US5980604A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Spray formed multifunctional materials
Assignee: University of California
•
Filing: 1996-06-13
•
Granted: 1999-11-09
•
Expires: 2016-06-13
Abstract
Abstract Spray atomization of molten metal and/or intermetallic matrix composites reinforced with ceramic particles is practiced by atomizing the matrix into micron sized droplets and depositing the semisolid droplets in a bulk deposition upon a temperature controlled substrate. The semiliquid droplets are injected with refinement particles while in a range of 0 to 40% by volume solid phase and deposited on the substrate surface while in a 40 to 90% by volume solid phase. Refined grain morphology, increased solid solubility, nonequilibrium phases, absence of macro segregation, and elimination of the need to handle fine reactive particles are all achieved by performing the spray deposition process under a controlled atmosphere. Materials fabricated by the process exhibit unusual combinations of properties, such as spatially varying properties.
Inventors
- 👤 Enrique J. Lavernia
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 04:09
CPC Classifications
C; C23; C23C; C23C4/00; C23C4/12; C23C4/123
Claims Analysis
Total Claims: 46
Claim 1
Independent Claim
91 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a substrate surface; and injecting at least one secondary material into said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray when a predetermined solidification condition has been achieved in said droplets of said atomized spray, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 2
Independent Claim
91 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a substrate surface; and injecting at least one secondary material into said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray when a predetermined solidification condition has been achieved in said droplets of said atomized spray, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 3
Dependent Claim
27 words
The method of claim 1 wherein said predetermined solidification condition is in the range of approximately 0 to 40% by volume of solid phase within said spray.
Claim 4
Dependent Claim
20 words
The method of claim 1 wherein said matrix is superheated to approximately 100 to 200° K. above its melting point.
Claim 5
Dependent Claim
39 words
The method of claim 1 wherein a predetermined distance is defined between where said spray is atomized and where said spray has secondary materials injected therein, said predetermined distance being in the range of approximately 200 to 500 mm.
Claim 6
Dependent Claim
20 words
The method of claim 1 wherein said droplets of said spray impinge upon said substrate in a predetermined solidification condition.
Claim 7
Dependent Claim
34 words
The method of claim 5 wherein said predetermined solidification condition of said droplets of said spray when impinging on said substrate is approximately 40 to 100% by volume of solid phase within said droplets.
Claim 8
Dependent Claim
38 words
The method of claim 6 wherein a predetermined distance is established between where said spray impinges upon said substrate and wherein said spray is atomized, said predetermined distance being in the range of approximately 200 to 600 mm.
Claim 9
Dependent Claim
29 words
The method of claim 1 further comprising moving said substrate as said spray is disposed on said substrate to manipulate deposition characteristics of said matrix with injected secondary materials.
Claim 10
Dependent Claim
22 words
The method of claim 1 wherein said sprayed matrix with injected secondary materials are solidified on said substrate in a nonequilibrium condition.
Claim 11
Dependent Claim
25 words
The method of claim 1 wherein said matrix and secondary materials are reactive and are disposed on said substrate without substantial reaction during spray deposition.
Claim 12
Independent Claim
96 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray; propagating said spray toward a substrate surface; and injecting at least one secondary material into said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray at a predetermined solidification condition of said atomized spray, and where said spray impinges upon said substrate in a predetermined solidification condition, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 13
Independent Claim
96 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray; propagating said spray toward a substrate surface; and injecting at least one secondary material into said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray at a predetermined solidification condition of said atomized spray, and where said spray impinges upon said substrate in a predetermined solidification condition, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 14
Dependent Claim
34 words
The method of claim 11 wherein said predetermined solidification condition of said droplets of said spray when impinging on said substrate is approximately 40 to 100% by volume of solid phase within said droplets.
Claim 15
Independent Claim
129 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray; propagating said spray toward a substrate surface; and injecting at least one secondary material into said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray at a predetermined solidification condition of said atomized spray, and where said spray impinges upon said substrate in a predetermined solidification condition, wherein a predetermined distance is established between where said spray impinges upon said substrate and wherein said spray is atomized, said predetermined distance being in the range of approximately 200 to 600 mm, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 16
Independent Claim
129 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray; propagating said spray toward a substrate surface; and injecting at least one secondary material into said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray at a predetermined solidification condition of said atomized spray, and where said spray impinges upon said substrate in a predetermined solidification condition, wherein a predetermined distance is established between where said spray impinges upon said substrate and wherein said spray is atomized, said predetermined distance being in the range of approximately 200 to 600 mm, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 17
Independent Claim
103 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a substrate surface; injecting at least one secondary material into said droplets of said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray at a predetermined solidification condition of said atomized spray; and solidifying said sprayed matrix with injected secondary material on said substrate in a nonequilibrium condition, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 18
Independent Claim
103 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a substrate surface; injecting at least one secondary material into said droplets of said spray prior to impingement of said spray on said substrate surface, wherein said secondary material is injected into said spray at a predetermined solidification condition of said atomized spray; and solidifying said sprayed matrix with injected secondary material on said substrate in a nonequilibrium condition, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 19
Dependent Claim
19 words
The method of claim 14 where propagating said spray toward a substrate surface is performed in an inert gas.
Claim 20
Dependent Claim
15 words
The method of claim 14 where said spray deposition is performed in a reactive gas.
Claim 21
Dependent Claim
20 words
The method of claim 16 where propagating said spray toward a substrate surface is performed in a reactive gas environment.
Claim 22
Dependent Claim
17 words
The method of claim 16 where atomizing said superheated matrix material is performed with a reactive gas.
Claim 23
Dependent Claim
19 words
The method of claim 16 where injecting said at least one secondary material is performed with a reactive gas.
Claim 24
Dependent Claim
35 words
The method of claim 14 where solidifying said sprayed matrix with injected secondary material on said substrate in a nonequilibrium condition solidifies said sprayed matrix with injected secondary material in physical nonequilibrium with each other.
Claim 25
Dependent Claim
35 words
The method of claim 14 where solidifying said sprayed matrix with injected secondary material on said substrate in a nonequilibrium condition solidifies said sprayed matrix with injected secondary material in chemical nonequilibrium with each other.
Claim 26
Independent Claim
96 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets using a reactive gas selected to form a target phase; propagating said spray toward a substrate surface; and reactively forming at least one secondary material in said droplets of said spray prior to impingement of said droplets on said substrate surface, wherein said sprayed matrix and secondary material are combined and solidified in a nonequilibrium condition, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 27
Independent Claim
96 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets using a reactive gas selected to form a target phase; propagating said spray toward a substrate surface; and reactively forming at least one secondary material in said droplets of said spray prior to impingement of said droplets on said substrate surface, wherein said sprayed matrix and secondary material are combined and solidified in a nonequilibrium condition, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by a controlled density.
Claim 28
Dependent Claim
19 words
The method of claim 22 where propagating said spray toward a substrate surface is performed in an inert gas.
Claim 29
Dependent Claim
15 words
The method of claim 22 where said spray deposition is performed in a reactive gas.
Claim 30
Dependent Claim
20 words
The method of claim 22 where propagating said spray toward a substrate surface is performed in a reactive gas environment.
Claim 31
Dependent Claim
17 words
The method of claim 22 where atomizing said superheated matrix material is performed with a reactive gas.
Claim 32
Dependent Claim
19 words
The method of claim 22 where injecting said at least one secondary material is performed with a reactive gas.
Claim 33
Dependent Claim
34 words
The method of claim 22 where combining said sprayed matrix with secondary material on said substrate in a nonequilibrium condition combines said sprayed matrix with said secondary material in physical nonequilibrium with each other.
Claim 34
Dependent Claim
34 words
The method of claim 22 where combining said sprayed matrix with secondary material on said substrate in a nonequilibrium condition combines said sprayed matrix with said secondary material in chemical nonequilibrium with each other.
Claim 35
Dependent Claim
56 words
The method of claim 22 where reactively forming said at least one secondary material comprises forming said at least one secondary material by a partial nonequilibrium reaction so that said secondary material is formed with a size approximately in the range 2 microns or less in diameter when said matrix material is solidified on said substrate.
Claim 36
Dependent Claim
26 words
The method of claim 30 where forming said at least one secondary material by a partial nonequilibrium reaction comprises injecting reactive gas into said propagating spray.
Claim 37
Independent Claim
69 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a substrate surface; and injecting low density microspheres into said droplets of spray prior to impingement of said droplets on said substrate surface, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by low density and high damping.
Claim 38
Independent Claim
69 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a substrate surface; and injecting low density microspheres into said droplets of spray prior to impingement of said droplets on said substrate surface, whereby, a rapidly solidified microstructure is deposited on said substrate surface characterized by low density and high damping.
Claim 39
Dependent Claim
27 words
The method of claim 32 where injecting low density microspheres into said spray prior to impingement of said spray on said substrate surface comprises injecting hollow microspheres.
Claim 40
Dependent Claim
26 words
The method of claim 33 where injecting hollow microspheres comprises injecting hollow ceramic microspheres having a diameter in the range of approximately 10 to 100 microns.
Claim 41
Independent Claim
111 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a fiber reinforced array; forming at least one secondary material in said droplets while being propagated toward said fiber reinforced array; and integrating said droplets of said spray with said at least one secondary material into said fiber reinforced array, where forming said at least one secondary material comprises injecting said droplets with said at least one secondary material into said fiber reinforced array in a predetermined solidification condition, whereby a rapidly solidified fiber reinforced microstructure is deposited characterized by a controlled density.
Claim 42
Independent Claim
111 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a fiber reinforced array; forming at least one secondary material in said droplets while being propagated toward said fiber reinforced array; and integrating said droplets of said spray with said at least one secondary material into said fiber reinforced array, where forming said at least one secondary material comprises injecting said droplets with said at least one secondary material into said fiber reinforced array in a predetermined solidification condition, whereby a rapidly solidified fiber reinforced microstructure is deposited characterized by a controlled density.
Claim 43
Independent Claim
114 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a fiber reinforced array; forming at least one secondary material in said droplets while being propagated toward said fiber reinforced array; and integrating said droplets of said spray with said at least one secondary material into said fiber reinforced array, where forming said at least one secondary material comprises integrating said droplets of spray in a predetermined solidification condition with injected secondary material into said fiber reinforced array in a nonequilibrium condition, whereby a rapidly solidified fiber reinforced microstructure is deposited characterized by a controlled density.
Claim 44
Independent Claim
114 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets; propagating said spray toward a fiber reinforced array; forming at least one secondary material in said droplets while being propagated toward said fiber reinforced array; and integrating said droplets of said spray with said at least one secondary material into said fiber reinforced array, where forming said at least one secondary material comprises integrating said droplets of spray in a predetermined solidification condition with injected secondary material into said fiber reinforced array in a nonequilibrium condition, whereby a rapidly solidified fiber reinforced microstructure is deposited characterized by a controlled density.
Claim 45
Independent Claim
144 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets using a reactive gas selected to form a target phase; propagating said spray toward a fiber reinforced array; forming at least one secondary material in said droplets while being propagated toward said fiber reinforced array; and integrating said droplets of said spray with said at least one secondary material into said fiber reinforced array, where forming said at least one secondary material comprises reactively forming said secondary material in said droplets of said spray prior to integration of said droplets of said spray into said fiber reinforced array, and wherein said at least one secondary material is combined with said matrix material in a nonequilibrium condition, whereby a rapidly solidified fiber reinforced microstructure is deposited characterized by a controlled density.
Claim 46
Independent Claim
144 words
A method for spray deposition synthesis of composite materials comprising: superheating a matrix material; atomizing said superheated matrix material into a spray of droplets using a reactive gas selected to form a target phase; propagating said spray toward a fiber reinforced array; forming at least one secondary material in said droplets while being propagated toward said fiber reinforced array; and integrating said droplets of said spray with said at least one secondary material into said fiber reinforced array, where forming said at least one secondary material comprises reactively forming said secondary material in said droplets of said spray prior to integration of said droplets of said spray into said fiber reinforced array, and wherein said at least one secondary material is combined with said matrix material in a nonequilibrium condition, whereby a rapidly solidified fiber reinforced microstructure is deposited characterized by a controlled density.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2002-11-08 | 2003-05-10 | 2003-11-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-11-08 | 2007-05-10 | 2007-11-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-11-08 | 2011-05-10 | 2011-11-09 | $7700.00 | Window Closed / Lapsed |