Patents by Inventor Sazol Kumar Das
Sazol Kumar Das 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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Publication number: 20240035136Abstract: Described herein are 6xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys are highly formable and exhibit high strength. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.Type: ApplicationFiled: October 16, 2023Publication date: February 1, 2024Applicant: Novelis Inc.Inventors: Sazol Kumar Das, Milan Felberbaum
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Patent number: 11821065Abstract: Described herein are 6xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys are highly formable and exhibit high strength. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.Type: GrantFiled: September 27, 2017Date of Patent: November 21, 2023Assignee: Novelis Inc.Inventors: Sazol Kumar Das, Milan Felberbaum
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Patent number: 11806779Abstract: Provided herein are systems and methods for producing thick gauge aluminum alloy articles such as plates, shates, slabs, sheet plates or the like. A method for producing thick gauge aluminum alloy articles can include continuously casting an aluminum alloy article and hot or warm rolling the aluminum alloy article. Also provided herein is a continuous casting system for producing thick gauge aluminum alloy articles. The disclosed thick gauge aluminum alloy articles can be provided in any suitable temper.Type: GrantFiled: September 27, 2017Date of Patent: November 7, 2023Assignee: Novelis Inc.Inventors: Milan Felberbaum, Corrado Bassi, Sazol Kumar Das, Simon Barker, Tudor Piroteala, Rajasekhar Talla
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Publication number: 20230349033Abstract: Provided herein are highly formable aluminum alloys and methods of making the same. The highly formable aluminum alloys described herein can be prepared from recycled materials without significant addition of primary aluminum alloy material. The aluminum alloys are prepared by casting an aluminum alloy that can include such recycled materials and processing the resulting cast aluminum alloy article. Also described herein are methods of using the aluminum alloys and alloy products.Type: ApplicationFiled: July 3, 2023Publication date: November 2, 2023Applicant: Novelis Inc.Inventors: Sazol Kumar Das, Matthew Heyen, Peter Evans, Martin Beech, ChangOok Son, Mark Marsh, Rajeev G. Kamat, Rainer Kossak, David Fryatt, David Scott Fisher, Guillaume Florey, Cyrille Bezencon, Juergen Timm
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Patent number: 11788178Abstract: Provided herein are highly-formable aluminum alloys and methods of making such alloys. The method of preparing aluminum alloys described herein can include a low final cold reduction step and/or an optional inter-annealing step to produce randomly distributed crystallographic texture components that produce an isotropic aluminum alloy product exhibiting improved formability and deep drawability. The methods described herein result in aluminum alloy microstructures having a balance of alpha fibers and beta fibers that promote improved formability of aluminum alloy sheets. The resulting improvements in quality allow for shaping processes with reduced rates of spoilage.Type: GrantFiled: July 22, 2019Date of Patent: October 17, 2023Assignee: Novelis Inc.Inventors: Sazol Kumar Das, Matthew Josef Heyen, ChangOok Son, Rashmi Ranjan Mohanty, Guillaume Florey
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Patent number: 11746400Abstract: Provided herein are ultra-high strength aluminum alloys and products prepared therefrom, along with methods of processing the ultra-high strength aluminum alloys. The aluminum alloys described herein are high solute alloys, including significant amounts of zinc (Zn), magnesium (Mg), copper (Cu), and other elements in addition to aluminum. The aluminum alloys described herein are amenable to post-aging processing without cracking.Type: GrantFiled: May 8, 2020Date of Patent: September 5, 2023Assignee: Novelis Inc.Inventors: Sazol Kumar Das, Rajeev G. Kamat, Samuel Robert Wagstaff, Simon William Barker, Rajasekhar Talla, Tudor Piroteala
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Publication number: 20230226598Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.Type: ApplicationFiled: January 23, 2023Publication date: July 20, 2023Applicant: NOVELIS INC.Inventors: MILAN FELBERBAUM, SAZOL KUMAR DAS, AURELE MARIAUX, DUANE E. BENDZINSKI, CYRILLE BEZENCON, SIMON WILLIAM BARKER, CORRADO BASSI, RAJEEV G. KAMAT, TUDOR PIROTEALA, RAJASEKHAR TALLA, ROBERT BRUCE WAGSTAFF
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Patent number: 11692255Abstract: Described herein are 7xxx series aluminum alloys with unexpected properties and novel methods of producing such aluminum alloys. The aluminum alloys exhibit high strength and are highly formable. The alloys are produced by continuous casting and can be hot rolled to a final gauge and/or a final temper. The alloys can be used in automotive, transportation, industrial, and electronics applications, just to name a few.Type: GrantFiled: September 27, 2017Date of Patent: July 4, 2023Assignee: Novelis Inc.Inventors: Milan Felberbaum, Sazol Kumar Das, Duane E. Bendzinski, Rajeev G. Kamat, Tudor Piroteala, Rajasekhar Talla
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Publication number: 20230193441Abstract: A system for heat-treating a coil of metal can include a furnace, an unwinding system, and a quenching system. The furnace may receive the coil of metal and elevate a temperature of the metal to be within a pre-heated temperature range, such as a homogenizing temperature range or an annealing temperature range. The unwinding system may unwind at least a portion of the coil in a heated state in which the metal is within the pre-heated temperature range or before the metal has cooled past a threshold amount below the pre-heated temperature range. The quenching system may receive the unwound portion of the coil from the unwinding device and reduce a temperature of the unwound portion to a within a quenched temperature range within a predetermined amount of time.Type: ApplicationFiled: October 13, 2020Publication date: June 22, 2023Applicant: Novelis Inc.Inventors: Timothy Francis Stanistreet, Mark Finn, Renato Rufino Xavier, Frank Su, Louis Mitchell Nazro, Tudor Piroteala, Samuel Robert Wagstaff, Barbara Lucille Hyde, David Anthony Gaensbauer, Sazol Kumar Das
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Patent number: 11649529Abstract: Disclosed are aluminum alloy products and methods of making and processing such products. Thus, disclosed are aluminum alloy products exhibiting controllable surface properties, including excellent bond durability, low contact resistance, and corrosion resistance. Aluminum alloy products described herein include a migrant element, a subsurface portion having a concentration of the migrant element, and a bulk portion having a concentration of the migrant element. The aluminum alloy product comprises an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the migrant element concentration in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminum alloy products surface and/or subsurface can contain phosphorus (e.g., elemental phosphorus or oxidized phosphorus). The phosphorus containing surface provides reduced electronic stress on an electrode tip of a resistance spot welding apparatus, and an extended service lifetime (e.g.Type: GrantFiled: October 23, 2018Date of Patent: May 16, 2023Assignee: NOVELIS INC.Inventors: Liangliang Li, Theresa Elizabeth MacFarlane, Sazol Kumar Das, Peter Lloyd Redmond, Changook Son, Dewei Zhu, Yudie Yuan, Luis Fanor Vega, Milan Felberbaum, Julio Malpica, Brian Paradis, Alp Manavbasi, Dechao Lin
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Publication number: 20230099830Abstract: Described are aluminum alloy products that generally have a microstructure and composition that resists corrosion. This corrosion resistance, in turn, allows the aluminum alloy products to exhibit favorable bond durability performance, such as when adhesively bonded to another product. The corrosion resistance can be achieved by controlling the composition of the aluminum alloy, including the presence and/or concentration of certain intermetallic particles, such as ?-phase intermetallic particles and ?-phase intermetallic particles.Type: ApplicationFiled: February 18, 2021Publication date: March 30, 2023Applicant: Novelis Inc.Inventors: Theresa Elizabeth MacFarlane, Lasitha Cumaranatunge, Sazol Kumar Das, Yudie Yuan, Thomas J. Beck, Rajeev G. Kamat, Peter Lloyd Redmond, John Anthony Hunter, Liangliang Li, Samuel Robert Wagstaff, Kumar Sundaram, Robert Bruce Wagstaff
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Publication number: 20230082861Abstract: Aluminum alloy products having a bulk and a micro-grained subsurface structure are described. The aluminum alloy products may exhibit superior bonding character and may comprise or have a silicon-containing layer thereon. The bulk may include a matrix including grains of an aluminum alloy and may comprise aluminum and one or more alloying elements such as zinc, magnesium, copper, chromium, silicon, iron, or manganese. The micro-grained subsurface structure may be substantially devoid of one or more defects (e.g., voids, transfer cracks, or fissures) or organics, oils, hydrocarbons, soils, inorganic residues, rolled-in oxides, or anodic oxides, which may commonly be present in rolled near-surface microstructures. The micro-grained subsurface structure may include or have thereon a first oxide layer having a thickness of from 1 nm to 20 nm. Methods of making aluminum alloy products are also described.Type: ApplicationFiled: February 18, 2021Publication date: March 16, 2023Applicant: Novelis Inc.Inventors: THERESA ELIZABETH MACFARLANE, SAZOL KUMAR DAS, RASHMI RANJAN MOHANTY, ALP MANAVBASI, YUDIE YUAN, THOMAS J. BECK
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Publication number: 20230074427Abstract: Described are aluminum alloy products and methods of making aluminum alloy products in which the aluminum alloy products have carefully controlled intermetallic particle density and particle size. Such aluminum alloy products may exhibit favorable formability. Control over intermetallic particle size and density may allow for use of high amounts of recycled source content in aluminum alloy products.Type: ApplicationFiled: January 20, 2021Publication date: March 9, 2023Applicant: Novelis Inc.Inventors: Daehoon Kang, Kyle David Dasch, Mitchell Glenn Roux, John Min Ho, Sazol Kumar Das, Rashmi Ranjan Mohanty, Dewei Zhu, Stephen Buckingham, Amanda Owens
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Patent number: 11590565Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.Type: GrantFiled: October 30, 2020Date of Patent: February 28, 2023Assignee: Novelis Inc.Inventors: Milan Felberbaum, Sazol Kumar Das, Aurele Mariaux, Duane E. Bendzinski, Cyrille Bezencon, Simon William Barker, Corrado Bassi, Rajeev G. Kamat, Tudor Piroteala, Rajasekhar Talla, Robert Bruce Wagstaff
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Patent number: 11466352Abstract: Described herein are formable, high strength aluminum alloy products and methods of preparing and processing the same. The methods of preparing and processing the aluminum alloy products include casting an aluminum alloy and performing tailored rolling and downstream thermal processing steps. The resulting aluminum alloy products possess high strength and formability properties.Type: GrantFiled: October 23, 2019Date of Patent: October 11, 2022Assignee: Novelis Inc.Inventors: Sazol Kumar Das, Rajeev G. Kamat, Rajasekhar Talla, Tudor Piroteala
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Patent number: 11180838Abstract: Provided herein are high performance aluminum alloy products having desirable mechanical properties and methods of making the same. The high performance aluminum alloy products described herein contain a high content of recycled material and are prepared by casting an aluminum alloy to form a cast aluminum alloy product and processing the cast aluminum alloy product. The method of processing the cast aluminum alloy product can include two hot rolling steps.Type: GrantFiled: July 5, 2018Date of Patent: November 23, 2021Assignee: NOVELIS INC.Inventors: Milan Felberbaum, Sazol Kumar Das, Simon William Barker, Tudor Piroteala, Duane E. Bendzinski
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Patent number: 10975461Abstract: Techniques are disclosed for casting high-strength and highly formable metal products from recycled metal scrap without the addition of substantial or any amounts of primary aluminum. Additional alloying elements, such as magnesium, can be added to metal scrap, which can be cast and processed to produce a desirable metal coil at final gauge having desirable metallurgical and mechanical properties, such as high strength and formability. Thus, inexpensive and recycled metal scrap can be efficiently repurposed for new applications, such as automotive applications and beverage can stock.Type: GrantFiled: March 23, 2018Date of Patent: April 13, 2021Assignee: Novelis Inc.Inventors: Sazol Kumar Das, Simon William Barker, Milan Felberbaum, Rajeev G. Kamat, Duane E. Bendzinski, Robert Bruce Wagstaff, Samuel R. Wagstaff
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Publication number: 20210046540Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.Type: ApplicationFiled: October 30, 2020Publication date: February 18, 2021Applicant: NOVELIS INC.Inventors: MILAN FELBERBAUM, SAZOL KUMAR DAS, AURELE MARIAUX, DUANE E. BENDZINSKI, CYRILLE BEZENCON, SIMON WILLIAM BARKER, CORRADO BASSI, RAJEEV G. KAMAT, TUDOR PIROTEALA, RAJASEKHAR TALLA, ROBERT BRUCE WAGSTAFF
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Patent number: 10913107Abstract: A continuous casting and rolling line for casting, rolling, and otherwise preparing metal strip can produce distributable metal strip without requiring cold rolling or the use of a solution heat treatment line. A metal strip can be continuously cast from a continuous casting device and coiled into a metal coil, optionally after being subjected to post-casting quenching. This intermediate coil can be stored until ready for hot rolling. The as-cast metal strip can undergo reheating prior to hot rolling, either during coil storage or immediately prior to hot rolling. The heated metal strip can be cooled to a rolling temperature and hot rolled through one or more roll stands. The rolled metal strip can optionally be reheated and quenched prior to coiling for delivery. This final coiled metal strip can be of the desired gauge and have the desired physical characteristics for distribution to a manufacturing facility.Type: GrantFiled: September 27, 2017Date of Patent: February 9, 2021Assignee: Novelis Inc.Inventors: Milan Felberbaum, Sazol Kumar Das, Aurele Mariaux, Duane E. Bendzinski, Cyrille Bezencon, Simon William Barker, Corrado Bassi, Rajeev G. Kamat, Tudor Piroteala, Rajasekhar Talla, Robert Bruce Wagstaff
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Publication number: 20200377976Abstract: Provided herein are ultra-high strength aluminum alloys and products prepared therefrom, along with methods of processing the ultra-high strength aluminum alloys. The aluminum alloys described herein are high solute alloys, including significant amounts of zinc (Zn), magnesium (Mg), copper (Cu), and other elements in addition to aluminum. The aluminum alloys described herein are amenable to post-aging processing without cracking.Type: ApplicationFiled: May 8, 2020Publication date: December 3, 2020Applicant: Novelis Inc.Inventors: Sazol Kumar Das, Rajeev G. Kamat, Samuel Robert Wagstaff, Simon William Barker, Rajasekhar Talla, Tudor Piroteala