Cr about 13 to about 17 Fe about 4 to about 20 Mo about 3 to about 9 W up to about 8 Co up to about 12 Al about 1 to about 3 Ti about 0.6 to about 3 Nb up to about 5.5 B about 0.001 to about 0.012 Mg about 0.0010 to about 0.0020 Zr about 0.01 to about 0.08 Si up to about 0.7 P up to about 0.05 and the balance is nickel, usual impurities, and minor amounts of other elements as residuals from alloying additions during melting. The alloy provides a combination of high strength, good creep resistance, and good resistance to crack growth. A method of heat treating a nickel base superalloy to improve the tensile ductility of the alloy is also disclosed. An article of manufacture made from the nickel base superalloy described herein is also disclosed.
    Type: Grant
    Filed: October 12, 2016
    Date of Patent: May 7, 2019
    Assignee: CRS HOLDINGS, INC.
    Inventors: Karl A. Heck, Samuel J. Kernion
  • Patent number: 10168392
    Abstract: A method includes producing an amorphous precursor to a nanocomposite, the amorphous precursor comprising a material that is substantially without crystals not exceeding 20% volume fraction; performing devitrification of the amorphous precursor, wherein the devitrification comprises a process of crystallization; forming, based on the devitrification, the nanocomposite with nano-crystals that contains an induced magnetic anisotropy; tuning, based on one or more of composition, temperature, configuration, and magnitude of stress applied during annealing and modification, the magnetic anisotropy of the nanocomposite; and adjusting, based on the tuned magnetic anisotropy, a magnetic permeability of the nanocomposite.
    Type: Grant
    Filed: May 15, 2014
    Date of Patent: January 1, 2019
    Assignees: Carnegie Mellon University, SPANG, INC., U.S. Department of Energy
    Inventors: Alex M. Leary, Paul R. Ohodnicki, Michael E. McHenry, Vladimir Keylin, Joseph Huth, Samuel J. Kernion
  • Publication number: 20180340245
    Abstract: A multi-principal element, corrosion resistant alloy is disclosed. The alloy has the following composition in weight percent: Co about 13 to about 28 Ni about 13 to about 28 Fe+Mn about 13 to about 28 Cr about 13 to about 37 Mo about 8 to about 28 N about 0.10 to about 1.00. The alloy also includes the usual impurities found in corrosion resistant alloys intended for the same or similar use. In addition, one or both of W and V may be substituted for some or all of the Mo. The alloy provides a solid solution that is substantially all FCC phase, but may include minor amounts of secondary phases that do not adversely affect the corrosion resistance and mechanical properties provided by the alloy.
    Type: Application
    Filed: March 8, 2018
    Publication date: November 29, 2018
    Inventors: Samuel J. Kernion, Alberto Polar-Rosas
  • Publication number: 20180336982
    Abstract: A soft magnetic alloy having a good combination of formability and magnetic properties is disclosed. The alloy has the formula Fe100-a-b-c-d-e-fSiaMbLcM?dM?eRf wherein M is Cr and/or Mo; L is Co and/or Ni; M? is one or more of Al, Mn, Cu, Ge, Ga; M? is one or more of Ti, V, Hf, Nb, W; and R is one or more of B, Zr, Mg, P, Ce. The elements Si, M, L, M?, M?, and R have the following ranges in weight percent: Si ?4-7 M 0.1-7? L 0.1-10 M? up to 7 M? up to 7 R up to 1 The balance of the alloy is iron and usual impurities. A thin-gauge article made from the alloy and a method of making the thin-gauge article are also disclosed.
    Type: Application
    Filed: May 17, 2018
    Publication date: November 22, 2018
    Inventors: Chins Chinnasamy, Samuel J. Kernion, Eric Fitterling, Alberto Polar-Rosas, Tao Wang
  • Publication number: 20180233258
    Abstract: An Fe-base, soft magnetic alloy is disclosed. The alloy has the general formula Fe100 a-b-c-d-x-y MaM?bM?cM??dPxMny where M is Co and/or Ni, M? is one or more of Zr, Nb, Cr, Mo, Hf, Sc, Ti, V, W, and Ta, M? is one or more of B, C, Si, and Al, and M?' is selected from the group consisting of Cu, Pt, Ir, Zn, Au, and Ag. The subscripts a, b, c, d, x, and y represent the atomic proportions of the elements and have the following atomic percent ranges: 0?a?10, 0?b?7, 5?c?20, 0?d?5, 0.1?x?15, and 0.1?y?5. The balance of the alloy is iron and usual impurities. Alloy powder, a magnetic article made therefrom, and an amorphous metal article made from the alloy are also disclosed.
    Type: Application
    Filed: February 15, 2018
    Publication date: August 16, 2018
    Inventors: Chins Chinnasamy, Samuel J. Kernion, James F. Scanlon
  • Publication number: 20180100222
    Abstract: A nickel-base alloy is disclosed that has the following weight percent composition. C about 0.005 to about 0.06 Cr about 13 to about 17 Fe about 4 to about 20 Mo about 3 to about 9 W up to about 8 Co up to about 12 Al about 1 to about 3 Ti about 0.6 to about 3 Nb up to about 5.5 B about 0.001 to about 0.012 Mg about 0.0010 to about 0.0020 Zr about 0.01 to about 0.08 Si up to about 0.7 P up to about 0.05 and the balance is nickel, usual impurities, and minor amounts of other elements as residuals from alloying additions during melting,. The alloy provides a combination of high strength, good creep resistance, and good resistance to crack growth. A method of heat treating a nickel base superalloy to improve the tensile ductility of the alloy is also disclosed. An article of manufacture made from the nickel base superalloy described herein is also disclosed.
    Type: Application
    Filed: October 12, 2016
    Publication date: April 12, 2018
    Inventors: Karl A. Heck, Samuel J. Kernion
  • Publication number: 20140338793
    Abstract: A method includes producing an amorphous precursor to a nanocomposite, the amorphous precursor comprising a material that is substantially without crystals not exceeding 20% volume fraction; performing devitrification of the amorphous precursor, wherein the devitrification comprises a process of crystallization; forming, based on the devitrification, the nanocomposite with nano-crystals that contains an induced magnetic anisotropy; tuning, based on one or more of composition, temperature, configuration, and magnitude of stress applied during annealing and modification, the magnetic anisotropy of the nanocomposite; and adjusting, based on the tuned magnetic anisotropy, a magnetic permeability of the nanocomposite.
    Type: Application
    Filed: May 15, 2014
    Publication date: November 20, 2014
    Inventors: Alex M. Leary, Paul R. Ohodnicki, Michael E. McHenry, Vladimir Keylin, Joseph Huth, Samuel J. Kernion