MERTON C FLEMINGS
Engineering in Cambridge, MA

6645323, Nov 11, 2003

Mar 25, 2002

10/104536

Merton C. Flemings - Cambridge MA
Raul A. Martinez-Ayers - Somerville MA
Anacleto M. de Figueredo - Newton MA
James A. Yurko - Boston MA

Massachusetts Institute of Technology - Cambridge MA

B22D 2708

148538, 148549, 164122

A skinless metal alloy composition free of entrapped gas and comprising primary solid discrete degenerate dendrites homogeneously dispersed within a secondary phase is formed by a process wherein the metal alloy is heated in a vessel to render it a liquid. The liquid is then rapidly cooled while vigorously agitating it under conditions to avoid entrapment of gas while forming solid nuclei homogeneously distributed in the liquid. Agitation then is ceased when the liquid contains a small fraction solid or the liquid-solid alloy is removed from the source of agitation while cooling is continued to form the primary solid discrete degenerate dendrites in liquid secondary phase. The solid-liquid mixture then can be formed such as by casting.

3951651, Apr 20, 1976

Jul 17, 1973

5/379990

Robert Mehrabian - Arlington MA
Merton C. Flemings - Cambridge MA

Massachusetts Institute of Technology - Cambridge MA

C22C 102, C22B 400

75135

This invention provides a composite composition comprising a metallic matrix having a concentration of third phase solid particles homogeneously dispersed throughout the metallic matrix. The metallic matrix can be liquid, solid or partially solid and can have (a) a dendritic structure or (b) up to 65 weight percent of a structure comprising degenerate dendritic or nodular primary discrete solid particles suspended in a secondary phase having a lower melting point than the primary particles which secondary phase can be solid or liquid. The third phase particles can be metallic, non-metallic or a combination metallic-nonmetallic compositions and have a surface composition which is not wet by the metallic matrix when the matrix is a liquid.

3948650, Apr 6, 1976

Jul 17, 1973

5/379991

Merton C. Flemings - Cambridge MA
Robert Mehrabian - Arlington MA
David B. Spencer - Bedford MA

Massachusetts Institute of Technology - Cambridge MA

C22C 102, C22B 406

75135

A metal composition characterized by degenerate dendritic or nodular primary discrete solid particles suspended in a secondary phase having a lower melting point than the primary particles and which secondary phase can be solid or liquid. The method involves raising the temperature of a metal alloy to a value at which the alloy is largely or completely in the molten state. The melt then is subjected to vigorous agitation and the temperature is reduced to increase the portion of the mixture in solid degenerate dendrite or nodular form up to about sixty-five percent, but usually up to about fifty percent, while continuing the agitation. At this juncture the temperature of the liquid-solid composition can be reduced to cause solidification thereof or it can be cast. The solidified composition can be stored and later it can be brought again to the liquid-solid mixture state and then recast.

4345637, Aug 24, 1982

Nov 15, 1979

6/094636

Merton C. Flemings - Cambridge MA
Rodney G. Riek - Maryland Heights MO
Kenneth P. Young - Ballwin MO

Massachusetts Institute of Technology - Cambridge MA

B22D 1700

164113

Die castings are made from metal compositions that are fully liquid or as a preferred embodiment contain between about 10 and 85 weight percent degenerate dendrites. The composition is injected into the cavity of a die at a mean die temperature which is as near to ambient temperature as possible and usually less than about 400. degree. F. The die is formed of a material having a thermal diffusivity of at least about 0. 5 cm. sup. 2 /sec. The castings are ejected and the die surface is sprayed with a liquid to bring the die surface temperature back to the mean die temperature or below in the shortest possible time. The time between injection and ejection is less than about 1 minute and the time between ejection and spraying is less than about 30 seconds.

6918427, Jul 19, 2005

Jan 21, 2004

10/761911

James A. Yurko - Holland MI, US
Rodger W. Brower - Allendale MI, US
Raul A. Martinez - Somerville MA, US
Merton C. Flemings - Cambridge MA, US
Paolo Bertelli - Brescia, IT

IdraPrince, Inc. - Holland MI

B22D027/08

164 711, 164113, 164122, 164900, 164312, 266241, 266242

A method and apparatus for producing a metal component from a non-dendritic, semi-solid metal alloy slurry involves the use of a graphite agitator that is functionally equivalent to conventional metal rod agitators, and has the additional advantage of having a very low surface wettability, whereby labor and expenses associated with removing a metal alloy skin formed after withdrawal of the agitator from a metal slurry is eliminated or at least substantially reduced. The invention also provides an improved process and apparatus for producing a metal component from a non-dendritic semi-solid metal slurry by transferring the slurry to a cooling vessel for subsequent cooling and raising of the solids content without agitation after the slurry has been formed with agitation in a first vessel, whereby more rapid cooling of the slurry and increased production rates are achievable.

4205983, Jun 3, 1980

Jul 12, 1978

5/924094

Merton C. Flemings - Cambridge MA
Kenneth P. Young - Arlington MA
Edmund M. Dunn - Walnut Creek CA

Massachusetts Institute of Technology - Cambridge MA

C22C 102

75135

A process for forming metal compositions containing cellular in situ composites. A metal composition containing at least 25 volume percent liquid is cooled to produce aligned columnar dendrite growth. The resultant composition then is subjected to isothermal coarsening in the semi-solid temperature range to form the cellular in situ composites. This composition then is solidified. The metal compositions are particularly useful in rotating machinery.

5076991, Dec 31, 1991

Feb 16, 1990

7/481914

John W. Poole - Bow NH
Merton C. Flemings - Cambridge MA
Thomas A. Gaspar - Columbus OH
Matthew A. Simpson - Manchester NH

Norton Company - Worcester MA

B29B 910

264500

A novel process for rapid solidification of ceramic melts combines certain features of cooling by atomization and by contact with chilling surfaces. The material to be solidified is divided into fine liquid droplets that are propelled by a rapid flow of gas toward a rapidly moving chill surface, striking the surface with sufficient velocity to flatten each drop into a flat flake like shape. Apparatus for the process is also disclosed. The process is particularly applicable to making very fine grained, or even amorphous, ceramic materials that can be powdered and then sintered into strong, tough ceramic structures.

4917852, Apr 17, 1990

Apr 29, 1988

7/188584

John W. Poole - Bow NH
Merton C. Flemings - Cambridge MA
Thomas A. Gaspar - Columbus OH
Matthew A. Simpson - Manchester NH

Norton Company - Worcester MA

B29B 910

264500

A novel process for rapid solidification of ceramic melts combines certain features of cooling by atomization and by contact with chilling surfaces. The material to be solidified is divided into fine liquid dropletes that are propelled by a rapid flow of gas toward a rapidly moving chill surface, striking the surface with sufficient velocity to flatten each drop into a flat flake like shape. Apparatus for the process is also disclosed. The process is particularly applicable to making very fine grained, or even amorphous, ceramic materials that can be powdered and then sintered into strong, tough ceramic structures.

4572818, Feb 25, 1986

Mar 16, 1984

6/590407

Merton C. Flemings - Cambridge MA
Andrew L. Lux - Creve MO

Massachusetts Institute of Technology - Cambridge MA

C22C 100, C22C 3300

420590

Purified metal compositions and metal compositions free of secondary phase material are produced by heating a metal alloy from the nonequilibrium solidus temperature while subjecting the liquid-solid mixture to high pressure and forcing the liquid through a filter. Compositions obtained by the process of this invention have a nondendritic structure which can be substantially free of secondary phase material.

6250365, Jun 26, 2001

Jul 9, 1999

9/349518

Merton C. Flemings - Cambridge MA
Sergio Gallo - Turin, IT

Teksid S.p.A. - Turin

B22C 908, B22D 1700

164113

Apparatus and methods of die casting which reduce waste, by providing heated channels to feed solidification shrinkage. The channels are heated to a temperature which prevents solidification in the channels, thus allowing the channels to be substantially smaller than conventional risers. An insulating layer in the mold prevents excessive heat loss from the channels to the mold cavity area.