Patents by Inventor Russell W. COCHRAN

Russell W. COCHRAN 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).

  • Patent number: 11993838
    Abstract: A method for heat treating an additively manufactured A205 aluminum alloy component (“AM205 component”) to produce a uniform grain distribution within the AM205 component is disclosed. The method includes solution aging the AM205 component at a first temperature for a first time period, wherein the first time period is less than five hours and overaging the AM205 component after the solution aging.
    Type: Grant
    Filed: October 21, 2019
    Date of Patent: May 28, 2024
    Assignee: The Boeing Company
    Inventors: Paul N. Wilson, Michael R. Zolnowski, Russell W. Cochran, Burke L. Reichlinger
  • Publication number: 20240042527
    Abstract: A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.
    Type: Application
    Filed: October 18, 2023
    Publication date: February 8, 2024
    Applicant: The Boeing Company
    Inventors: Elaine MacDonald, Russell W. Cochran, Daniel J. Braley
  • Patent number: 11826824
    Abstract: A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.
    Type: Grant
    Filed: June 28, 2021
    Date of Patent: November 28, 2023
    Assignee: The Boeing Company
    Inventors: Elaine MacDonald, Russell W. Cochran, Daniel J. Braley
  • Publication number: 20220080507
    Abstract: A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.
    Type: Application
    Filed: June 28, 2021
    Publication date: March 17, 2022
    Applicant: The Boeing Company
    Inventors: Elaine MacDonald, Russell W. Cochran, Daniel J. Braley
  • Publication number: 20210115545
    Abstract: A method for heat treating an additively manufactured A205 aluminum alloy component (“AM205 component”) to produce a uniform grain distribution within the AM205 component is disclosed. The method includes solution aging the AM205 component at a first temperature for a first time period, wherein the first time period is less than five hours and overaging the AM205 component after the solution aging.
    Type: Application
    Filed: October 21, 2019
    Publication date: April 22, 2021
    Inventors: Paul N. Wilson, Michael R. Zolnowski, Russell w. Cochran, Burke L. Reichlinger
  • Patent number: 10940531
    Abstract: Methods of improving a surface finish of a casting pattern for an investment casting process, methods of forming an investment casting, and smoothed casting patterns. The methods for forming the casting patterns having an improved surface finish include sealing the casting pattern with a first coating material to form a sealed casting pattern and smoothing the sealed casting pattern with a second coating material to form a smoothed casting pattern. The methods for forming the investment casting include covering a smoothed casting pattern with a mold material to define an enclosed mold volume, curing the mold material to form a cured mold material, flowing the smoothed casting pattern from the enclosed mold volume to define a void space, filling the void space with a liquid investment casting material, and solidifying the liquid casting material to define an investment casting.
    Type: Grant
    Filed: October 31, 2019
    Date of Patent: March 9, 2021
    Assignee: The Boeing Company
    Inventors: Elaine MacDonald, Daniel Joseph Braley, Brandon Heath Wegge, Russell W. Cochran
  • Patent number: 10882291
    Abstract: In one aspect, A method of forming a product using an additive-manufacturing head includes forming a new layer of material of the product with the additive-manufacturing head. Forming the new layer of material includes depositing the new layer of material on an existing layer of material and melting the new layer of material so that the new layer of material is welded to the existing layer of material. The method also includes processing at least one of the new layer of material or the existing layer of material with a laser-emitting device, coupled to the additive-manufacturing head. Processing the at least one of the new layer of material or the existing layer of material with the laser-emitting device comprises smoothing a lateral surface of at least one of the new layer of material or the existing layer of material with a laser beam, emitted from the laser-emitting device.
    Type: Grant
    Filed: August 28, 2017
    Date of Patent: January 5, 2021
    Assignee: THE BOEING COMPANY
    Inventors: David Michael Dietrich, Russell W. Cochran, Daniel D. Bloch, Gary W. Coleman
  • Patent number: 10571894
    Abstract: A method of manufacturing a vehicle control surface includes generating, using an electronic controller, a three-dimensional plan for the vehicle control surface. The three-dimensional plan includes, at least, non-vehicular support structure dimensions, for a non-vehicular support structure, and skin dimensions for a skin. The method further includes configuring the dimensions of the non-vehicular support structure based on build environment characteristics associated with an additive manufacturing process of the control surface. The additive manufacturing process is based on the three-dimensional plan. The method further includes fabricating the vehicle control surface, using the additive manufacturing process, based on the three-dimensional plan.
    Type: Grant
    Filed: July 18, 2017
    Date of Patent: February 25, 2020
    Assignee: The Boeing Company
    Inventors: Richard W. Aston, Michael J. Langmack, Matthew J. Herrmann, Russell W. Cochran, Philip R. Munoz, Nicole M. Hastings
  • Publication number: 20190025797
    Abstract: A method of manufacturing a vehicle control surface includes generating, using an electronic controller, a three-dimensional plan for the vehicle control surface. The three-dimensional plan includes, at least, non-vehicular support structure dimensions, for a non-vehicular support structure, and skin dimensions for a skin. The method further includes configuring the dimensions of the non-vehicular support structure based on build environment characteristics associated with an additive manufacturing process of the control surface. The additive manufacturing process is based on the three-dimensional plan. The method further includes fabricating the vehicle control surface, using the additive manufacturing process, based on the three-dimensional plan.
    Type: Application
    Filed: July 18, 2017
    Publication date: January 24, 2019
    Applicant: The Boeing Company
    Inventors: Richard W. Aston, Michael J. Langmack, Matthew J. Herrmann, Russell W. Cochran, Philip R. Munoz, Nicole M. Hastings
  • Publication number: 20180001548
    Abstract: Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.
    Type: Application
    Filed: August 28, 2017
    Publication date: January 4, 2018
    Inventors: David Michael DIETRICH, Russell W. COCHRAN, Daniel D. BLOCH, Gary W. COLEMAN
  • Patent number: 9751260
    Abstract: Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.
    Type: Grant
    Filed: July 24, 2013
    Date of Patent: September 5, 2017
    Assignee: THE BOEING COMPANY
    Inventors: David Michael Dietrich, Russell W. Cochran, Daniel D. Bloch, Gary W. Coleman
  • Publication number: 20150048553
    Abstract: Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.
    Type: Application
    Filed: July 24, 2013
    Publication date: February 19, 2015
    Applicant: The Boeing Company
    Inventors: David Michael DIETRICH, Russell W. COCHRAN, Daniel D. BLOCH, Gary W. COLEMAN