US 12,037,669 B1
Metal-alloy biphasic systems, and powders and methods for making metal-alloy biphasic systems
John H. Martin, Oxnard, CA (US); Julie Miller, Los Angeles, CA (US); Brennan D. Yahata, Los Angeles, 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 Feb. 7, 2020, as Appl. No. 16/784,890.
Claims priority of provisional application 62/944,779, filed on Dec. 6, 2019.
Claims priority of provisional application 62/828,606, filed on Apr. 3, 2019.
Int. Cl. C22C 9/00 (2006.01); B22F 9/02 (2006.01); B23K 26/342 (2014.01); B33Y 70/00 (2020.01); C22C 5/02 (2006.01); C22C 5/06 (2006.01); C22C 11/00 (2006.01); C22C 12/00 (2006.01); C22C 13/00 (2006.01); C22C 14/00 (2006.01); C22C 16/00 (2006.01); C22C 18/00 (2006.01); C22C 19/03 (2006.01); C22C 19/07 (2006.01); C22C 21/00 (2006.01); C22C 22/00 (2006.01); C22C 27/00 (2006.01); C22C 27/02 (2006.01); C22C 27/04 (2006.01); C22C 27/06 (2006.01); C22C 28/00 (2006.01); C22C 38/00 (2006.01); C22C 49/14 (2006.01); B33Y 10/00 (2015.01)
CPC C22C 9/00 (2013.01) [B22F 9/02 (2013.01); B23K 26/342 (2015.10); B33Y 70/00 (2014.12); C22C 5/02 (2013.01); C22C 5/06 (2013.01); C22C 11/00 (2013.01); C22C 12/00 (2013.01); C22C 13/00 (2013.01); C22C 14/00 (2013.01); C22C 16/00 (2013.01); C22C 18/00 (2013.01); C22C 19/03 (2013.01); C22C 19/07 (2013.01); C22C 21/00 (2013.01); C22C 22/00 (2013.01); C22C 27/00 (2013.01); C22C 27/02 (2013.01); C22C 27/04 (2013.01); C22C 27/06 (2013.01); C22C 28/00 (2013.01); C22C 38/00 (2013.01); C22C 49/14 (2013.01); B22F 2304/10 (2013.01); B33Y 10/00 (2014.12)] 16 Claims
OG exemplary drawing
 
1. A metal-alloy biphasic system containing at least a first metal phase and a second metal phase,
wherein said first metal phase consists of a first metal M1 selected from the group consisting of W, Nb, V, Ta, Mo, Cr, Al, Ce, Bi, Zr, Hf, Ti, Mn, Fe, Co, Ni, Cu, Ag, Au, Zn, Sn, Pb, alloys thereof, and combinations of the foregoing;
wherein said second metal phase consists of a second metal M2 selected from the group consisting of W, Nb, V, Ta, Mo, Cr, Al, Ce, Bi, Zr, Hf, Ti, Mn, Fe, Co, Ni, Cu, Ag, Au, Zn, Sn, Pb, alloys thereof, and combinations of the foregoing, wherein said second metal is different than said first metal;
wherein said first metal phase is characterized by a first melting temperature, and wherein said second metal phase is characterized by a second melting temperature that is lower than said first melting temperature;
wherein said metal-alloy biphasic system is characterized by a hierarchical microstructure containing a first length scale and a second length scale that is at least one order of magnitude smaller than said first length scale, wherein said first length scale is associated with said first metal phase, wherein said second length scale is also associated with said first metal phase, wherein said first length scale is from about 1 micron to about 100 microns, and wherein said second length scale is from about 0.01 microns to about 1 micron; and
wherein said metal-alloy biphasic system is a solidification-based additively manufactured structure with a three-dimensional scalloped build pattern, wherein said additively manufactured structure has a microstructure containing a plurality of layers having differing primary growth-direction angles with respect to each other, wherein said microstructure has a crystallographic texture that is not solely oriented in an additive-manufacturing build direction, wherein said solidification-based additively manufactured structure is produced via melting and resolidification of both of said first metal phase and said second metal phase, and wherein said first metal phase and said second metal phase are immiscible at said second melting temperature.