US 12,280,432 B2
Additive manufacturing with nanofunctionalized precursors
John H. Martin, Oxnard, CA (US); Brennan Yahata, Santa Barbara, CA (US); Tobias A. Schaedler, Oak Park, CA (US); and Jacob M. Hundley, Thousand Oaks, CA (US)
Assigned to HRL Laboratories, LLC, Malibu, CA (US)
Filed by HRL Laboratories, LLC, Malibu, CA (US)
Filed on Nov. 22, 2023, as Appl. No. 18/517,092.
Application 17/332,229 is a division of application No. 15/880,488, filed on Jan. 25, 2018, granted, now 11,117,193, issued on Sep. 14, 2021.
Application 18/517,092 is a continuation of application No. 17/332,229, filed on May 27, 2021, granted, now 11,919,085.
Claims priority of provisional application 62/463,952, filed on Feb. 27, 2017.
Claims priority of provisional application 62/463,991, filed on Feb. 27, 2017.
Claims priority of provisional application 62/452,989, filed on Feb. 1, 2017.
Prior Publication US 2024/0082913 A1, Mar. 14, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. B22F 5/12 (2006.01); B22F 1/054 (2022.01); B22F 1/08 (2022.01); B22F 5/02 (2006.01); B22F 7/04 (2006.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/32 (2021.01); B22F 10/36 (2021.01); B22F 10/64 (2021.01); B22F 10/66 (2021.01); B22F 10/68 (2021.01); B22F 12/41 (2021.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); C22C 1/05 (2023.01)
CPC B22F 5/12 (2013.01) [B22F 1/054 (2022.01); B22F 1/056 (2022.01); B22F 1/08 (2022.01); B22F 5/02 (2013.01); B33Y 10/00 (2014.12); B33Y 70/00 (2014.12); B22F 2007/042 (2013.01); B22F 10/25 (2021.01); B22F 10/28 (2021.01); B22F 10/32 (2021.01); B22F 10/36 (2021.01); B22F 10/64 (2021.01); B22F 10/66 (2021.01); B22F 10/68 (2021.01); B22F 12/41 (2021.01); B22F 2301/052 (2013.01); B22F 2301/054 (2013.01); B22F 2301/058 (2013.01); B22F 2301/10 (2013.01); B22F 2301/15 (2013.01); B22F 2301/205 (2013.01); B22F 2301/255 (2013.01); B22F 2301/30 (2013.01); B22F 2304/05 (2013.01); B22F 2999/00 (2013.01); C22C 1/05 (2013.01); Y02P 10/25 (2015.11)] 19 Claims
OG exemplary drawing
 
1. A process for additive manufacturing of a nanofunctionalized metal alloy, said process comprising:
(a) selecting one or more metals;
(b) selecting one or more grain-refining nanoparticles;
(c) providing a nanofunctionalized metal precursor containing said one or more metals and said grain-refining nanoparticles that are chemically and/or physically disposed on surfaces of said one or more metals;
(d) exposing a first amount of said nanofunctionalized metal precursor to an energy source for melting said first amount of said nanofunctionalized metal precursor, thereby generating a first melt layer; and
(e) solidifying said first melt layer, thereby generating an additively manufactured, nanofunctionalized metal alloy,
wherein said additively manufactured, nanofunctionalized metal alloy is characterized by an average grain size of 1 micron or less,
wherein said additively manufactured, nanofunctionalized metal alloy has a microstructure with equiaxed grains, and
wherein said microstructure is substantially crack-free.