Jack D Ayers, Age 83Vancouver, WA

6423113, Jul 23, 2002

Jun 14, 1996

08/673762

Jack Ayers - Oakton VA
Khershed P. Cooper - Fairfax VA

The United States of America as represented by the Secretary of the Navy - Washington DC

B22F 906

75338, 75331, 75333, 75334, 75339, 75340

Fine powders are made from molten metals and alloys on a continuous basis. A rapidly spinning shallow cup has an atomizing fluid such as water, oil or any other hydrocarbon supplied to the cup to form a thin sheet or layer which is distributed on the inner surface of the cup. Within the cup a stream or spray of molten metal is propelled into this thin sheet of atomizing fluid. The metal interacts with the atomizing fluid film and is fragmented or broken down into many small droplets which are quenched by the atomizing fluid and solidified into fine powder. These powders in the form of a slurry with the atomizing fluid can be continuously removed as the slurry discharges up over the lip of the cup by centrifugal force and the powders can be recovered. In a preferred embodiment a preatomizer is positioned between the incoming stream of molten metal and the spinning cup. This breaks up the molten stream into a series of droplets that will be directed to the atomizing liquid film on the inner wall of the spinning cup so that even finer particles will be produced.

H16314, Feb 4, 1997

Oct 27, 1995

8/563086

John A. Montgomery - Reston VA
Jack D. Ayers - Oakton VA
Gregory Cowart - Alexandria VA

United States of America - Washington DC

H01Q 1700
H01Q 704

342 1

The present invention is a method for making radar chaff consisting of metal rings having varying diameters, using photolithographic processes. One aspect of the invention has the steps of: providing a metal foil having a thickness suitable for use in radar chaff; overcoating the metal foil with a photoresist, to form a layered structure; undercoating the metal foil with a removable backing; exposing the photoresist to a quantity of actinic radiation for chemically modifying the photoresist into a photoproduct suitable for subsequent development, where the actinic radiation is patterned into a series of concentric rings; developing the photoresist, to expose the underlying metal in a series of concentric rings; removing the exposed metal to form a series of concentric metal rings on the removable backing; and removing the removable backing. Another aspect of the invention is a metal chaff precursor, comprising: a removable backing, coated with a plurality of concentric metal foil rings.

4619845, Oct 28, 1986

Feb 22, 1985

6/704117

Jack D. Ayers - Oakton VA
Iver E. Anderson - Alexandria VA

The United States of America as represented by the Secretary of the Navy - Washington DC

B05D 102

427422

A method for generating fine sprays of molten metal for spray coating and wder making is disclosed. Liquid metal is fed via a melt tube to a nozzle that is shaped like the frustrum of a cone. The nozzle is surrounded with gas jets in a coaxial pattern around the melt tube orifice. High pressure gas causes the formation of a low pressure region immediately next to the melt tube orifice that draws metal out of the orifice at a higher rate than would otherwise be the case. The coaxial gas stream atomizes the metal into droplets and thereafter forms a narrow, supersonic spray containing very fine metal droplets suitable for powder making or application of a coating.

4200669, Apr 29, 1980

Nov 22, 1978

5/962855

Robert J. Schaefer - Springfield VA
Jack D. Ayers - Oakton VA

The United States of America as represented by the Secretary of the Navy - Washington DC

B05D 306

427 531

A method and apparatus for spraying a surface which comprises: introducing into a laser beam, a powder with a vapor pressure from 10. sup. -2 to 10. sup. -1 atm. in excess of the ambient pressure at a temperature up to about 500. degree. C. above the melting point thereof and with a heat-absorption coefficient from 0. 2 to 1; and passing the laser beam over said surface. Since the method and apparatus can coat or alloy or dope a surface, a wide variety of protective coatings can be fabricated.

5073409, Dec 17, 1991

Jun 28, 1990

7/545005

Iver E. Anderson - Ames IA
Jack D. Ayers - Oakton VA

The United States of America as represented by the Secretary of the Navy - Washington DC

B05D 714

427217

Fine metal alloy powders coated with a protective film are disclosed which re produced by the gas atomization process. The protective films are formed during the gas atomization process by gas atomizing a molten mixture of a metal alloy containing an alloy addition agent in an atomizing gas which will selectively react with the alloy addition agent to form a thin protective film on the surface of the metal powder.

5110334, May 5, 1992

Jul 31, 1990

7/560703

Jack D. Ayers - Oakton VA

The United States of America as represented by the Secretary of the Navy - Washington DC

C03B 37025
C03B 37075

65 2

A process is provided for forming a glass fiber having one or more metal aments in its core. In the process, a metal rod or particles of a metal or semiconducting material optionally mixed with glass powder is introduced into a hollow glass tube closed at one end, and the tube is evacuated while the closed end is heated and a fiber drawn therefrom. The resultant glass fiber contains one or more discrete filaments of the metal or semiconducting material.

5202602, Apr 13, 1993

Dec 10, 1991

7/804558

Jack D. Ayers - Oakton VA

The United States of America as represented by the Secretary of the Navy - Washington DC

H01J 130
H01J 190

313309

A field-emitting array is provided which comprises at least one thin wafer aving electrically conducting filaments extending through a glass matrix between a first and second parallel surface of the wafer. At the first surface, the filaments extend beyond the plane of the glass matrix. The filaments extending beyond the first surface have an electron-emitting coating on their cylindrical surfaces. The coating extends beyond the filament end to create a shape that emits electrons when an electrical field is applied between the filaments and an anode. In an alternative embodiment, the filaments are recessed below the first surface and a conducting coating forms an extractor on that surface.

4775000, Oct 4, 1988

Aug 27, 1986

6/900803

Jack D. Ayers - Oakton VA

B22D 1104
B22D 1110
B22D 1302
B22D 1308

164464

An apparatus and process for the continuous casting of tubular shapes wherein molten metal from which the tubular shape is formed is centrifugally deposited adjacent to the outlet of a fluid-cooled mold by a nozzle assembly, with the metal being cooled and rapidly solidified by the mold to form a cylindrical shell upon which additional metal is deposited to incrementally build the thickness of the tubular shape. The tubular shape being formed is withdrawn continuously from the mold, and is further cooled by coolant directed thereon. The nozzle assembly may be rotated to discharge the molten metal or, alternatively, the mold may be rotated as the metal is deposited thereon. Single-layer tubular shapes, with or without reinforcing material, may be cast and multiple-layer composite shapes may be produced having layers of different material composition and thicknesses. An inert atmosphere is maintained to prevent oxidation of the molten metal. Tubular shapes cast may be longitudinally split and flattened to form sheet metal having desirable, refined microstructures.