Patents by Inventor Roger W. Kaufold
Roger W. Kaufold 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: 20170283973Abstract: A coating process using a welding electrode comprises the steps of: electro-spark depositing a composite on to a substrate, wherein the composite consists essentially of alumina particles in a matrix, wherein the matrix is a metal selected from the group consisting of aluminum or an aluminum alloy. The substrate herein is an aluminum alloy. The coatings involve only aluminum and aluminum compounds, thereby intermetallic compound formation and galvanic corrosion of the coating-substrate materials system is avoided.Type: ApplicationFiled: May 10, 2017Publication date: October 5, 2017Inventors: Bruce M. Warnes, Joseph A. Downie, Andrew C. Towns, Roger W. Kaufold
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Patent number: 9757812Abstract: A protective coating for aluminum alloys, electrode for producing same and a coating process using the welding electrode. The protective coating and electrode comprise a composite consisting essentially of alumina particles in a matrix, wherein the matrix is a metal selected from the group consisting of aluminum or an aluminum alloy. The alumina particles consist of aluminum oxide in powder form. The coating process using the welding electrode above comprises the steps of: electro-spark depositing a composite on to a substrate, wherein the composite consists essentially of alumina particles in a matrix, wherein the matrix is a metal selected from the group consisting of aluminum or an aluminum alloy. The substrate herein is an aluminum alloy. The coatings involve only aluminum and aluminum compounds, thereby intermetallic compound formation and galvanic corrosion of the coating-substrate materials system is avoided.Type: GrantFiled: June 21, 2016Date of Patent: September 12, 2017Assignee: Al-ArmorInventors: Bruce M. Warnes, Joseph A. Downie, Andrew C. Towns, Roger W. Kaufold
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Publication number: 20170028498Abstract: A protective coating for aluminum alloys, electrode for producing same and a coating process using the welding electrode. The protective coating and electrode comprise a composite consisting essentially of alumina particles in a matrix, wherein the matrix is a metal selected from the group consisting of aluminum or an aluminum alloy. The alumina particles consist of aluminum oxide in powder form. The coating process using the welding electrode above comprises the steps of: electro-spark depositing a composite on to a substrate, wherein the composite consists essentially of alumina particles in a matrix, wherein the matrix is a metal selected from the group consisting of aluminum or an aluminum alloy. The substrate herein is an aluminum alloy. The coatings involve only aluminum and aluminum compounds, thereby intermetallic compound formation and galvanic corrosion of the coating-substrate materials system is avoided.Type: ApplicationFiled: June 21, 2016Publication date: February 2, 2017Inventors: Bruce M. Warnes, Joseph A. Downie, Andrew C. Towns, Roger W. Kaufold
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Patent number: 8419139Abstract: The present disclosure relates to tank wheel assembly systems, methods, and apparatus. In one embodiment, a tank wheel assembly includes a first wheel and a second wheel. A first face of the first wheel faces a second face of the second wheel. A guide tunnel is defined by at least a portion of the first face and at least a portion of the second face. The guide tunnel has outer surfaces and is configured to receive a center guide of a tank tread. The guide tunnel and center guide at least partially maintain the tank tread of the tank wheel assembly. A wear resistant coating is located on at least a portion of the outer surfaces of the guide tunnel, restricts the center guide of the tank tread from abrading the outer surfaces of the guide tunnel, and has a thickness of at least about 0.025 inch.Type: GrantFiled: January 8, 2010Date of Patent: April 16, 2013Assignee: Alcoa Inc.Inventors: Roger W. Kaufold, Ian D. L. Murray
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Publication number: 20110278120Abstract: The present disclosure relates to wear resistant transportation systems, methods, and apparatus. In one embodiment, a system includes a contact device, a conductor bar, and a mobile unit. The contact device is coupled to the mobile unit and in electrical communication with both the conductor bar and the mobile unit. The contact device is configured to travel across, and is in contact with, the conductor bar coincidental to movement of the mobile unit. A thin, conductive wear resistant coating is located on an outer surface of at least one of the conductor bar and contact device. The thin, conductive wear resistant coating restricts abrading of the outer surface of at least one of the conductor bar and the contact device.Type: ApplicationFiled: May 17, 2010Publication date: November 17, 2011Applicant: Alcoa Inc.Inventors: Roger W. Kaufold, Thomas J. Kasun, Neville C. Whittle
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Publication number: 20110169325Abstract: The present disclosure relates to tank wheel assembly systems, methods, and apparatus. In one embodiment, a tank wheel assembly includes a first wheel and a second wheel. A first face of the first wheel faces a second face of the second wheel. A guide tunnel is defined by at least a portion of the first face and at least a portion of the second face. The guide tunnel has outer surfaces and is configured to receive a center guide of a tank tread. The guide tunnel and center guide at least partially maintain the tank tread of the tank wheel assembly. A wear resistant coating is located on at least a portion of the outer surfaces of the guide tunnel, restricts the center guide of the tank tread from abrading the outer surfaces of the guide tunnel, and has a thickness of at least about 0.025 inch.Type: ApplicationFiled: January 8, 2010Publication date: July 14, 2011Applicant: Alcoa Inc.Inventors: Roger W. Kaufold, Ian D. L. Murray
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Publication number: 20110020665Abstract: A surface finishing and coating methodology that provides a superior looking aluminum product with acceptable corrosion performance for outdoor use. In one embodiment, a coating of high purity aluminum is applied first to an aluminum article or product via cold or thermal spray and the mechanical surface modification (e.g., polishing, buffing, brushing, etc.) is clone second. The resulting product has the desirable light weight and mechanical properties of aluminum with the chosen look and performance of the high purity aluminum coating. The aluminum product to be coated may be obtained by extrusion, forging, casting, or rolling.Type: ApplicationFiled: June 13, 2008Publication date: January 27, 2011Applicant: ALCOA INC.Inventors: Daniel L. Serafin, Ian A. McCallum, Roger W. Kaufold, Robert E. Bombalski, Luis Fanor Vega, Donald Robert Smith
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Publication number: 20100304078Abstract: The present disclosure relates to fire-resistant systems, methods, and apparatus. In one embodiment, a fire-resistant system includes a fire-resistant panel and a protected material coupled to the fire-resistant panel. The fire-resistant panel includes a passive layer and a back layer. The passive layer comprises a phyllosilicate material. The back layer comprises an inorganic material and may be coupled to the passive layer. Optionally, the fire-resistant panel may include a secondary layer comprising a functional material, where the functional material comprises one of a phase change material or an endothermic material.Type: ApplicationFiled: June 1, 2010Publication date: December 2, 2010Applicant: Alcoa Inc.Inventors: Israel Stol, Robert J. Speer, Jean Ann Skiles, Paula L. Kolek, Roger W. Kaufold, James T. Burg, Lori A. Barrage, Brett Page Conner
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Patent number: 6881491Abstract: An aluminum alloy article is cleaned to remove oxides and organic matter from a coatable surface, coated with a composition comprising an organic resin and a fluorine compound, and then heated to an elevated temperature to decompose the organic resin and at least a portion of the fluorine compound. After heating the coated surface is left with a protective oxyfluoride film that prevents blistering and hydrogen pickup and promotes hydrogen degassing from the article.Type: GrantFiled: May 16, 2003Date of Patent: April 19, 2005Assignee: Alcoa Inc.Inventors: Sally A. Jankosky, Susanne M. Opalka, Paula L. Kolek, Joseph P. Harenski, Roger W. Kaufold, Larry F. Wieserman
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Patent number: 6872425Abstract: A method of coating a vehicle wheel to increase wear and corrosion resistance of the vehicle wheel, includes the steps of providing a vehicle wheel and applying a wear and corrosion resistant coating onto a surface of the vehicle wheel. The coating is applied to at least a tire bead retaining flange of the vehicle wheel. The coating is of particular use with vehicle wheels made of forged aluminum. The coating is selected from tungsten carbide, optionally including cobalt or chrome, a nickel-based superalloy, aluminum and silicon carbide, or stainless steel. The coating is typically applied to a thickness of about 0.004-0.01 inch. The surface of the vehicle wheel may be prepared by mechanically abrading the surface or chemically etching the surface of the vehicle wheel. The coating may be applied by cold spraying, thermal spraying, or triboelectric discharge kinetic spraying and other similar processes.Type: GrantFiled: September 25, 2003Date of Patent: March 29, 2005Assignee: Alcoa Inc.Inventors: Roger W. Kaufold, Neville C. Whittle, Edward P. Patrick, A. Victor Pajerski
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Publication number: 20040229071Abstract: An aluminum alloy article is cleaned to remove oxides and organic matter from a coatable surface, coated with a composition comprising an organic resin and a fluorine compound, and then heated to an elevated temperature to decompose the organic resin and at least a portion of the fluorine compound. After heating the coated surface is left with a protective oxyfluoride film that prevents blistering and hydrogen pickup and promotes hydrogen degassing from the article.Type: ApplicationFiled: May 16, 2003Publication date: November 18, 2004Inventors: Sally A. Jankosky, Susanne M. Opalka, Paula L. Kolek, Joseph P. Harenski, Roger W. Kaufold, Larry F. Wieserman
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Publication number: 20040142109Abstract: A method of coating a vehicle wheel to increase wear and corrosion resistance of the vehicle wheel, includes the steps of providing a vehicle wheel and applying a wear and corrosion resistant coating onto a surface of the vehicle wheel. The coating is applied to at least a tire bead retaining flange of the vehicle wheel. The coating is of particular use with vehicle wheels made of forged aluminum. The coating is selected from tungsten carbide, optionally including cobalt or chrome, a nickel-based superalloy, aluminum and silicon carbide, or stainless steel.Type: ApplicationFiled: September 25, 2003Publication date: July 22, 2004Inventors: Roger W. Kaufold, Neville C. Whittle, Edward P. Patrick, A. Victor Pajerski
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Patent number: 6702886Abstract: A coating for a mold surface of a casting mold includes a metallic bond coat bonded to the mold surface and having a continuous, uniform thickness of between about 0.002 to 0.005 inch on the mold surface. A topcoat of yttria stabilized zirconia is located on top of the metallic bond coat and has a continuous, uniform thickness of between about 0.005 to 0.030 inch. The topcoat has a porosity between 5-15%. The topcoat has a surface layer having a thickness of between about 0.001 to 0.002 inch and a porosity of less than 1%.Type: GrantFiled: November 20, 2002Date of Patent: March 9, 2004Assignee: Alcoa Inc.Inventors: Neville C. Whittle, Roger W. Kaufold, Jamal Righi, Joseph P. Harenski
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Patent number: 6669897Abstract: A method of treating a surface of a stacked aluminum alloy ingot during a heating process. Spacer blocks are positioned adjacent aluminum alloy ingots to form a stack, wherein the spacer block has a support surface contacting a contact surface of the aluminum alloy ingot, and at least one of the support surface and the contact surface include a fluorine containing material. The stack is heated to at least a temperature at which the fluorine containing material decomposes or vaporizes such that a layer of a fluorinated oxide compound is formed at the interfaces between the ingots and the spacer blocks.Type: GrantFiled: April 22, 2002Date of Patent: December 30, 2003Assignee: Alcca Inc.Inventors: Joseph P. Harenski, Roger W. Kaufold, Brian J. Morrissey, Robert L. Shadwick, Jr., Larry F. Wieserman
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Publication number: 20030124395Abstract: A coating for a mold surface of a casting mold includes a metallic bond coat bonded to the mold surface and having a continuous, uniform thickness of between about 0.002 to 0.005 inch on the mold surface. A topcoat of yttria stabilized zirconia is located on top of the metallic bond coat and has a continuous, uniform thickness of between about 0.005 to 0.030 inch. The topcoat has a porosity between 5-15%. The topcoat has a surface layer having a thickness of between about 0.001 to 0.002 inch and a porosity of less than 1%.Type: ApplicationFiled: November 20, 2002Publication date: July 3, 2003Inventors: Neville C. Whittle, Roger W. Kaufold, Jamal Righi, Joseph P. Harenski
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Patent number: 6569379Abstract: A spacer member in a furnace including an aluminum tube containing a ceramic material. The ceramic material provides high compressive strength and the composite product resists high temperature creep.Type: GrantFiled: July 24, 2001Date of Patent: May 27, 2003Assignee: Alcoa Inc.Inventors: Calvin Bates, Daniel W. Severa, Joseph P. Harenski, Roger W. Kaufold, Patricia A. Stewart, Larry F. Wieserman
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Patent number: 6551664Abstract: A method for making an aluminum substrate that is subjected to repeated impaction more wear resistant. The method comprises applying at least about 0.005 inch thick coating of an amorphous composition directly to only portions of this substrate, preferably after it is shaped into a product for transporting consumable materials. The coating composition to which steel, aluminum, PTFE and/or polyethylene may be added, can be thermally sprayed to the substrate surface.Type: GrantFiled: February 28, 2001Date of Patent: April 22, 2003Assignee: Alcoa Inc.Inventors: Roger W. Kaufold, Neville C. Whittle, Daniel D. Roup
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Publication number: 20030031973Abstract: A spacer member in a furnace including an aluminum tube containing a ceramic material. The ceramic material provides high compressive strength and the composite product resists high temperature creep.Type: ApplicationFiled: July 24, 2001Publication date: February 13, 2003Inventors: Calvin Bates, Daniel W. Severa, Joseph P. Harenski, Roger W. Kaufold, Patricia A. Stewart, Larry F. Wieserman
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Publication number: 20020163110Abstract: A method of treating a surface of a stacked aluminum alloy ingot during a heating process. Spacer blocks are positioned adjacent aluminum alloy ingots to form a stack, wherein the spacer block has a support surface contacting a contact surface of the aluminum alloy ingot, and at least one of the support surface and the contact surface include a fluorine containing material. The stack is heated to at least a temperature at which the fluorine containing material decomposes or vaporizes such that a layer of a fluorinated oxide compound is formed at the interfaces between the ingots and the spacer blocks.Type: ApplicationFiled: April 22, 2002Publication date: November 7, 2002Inventors: Joseph P. Harenski, Roger W. Kaufold, Brian J. Morrissey, Robert L. Shadwick, Larry F. Wieserman
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Patent number: 6461451Abstract: A method of treating a surface of a stacked aluminum alloy ingot during a heating process. Spacer blocks are positioned adjacent aluminum alloy ingots to form a stack, wherein the spacer block has a support surface contacting a contact surface of the aluminum alloy ingot, and at least one of the support surface and the contact surface include a fluorine containing material. The stack is heated to at least a temperature at which the fluorine containing material decomposes or vaporizes such that a layer of a fluorinated oxide compound is formed at the interfaces between the ingots and the spacer blocks.Type: GrantFiled: December 13, 2000Date of Patent: October 8, 2002Assignee: Alcoa Inc.Inventors: Joseph P. Harenski, Roger W. Kaufold, Brian J. Morrissey, Robert L. Shadwick, Jr., Larry F. Wieserman