Patents by Inventor Zachary C. Sims
Zachary C. Sims 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: 11718898Abstract: An alloy includes aluminum, a rare earth element, and an alloying element selected from the following: Si, Cu, Mg, Fe, Ti, Zn, Zr, Mn, Ni, Sr, B, Ca, and a combination thereof. The aluminum (Al), the rare earth element (RE), and the alloying element are characterized by forming at least one form of an intermetallic compound. An amount of the rare earth element in the alloy is in a range of about 1 wt. % to about 12 wt. %, and an amount of the alloying element in the alloy is greater than an amount of the alloying element present in the intermetallic compound.Type: GrantFiled: July 13, 2020Date of Patent: August 8, 2023Assignees: Lawrence Livermore National Security, LLC, University of Tennessee Research Foundation, Iowa State University Research Foundation, Inc., UT-Battelle, LLC, Eck Industries, Inc.Inventors: Emily E. Moore, Hunter B. Henderson, Aurelien Perron, Scott K. McCall, Orlando Rios, Zachary C. Sims, Michael S. Kesler, David Weiss, Patrice E. A. Turchi, Ryan T. Ott
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Publication number: 20230235432Abstract: MMC’s comprising an Al—RE alloy-based matrix and ceramic, metal and/or intermetallic reinforcement particulates dispersed in the alloy matrix provide improved strength and ductility wherein the reinforcement particulates have a higher melting temperature than the matrix alloy.Type: ApplicationFiled: January 23, 2023Publication date: July 27, 2023Inventors: Ryan T. Ott, Fanqiang Meng, Scott K. McCall, Hunter B. Henderson, Oriando Rios, Zachary C. Sims, David Weiss
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Patent number: 11667996Abstract: A solid aluminum-fiber composite comprising: (i) an aluminum-containing matrix comprising elemental aluminum; (ii) coated or uncoated fibers embedded within said aluminum-containing matrix, wherein said fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said fibers embedded therein; and (iii) an intermetallic layer present as an interface between each of said fibers and the aluminum-containing matrix, wherein said intermetallic layer has a composition different from said aluminum-containing matrix and said fibers, and said intermetallic layer contains at least one element that is also present in the aluminum-containing matrix and at least one element present in the fibers, whether from the coated or interior portion of the fibers. Methods of producing the above-described composite are also described.Type: GrantFiled: November 29, 2018Date of Patent: June 6, 2023Assignees: UT-Battelle, LLC, Eck Industries, Inc.Inventors: Orlando Rios, Michael S. Kesler, Zachary C. Sims, Edgar Lara-Curzio, David Weiss
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Patent number: 11535912Abstract: An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.Type: GrantFiled: June 29, 2021Date of Patent: December 27, 2022Assignees: UT-Battelle, LLC, Eck Industries, Inc.Inventors: Orlando Rios, David Weiss, Zachary C. Sims, William G. Carter, Michael S. Kesler
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Publication number: 20220380868Abstract: Production of a bulk Al-RE alloy body (product) using cast billets/ingots (cooling rates <100 C/s) or rapidly solidified Al-RE particulates (cooling rates 102-106° C./second) that have beneficial microstructural refinements that are further refined by subsequent consolidation to produce a consolidated bulk alloy product having excellent mechanical properties over a wide temperature range such as up to and above 230° C.Type: ApplicationFiled: May 25, 2022Publication date: December 1, 2022Inventors: Ryan T. Ott, Orlando Rios, Zachary C. Sims, David Weiss, Michael G. Kesler, Fanqiang Meng, Scott K. McCall, Hunter B. Henderson
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Additive manufacturing methods using aluminum-rare earth alloys and products made using such methods
Patent number: 11491546Abstract: Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.Type: GrantFiled: July 9, 2020Date of Patent: November 8, 2022Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation, Iowa State University Research Foundation, Inc., Eck Industries IncorporatedInventors: Alex J. Plotkowski, Orlando Rios, Sudarsanam Suresh Babu, Ryan R. Dehoff, Ryan Ott, Zachary C. Sims, Niyanth Sridharan, David Weiss, Hunter B. Henderson -
Publication number: 20210324500Abstract: An alloy for structural direct-writing additive manufacturing comprising a base element selected from the group consisting of aluminum (Al), nickel (Ni) and a combination thereof, and a rare earth element selected from the group consisting of cerium (Ce), lanthanide (La) and a combination thereof, and a eutectic intermetallic present in said alloy in an amount ranging from about 0.5 wt. % to 7.5 wt. %. The invention is also directed to a method of structural direct-write additive manufacturing using the above-described alloy, as well as 3D objects produced by the method. The invention is also directed to methods of producing the above-described alloy.Type: ApplicationFiled: June 29, 2021Publication date: October 21, 2021Applicants: UT-Battelle, LLC, Eck Industries, Inc.Inventors: Orlando RIOS, David WEISS, Zachary C. SIMS, William G. CARTER, Michael S. KESLER
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Publication number: 20210129270Abstract: Disclosed herein are embodiments of an Al—Ce—Ni alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.Type: ApplicationFiled: October 29, 2020Publication date: May 6, 2021Inventors: Ryan R. Dehoff, Hunter B. Henderson, Scott McCall, Richard Michi, Peeyush Nandwana, Ryan Ott, Alexander J. Plotkowski, Orlando Rios, Amit Shyam, Zachary C. Sims, Kevin D. Sisco, David Weiss, Ying Yang
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Publication number: 20210130934Abstract: Disclosed herein are embodiments of an Al—Ce—Cu alloy for use in additive manufacturing. The disclosed alloy embodiments provide fabricated objects, such as bulk components, comprising a heterogeneous microstructure and having good mechanical properties even when exposed to conditions used during the additive manufacturing process. Methods for making and using alloy embodiments also are disclosed herein.Type: ApplicationFiled: October 29, 2020Publication date: May 6, 2021Inventors: Sumit Bahl, Ryan R. Dehoff, Hunter B. Henderson, Scott McCall, Ryan Ott, Alexander J. Plotkowski, Orlando Rios, Amit Shyam, Zachary C. Sims, Kevin D. Sisco, David Weiss, Ying Yang
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Publication number: 20210108292Abstract: An alloy includes aluminum, a rare earth element, and an alloying element selected from the following: Si, Cu, Mg, Fe, Ti, Zn, Zr, Mn, Ni, Sr, B, Ca, and a combination thereof. The aluminum (Al), the rare earth element (RE), and the alloying element are characterized by forming at least one form of an intermetallic compound. An amount of the rare earth element in the alloy is in a range of about 1 wt. % to about 12 wt. %, and an amount of the alloying element in the alloy is greater than an amount of the alloying element present in the intermetallic compound.Type: ApplicationFiled: July 13, 2020Publication date: April 15, 2021Inventors: Emily E. Moore, Hunter B. Henderson, Aurelien Perron, Scott K. McCall, Orlando Rios, Zachary C. Sims, Michael S. Kesler, David Weiss, Patrice E. A. Turchi, Ryan T. Ott
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ADDITIVE MANUFACTURING METHODS USING ALUMINUM-RARE EARTH ALLOYS AND PRODUCTS MADE USING SUCH METHODS
Publication number: 20200340082Abstract: Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.Type: ApplicationFiled: July 9, 2020Publication date: October 29, 2020Applicants: UT-Battelle, LLC, University of Tennessee Research Foundation, Iowa State University Research Foundation, Inc., Eck Industries IncorporatedInventors: Alex J. Plotkowski, Orlando Rios, Sudarsanam Suresh Babu, Ryan R. Dehoff, Ryan Ott, Zachary C. Sims, Niyanth Sridharan, David Weiss, Hunter B. Henderson -
Additive manufacturing methods using aluminum-rare earth alloys and products made using such methods
Patent number: 10760148Abstract: Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.Type: GrantFiled: July 14, 2017Date of Patent: September 1, 2020Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation, Iowa State University Research Foundation, Inc., Eck Industries IncorporatedInventors: Alex J. Plotkowski, Orlando Rios, Sudarsanam Suresh Babu, Ryan R. Dehoff, Ryan Ott, Zachary C. Sims, Niyanth Sridharan, David Weiss, Hunter B. Henderson -
Patent number: 10694590Abstract: A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material and a plurality of rollers for advancing the working material. An electromagnetic heater is provided to heat and deposit molten working material as a new supply of working material is forced through the material guide.Type: GrantFiled: April 11, 2017Date of Patent: June 23, 2020Assignee: UT-BATTELLE, LLCInventors: Orlando Rios, William G. Carter, Zachary C. Sims, Lonnie J. Love, Phillip C. Chesser
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Patent number: 10584403Abstract: Embodiments of surface-hardened aluminum-rare earth alloys and methods of making the alloys are disclosed. In some embodiments, the alloy comprises aluminum and 4 wt % to 60 wt % of a rare earth component X having a maximum solid solubility of ?0.5 wt % in aluminum. The surface-hardened alloy component has an alloy bulk portion and a hardened alloy surface portion. At least a portion of the hardened alloy surface portion has a Vickers hardness that is at least 30% greater than a Vickers hardness of the alloy bulk portion.Type: GrantFiled: July 14, 2017Date of Patent: March 10, 2020Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation, Iowa State University Research Foundation, Inc., Eck Industries IncorporatedInventors: Orlando Rios, Sudarsanam Suresh Babu, Ryan R. Dehoff, Ryan Ott, Alex J. Plotkowski, Zachary C. Sims, Niyanth Sridharan, David Weiss, Hunter B. Henderson
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Patent number: 10542589Abstract: A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material. An advancement mechanism comprising one or more pistons, pushers, plungers and/or pressure regulation systems are positioned behind at least a portion of the supply of working material for advancing the working material forward. The working material is heated using an electro-magnetic heating element and the melted or molten working material is deposited from a tip positioned at an end of the material guide.Type: GrantFiled: April 11, 2017Date of Patent: January 21, 2020Assignee: UT-BATTELLE, LLCInventors: Orlando Rios, William G. Carter, Zachary C. Sims
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Publication number: 20190169725Abstract: A solid aluminum-fiber composite comprising: (i) an aluminum-containing matrix comprising elemental aluminum; (ii) coated or uncoated fibers embedded within said aluminum-containing matrix, wherein said fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said fibers embedded therein; and (iii) an intermetallic layer present as an interface between each of said fibers and the aluminum-containing matrix, wherein said intermetallic layer has a composition different from said aluminum-containing matrix and said fibers, and said intermetallic layer contains at least one element that is also present in the aluminum-containing matrix and at least one element present in the fibers, whether from the coated or interior portion of the fibers. Methods of producing the above-described composite are also described.Type: ApplicationFiled: November 29, 2018Publication date: June 6, 2019Inventors: Orlando RIOS, Michael S. KESLER, Zachary C. SIMS, Edgar LARA-CURZIO, David WEISS
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Patent number: 9963770Abstract: A cast alloy includes aluminum and from about 5 to about 30 weight percent of at least one material selected from the group consisting of cerium, lanthanum, and mischmetal. The cast alloy has a strengthening Al11X3 intermetallic phase in an amount in the range of from about 5 to about 30 weight percent, wherein X is at least one of cerium, lanthanum, and mischmetal. The Al11X3 intermetallic phase has a microstructure that includes at least one of lath features and rod morphological features. The morphological features have an average thickness of no more than 700 um and an average spacing of no more than 10 um, the microstructure further comprising an eutectic microconstituent that comprises more than about 10 volume percent of the microstructure.Type: GrantFiled: July 7, 2016Date of Patent: May 8, 2018Assignee: UT-Battelle, LLCInventors: Orlando Rios, Alexander H. King, Scott K. McCall, Michael A. McGuire, Zachary C. Sims, Cori Thorne, David Weiss, Gerard M. Ludtka
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Publication number: 20180080102Abstract: Embodiments of surface-hardened aluminum-rare earth alloys and methods of making the alloys are disclosed. In some embodiments, the alloy comprises aluminum and 4 wt % to 60 wt % of a rare earth component X having a maximum solid solubility of ?0.5 wt % in aluminum. The surface-hardened alloy component has an alloy bulk portion and a hardened alloy surface portion. At least a portion of the hardened alloy surface portion has a Vickers hardness that is at least 30% greater than a Vickers hardness of the alloy bulk portion.Type: ApplicationFiled: July 14, 2017Publication date: March 22, 2018Inventors: Orlando Rios, Sudarsanam Suresh Babu, Ryan R. Dehoff, Ryan Ott, Alex J. Plotkowski, Zachary C. Sims, Niyanth Sridharan, David Weiss, Hunter B. Henderson
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ADDITIVE MANUFACTURING METHODS USING ALUMINUM-RARE EARTH ALLOYS AND PRODUCTS MADE USING SUCH METHODS
Publication number: 20180080103Abstract: Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.Type: ApplicationFiled: July 14, 2017Publication date: March 22, 2018Inventors: Alex J. Plotkowski, Orlando Rios, Sudarsanam Suresh Babu, Ryan R. Dehoff, Ryan Ott, Zachary C. Sims, Niyanth Sridharan, David Weiss, Hunter B. Henderson -
Publication number: 20180027615Abstract: A method and apparatus for additive manufacturing that includes a material guide for directing a supply of working material and a plurality of rollers for advancing the working material. An electromagnetic heater is provided to heat and deposit molten working material as a new supply of working material is forced through the material guide.Type: ApplicationFiled: April 11, 2017Publication date: January 25, 2018Applicant: UT-BATTELLE,LLCInventors: Orlando RIOS, William G. CARTER, Zachary C. SIMS, Lonnie J. LOVE, Phillip C. CHESSER