Patents by Inventor Robin M. Forbes Jones
Robin M. Forbes Jones 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: 20100276112Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.Type: ApplicationFiled: July 7, 2010Publication date: November 4, 2010Applicant: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy
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Publication number: 20100258262Abstract: Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.Type: ApplicationFiled: June 23, 2010Publication date: October 14, 2010Applicant: ATI Properties, Inc.Inventor: Robin M. Forbes Jones
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Patent number: 7803211Abstract: Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.Type: GrantFiled: March 21, 2008Date of Patent: September 28, 2010Assignee: ATI Properties, Inc.Inventor: Robin M. Forbes Jones
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Patent number: 7803212Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.Type: GrantFiled: March 21, 2008Date of Patent: September 28, 2010Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy
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Patent number: 7798199Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.Type: GrantFiled: December 4, 2007Date of Patent: September 21, 2010Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Sterry A. Shaffer
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Publication number: 20100012629Abstract: An apparatus for melting an electrically conductive metallic material comprises an auxiliary ion plasma electron emitter configured to produce a focused electron field including a cross-sectional profile having a first shape. The apparatus further comprises a steering system configured to direct the focused electron field to impinge the focused electron field on at least a portion of the electrically conductive metallic material to at least one of melt or heat any solidified portions of the electrically conductive metallic material, any solid condensate within the electrically conductive metallic material, and/or regions of a solidifying ingot.Type: ApplicationFiled: August 25, 2009Publication date: January 21, 2010Applicant: ATI Properties, Inc.Inventor: Robin M. Forbes Jones
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Publication number: 20090272228Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.Type: ApplicationFiled: July 14, 2009Publication date: November 5, 2009Applicant: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy
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Patent number: 7578960Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.Type: GrantFiled: September 22, 2005Date of Patent: August 25, 2009Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy
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Publication number: 20090139682Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.Type: ApplicationFiled: December 4, 2007Publication date: June 4, 2009Applicant: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Sterry A. Shaffer
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Publication number: 20080237200Abstract: An apparatus for melting an electrically conductive metallic material includes a vacuum chamber and a hearth disposed in the vacuum chamber. At least one wire-discharge ion plasma electron emitter is disposed in or adjacent the vacuum chamber and is positioned to direct a wide-area field of electrons into the vacuum chamber, wherein the wide-area electron field has sufficient energy to heat the electrically conductive metallic material to its melting temperature. The apparatus may further include at least one of a mold and an atomizing apparatus which is in communication with the vacuum chamber and is positioned to receive molten material from the hearth.Type: ApplicationFiled: March 26, 2008Publication date: October 2, 2008Applicant: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy
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Publication number: 20080223174Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.Type: ApplicationFiled: August 20, 2007Publication date: September 18, 2008Inventors: Robin M. Forbes Jones, Richard L. Kennedy, Helmut Gerhard Conrad, Ted Szylowiec, Wayne Conrad, Richard Stanley Phillips, Andrew Richard Henry Phillips
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Publication number: 20080179034Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.Type: ApplicationFiled: March 21, 2008Publication date: July 31, 2008Applicant: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy
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Publication number: 20080179033Abstract: Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.Type: ApplicationFiled: March 21, 2008Publication date: July 31, 2008Applicant: ATI Properties, Inc.Inventor: Robin M. Forbes Jones
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Publication number: 20080115905Abstract: An apparatus for casting metals by a nucleated casting technique to create a preform, the apparatus including a mold having a base and a side wall where the base can be moved relative to the side wall to withdraw the preform as it is being created. In various circumstances, portions of a droplet spray created by an atomizing nozzle, i.e., overspray, may accumulate on a top surface of the side wall and prevent or inhibit the preform from being moved relative to the side wall. The atomizing nozzle can be oriented such that the droplet spray passes over the top of the side wall to remelt and remove at least a portion of the overspray that has accumulated thereon. The mold can be rotated such that the overspray formed on a region of or on the entire perimeter of the top surface can pass through the droplet spray and can be removed from the side wall.Type: ApplicationFiled: October 30, 2007Publication date: May 22, 2008Inventors: Robin M. Forbes Jones, Sterry A. Shaffer
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Patent number: 7374598Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.Type: GrantFiled: August 9, 2004Date of Patent: May 20, 2008Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy, Helmut Gerhard Conrad, Ted Szylowiec, Wayne Conrad, Richard Stanley Phillips, Andrew Richard Henry Phillips
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Patent number: 7154932Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.Type: GrantFiled: May 30, 2002Date of Patent: December 26, 2006Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy, Ramesh S. Minisandram
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Patent number: 7114548Abstract: A method of making an article includes forming a molten material by melting at least a portion of a mass of a metal and an alloy. The method further includes forming the article by solidifying at least a portion of the molten material within a mold, and contacting the article with plasma during formation of the article. A method for making an article also is disclosed wherein a molten material is formed by melting at least a portion of a mass of one of a metal and an alloy, the molten material is collected within a mold, and at least a portion of the molten material is magnetohydrodynamically stirred within the mold.Type: GrantFiled: December 9, 2004Date of Patent: October 3, 2006Assignee: ATI Properties, Inc.Inventor: Robin M. Forbes Jones
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Patent number: 6772961Abstract: The present invention is directed to methods and apparatus that use electrostatic and/or electromagnetic fields to enhance the process of spray forming preforms or powders. The present invention also describes methods and apparatus for atomization and heat transfer with non-equilibrium plasmas. The present invention is also directed to articles, particularly for use in gas turbine engines, produced by the methods of the invention.Type: GrantFiled: June 18, 2001Date of Patent: August 10, 2004Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy, Helmut Gerhard Conrad, Ted Szylowiec, Wayne Conrad, Richard Stanley Phillips, Andrew Richard Henry Phillips
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Publication number: 20030016723Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.Type: ApplicationFiled: May 30, 2002Publication date: January 23, 2003Inventors: Robin M. Forbes Jones, Richard L. Kennedy, Ramesh S. Minisandram
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Patent number: 6496529Abstract: A method for refining and casting metals and metal alloys includes melting and refining a metallic material and then casting the refined molten material by a nucleated casting technique. The refined molten material is provided to the atomizing nozzle of the nucleated casting apparatus through a transfer apparatus adapted to maintain the purity of the molten refined material. An apparatus including a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus, in serial fluid communication, also is disclosed.Type: GrantFiled: November 15, 2000Date of Patent: December 17, 2002Assignee: ATI Properties, Inc.Inventors: Robin M. Forbes Jones, Richard L. Kennedy, Ramesh S. Minisandram