Patents by Inventor Gerald E. Hicks
Gerald E. Hicks has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20220143900Abstract: Methods for in-situ solution heat treating an additively manufactured metallic component in order to increase the mechanical properties thereof and systems to perform the same. The method can include depositing filler material on a substrate forming a deposition layer, measuring the temperature of a heat affected zone corresponding to the deposition layer, and solution heat treating the deposition layer subsequent to the depositing and proximate to the deposition head. The solution heat treating can include heating the deposition layer to a solution temperature so as to achieve solution heat treatment and controlling the cooling rate of the deposition layer to at or above the critical cooling rate of the filler material until a target temperature is reached. Optionally, the method can include inducing an electron flow in the deposition layer to electromagnetically stir molten filler material in the heat affected zone.Type: ApplicationFiled: November 9, 2020Publication date: May 12, 2022Applicant: Sprit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, Paul R. Toivonen, Gerald E. Hicks, JR., Daniel R. Klenosky
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Patent number: 10822682Abstract: A method for heat-treating a titanium alloy, such as Ti-6Al-4V. The method may occur after or include a step of forging the titanium alloy such that localized, highly deformed grains are formed in the titanium alloy. Then the method may include steps of recrystallization annealing the titanium alloy by heating the titanium alloy to a temperature in a range between 30° F. to 200° F. below beta transus of the titanium alloy for 1 hour to 6 hours and then furnace cooling of the titanium alloy to 1200° F. to 1500° F. at a rate of 50° F. to 500° F. per hour. Following the recrystallization annealing, the method may include beta annealing the titanium alloy. These steps may be performed in a single heat treating cycle.Type: GrantFiled: October 4, 2018Date of Patent: November 3, 2020Assignee: Spirit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, Gerald E. Hicks, Michael A. Walker, Craig M. Clasper
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Patent number: 10266933Abstract: Aluminum alloys are provided that can comprise boron and vanadium and high amounts of titanium and zirconium. The aluminum alloys described herein can exhibit superior tensile properties at both room temperature and elevated temperatures and still maintain desirable ductility. The aluminum alloys can be used in applications where resistance to fatigue and breakdown at elevated temperatures is desirable, which includes applications in the aerospace and aeronautical fields.Type: GrantFiled: August 27, 2013Date of Patent: April 23, 2019Assignee: SPIRIT AEROSYSTEMS, INC.Inventors: Rahbar Nasserrafi, David E. Jakstis, Gerald E. Hicks, Darrell Wade
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Publication number: 20190032184Abstract: A method for heat-treating a titanium alloy, such as Ti-6Al-4V. The method may occur after or include a step of forging the titanium alloy such that localized, highly deformed grains are formed in the titanium alloy. Then the method may include steps of recrystallization annealing the titanium alloy by heating the titanium alloy to a temperature in a range between 30° F. to 200° F. below beta transus of the titanium alloy for 1 hour to 6 hours and then furnace cooling of the titanium alloy to 1200° F. to 1500° F. at a rate of 50° F. to 500° F. per hour. Following the recrystallization annealing, the method may include beta annealing the titanium alloy. These steps may be performed in a single heat treating cycle.Type: ApplicationFiled: October 4, 2018Publication date: January 31, 2019Applicant: Spirit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, Gerald E. Hicks, Michael A. Walker, Craig M. Clasper
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Patent number: 10094013Abstract: A method for heat-treating a titanium alloy, such as Ti-6Al-4V. The method may occur after or include a step of forging the titanium alloy such that localized, highly deformed grains are formed in the titanium alloy. Then the method may include steps of recrystallization annealing the titanium alloy by heating the titanium alloy to a temperature in a range between 30° F. to 200° F. below beta transus of the titanium alloy for 1 hour to 6 hours and then furnace cooling of the titanium alloy to 1200° F. to 1500° F. at a rate of 50° F. to 500° F. per hour. Following the recrystallization annealing, the method may include beta annealing the titanium alloy. These steps may be performed in a single heat treating cycle.Type: GrantFiled: December 17, 2015Date of Patent: October 9, 2018Assignee: Spirit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, Gerald E. Hicks, Michael A. Walker, Craig M. Clasper
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Patent number: 9995247Abstract: An aircraft thrust reverser inner wall and method of manufacturing the same. The aircraft thrust reverser inner wall may include a face sheet, a perforated back sheet, and a core sandwiched between the face sheet and the perforated back sheet. The face sheet may have an inner face sheet surface and an outer face sheet surface, and the core may have an inner core surface, an outer core surface, and a plurality of cell walls extending therebetween. An electro-depositable material may be applied, via electrodeposition, in a substantially continuous layer over the outer core surface, the cell walls, and the outer face sheet surface, thus bonding the face sheet and core together. The perforated back sheet may be attached to the core at the outer core surface, and a conductive coating may be applied to the inner face sheet surface.Type: GrantFiled: October 6, 2015Date of Patent: June 12, 2018Assignee: Spirit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, Craig Clasper, Micheal A. Walker, Gerald E. Hicks, Linda Cadwell Stancin
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Publication number: 20170175241Abstract: A method for heat-treating a titanium alloy, such as Ti-6Al-4V. The method may occur after or include a step of forging the titanium alloy such that localized, highly deformed grains are formed in the titanium alloy. Then the method may include steps of recrystallization annealing the titanium alloy by heating the titanium alloy to a temperature in a range between 30° F. to 200° F. below beta transus of the titanium alloy for 1 hour to 6 hours and then furnace cooling of the titanium alloy to 1200° F. to 1500° F. at a rate of 50° F. to 500° F. per hour. Following the recrystallization annealing, the method may include beta annealing the titanium alloy. These steps may be performed in a single heat treating cycle.Type: ApplicationFiled: December 17, 2015Publication date: June 22, 2017Applicant: Spirit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, Gerald E. Hicks, Michael A. Walker, Craig M. Clasper
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Publication number: 20170096964Abstract: An aircraft thrust reverser inner wall and method of manufacturing the same. The aircraft thrust reverser inner wall may include a face sheet, a perforated back sheet, and a core sandwiched between the face sheet and the perforated back sheet. The face sheet may have an inner face sheet surface and an outer face sheet surface, and the core may have an inner core surface, an outer core surface, and a plurality of cell walls extending therebetween. An electro-depositable material may be applied, via electrodeposition, in a substantially continuous layer over the outer core surface, the cell walls, and the outer face sheet surface, thus bonding the face sheet and core together. The perforated back sheet may be attached to the core at the outer core surface, and a conductive coating may be applied to the inner face sheet surface.Type: ApplicationFiled: October 6, 2015Publication date: April 6, 2017Applicant: SPIRIT AEROSYSTEMS INC.Inventors: RAHBAR NASSERRAFI, CRAIG CLASPER, MICHEAL A. WALKER, GERALD E. HICKS, LINDA CADWELL STANCIN
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Patent number: 9347558Abstract: Aluminum-based alloys for casting or wrought processing having improved combinations of properties, including improved high temperature strength, are provided. The alloys generally comprise copper, magnesium, silver, and titanium, along with scandium and/or cobalt. Zirconium, zinc, and/or vanadium may also optionally be present in the alloy. When cobalt is present in the alloy, nickel may also optionally be present. Cast and wrought products, as well as methods of making the same using the alloys, are also disclosed.Type: GrantFiled: August 25, 2011Date of Patent: May 24, 2016Assignee: Spirit AeroSystems, Inc.Inventors: Rahbar Nasserrafi, LaVerne L. Waalkes, Gerald E. Hicks, Kevin Obrachta, David E. Jakstis
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Publication number: 20160047022Abstract: Aluminum alloys are provided that can comprise boron and vanadium and high amounts of titanium and zirconium. The aluminum alloys described herein can exhibit superior tensile properties at both room temperature and elevated temperatures and still maintain desirable ductility. The aluminum alloys can be used in applications where resistance to fatigue and breakdown at elevated temperatures is desirable, which includes applications in the aerospace and aeronautical fields.Type: ApplicationFiled: August 27, 2013Publication date: February 18, 2016Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Rahbar Nasserrafi, David E. Jakstis, Gerald E. Hicks, Darrell Wade
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Publication number: 20120048390Abstract: Aluminum-based alloys for casting or wrought processing having improved combinations of properties, including improved high temperature strength, are provided. The alloys generally comprise copper, magnesium, silver, and titanium, along with scandium and/or cobalt. Zirconium, zinc, and/or vanadium may also optionally be present in the alloy. When cobalt is present in the alloy, nickel may also optionally be present. Cast and wrought products, as well as methods of making the same using the alloys, are also disclosed.Type: ApplicationFiled: August 25, 2011Publication date: March 1, 2012Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Rahbar Nasserrafi, LaVerne L. Waalkes, Gerald E. Hicks, Kevin Obrachta, David E. Jakstis