Ricardo Alberto Salas

US Patent:

20220372604, Nov 24, 2022

Filed:

Aug 5, 2022

Appl. No.:

17/882525

Inventors:

- Lake Forest CA, US
Ricardo Salas - Lake Forest CA, US
Evelina Vogli - Lake Forest CA, US

International Classification:

C22C 45/02
B22F 1/05
B33Y 70/00

Abstract:

Embodiments disclosed herein relate to the production of amorphous metals having compositions of iron, chromium, molybdenum, carbon and boron for usage in additive manufacturing, such as in layer-by-layer deposition to produce multi-functional parts. Such parts demonstrate ultra-high strength without sacrificing toughness and also maintain the amorphous structure of the materials during and after manufacturing processes. Two additive manufacturing techniques are provided: (1) the complete melting of amorphous powder and re-solidifying to amorphous structure to eliminate the formation of crystalline structure therein by controlling a heating source power and cooling rate without affecting previous deposited layers; and (2) partial melting of the outer surface of the amorphous powder, and solidifying powder particles with each-other without undergoing a complete melting stage. Amorphous alloy compositions have oxygen impurities in low concentration levels to optimize glass forming ability (GFA). Specific techniques of additive manufacturing include those based on lasers, electron beams and ultrasonic sources.

US Patent:

20220297227, Sep 22, 2022

Filed:

Jun 7, 2022

Appl. No.:

17/834188

Inventors:

- Lake Forest CA, US
John KANG - Lake Forest CA, US
Ricardo Salas - Lake Forest CA, US

International Classification:

B23K 20/10
C22C 16/00
C22C 14/00
C22C 19/05
B32B 7/04
B32B 15/01
B32B 15/04
B23K 26/0622
B23K 26/00
B23K 26/352
B23K 20/227
B23K 20/233
B23K 20/24
C23C 4/067
C23C 4/12
B32B 15/20
C23C 4/00
C23C 4/04
C23C 30/00
C23C 28/02
C23C 4/08
C23C 4/137
C23C 28/00
C22C 9/00
C22C 45/10
C22C 45/00

Abstract:

An embodiment relates to a cladded composite comprising a cladding layer of a bulk metallic glass and a substrate; wherein the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

US Patent:

20230058507, Feb 23, 2023

Filed:

Oct 25, 2022

Appl. No.:

17/972897

Inventors:

- Lake Forest CA, US
- Columbus OH, US
Ricardo Salas - Lake Forest CA, US
Adam Hehr - Columbus OH, US

International Classification:

B23K 20/10
C22C 16/00
C22C 14/00
C22C 19/05
B32B 7/04
B32B 15/01
B32B 15/04
B23K 26/0622
B23K 26/00
B23K 26/352
B23K 20/227
B23K 20/233
B23K 20/24
C23C 4/067
C23C 4/12
B32B 15/20
C23C 4/00
C23C 4/04
C23C 30/00
C23C 28/02
C23C 4/08
C23C 4/137
C23C 28/00
C22C 9/00
C22C 45/10
C22C 45/00

Abstract:

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

US Patent:

20210108299, Apr 15, 2021

Filed:

Oct 11, 2019

Appl. No.:

16/599138

Inventors:

- Lake Forest CA, US
Evelina VOGLI - Lake Forest CA, US
Ricardo SALAS - Lake Forest CA, US

International Classification:

C22C 45/00
C23C 4/08
E21B 17/10

Abstract:

An embodiment relates to a composition comprising an amorphous alloy having a low coefficient of friction (COF) of 0.15 or less, wherein the amorphous alloy is substantially free of phosphor (P) and substantially free of boron (B). An embodiment relates to a method comprising solidifying a molten layer of an amorphous feedstock on a preexisting layer by controlling a heating source and a cooling rate so as to avoid formation of crystals in the molten layer and not affect a crystalline structure of the preexisting layer, and forming a specimen; wherein, the at least a portion specimen has the low COF. Another embodiment relates to a system comprising a drill string, wherein the drill string comprises a drilling bit and a drill pipe connected thereto, wherein at least a portion of the drill pipe comprises a coating having the low COF.

US Patent:

20210087663, Mar 25, 2021

Filed:

Sep 19, 2019

Appl. No.:

16/575842

Inventors:

- LAKE FOREST CA, US
Ricardo SALAS - LAKE FOREST CA, US
Evelina VOGLI - LAKE FOREST CA, US

International Classification:

C22C 45/02
B33Y 10/00
B33Y 70/00
B33Y 40/10
B22F 1/00
B23K 20/10
C22C 33/00
C21D 6/00
B23K 26/342

Abstract:

Embodiments disclosed herein relate to the production of amorphous metals having compositions of iron, chromium, molybdenum, carbon and boron for usage in additive manufacturing, such as in layer-by-layer deposition to produce multi-functional parts. Such parts demonstrate ultra-high strength without sacrificing toughness and also maintain the amorphous structure of the materials during and after manufacturing processes. Two additive manufacturing techniques are provided: (1) the complete melting of amorphous powder and re-solidifying to amorphous structure to eliminate the formation of crystalline structure therein by controlling a heating source power and cooling rate without affecting previous deposited layers; and (2) partial melting of the outer surface of the amorphous powder, and solidifying powder particles with each-other without undergoing a complete melting stage. Amorphous alloy compositions have oxygen impurities in low concentration levels to optimize glass forming ability (GFA). Specific techniques of additive manufacturing include those based on lasers, electron beams and ultrasonic sources.

US Patent:

20200376809, Dec 3, 2020

Filed:

Mar 30, 2020

Appl. No.:

16/834195

Inventors:

- Lake Forest CA, US
John Kang - Lake Forest CA, US
Ricardo Salas - Lake Forest CA, US

International Classification:

B32B 15/04
B32B 15/01
B32B 7/04

Abstract:

An embodiment relates to a cladded composite comprising a cladding layer of a bulk metallic glass and a substrate; wherein the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

US Patent:

20200324362, Oct 15, 2020

Filed:

Mar 30, 2020

Appl. No.:

16/834201

Inventors:

- Lake Forest CA, US
- Columbus OH, US
Ricardo SALAS - Lake Forest CA, US
Adam HEHR - Columbus OH, US

International Classification:

B23K 20/10
C22C 16/00
C22C 19/05
C22C 14/00

Abstract:

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.