Patents by Inventor Andy Szuromi

Andy Szuromi 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: 10940566
    Abstract: A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.
    Type: Grant
    Filed: August 9, 2018
    Date of Patent: March 9, 2021
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Steve Starr, Donald G. Godfrey, Mark C. Morris
  • Patent number: 10933497
    Abstract: A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.
    Type: Grant
    Filed: August 9, 2018
    Date of Patent: March 2, 2021
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Steve Starr, Donald G. Godfrey, Mark C. Morris
  • Publication number: 20180345423
    Abstract: A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.
    Type: Application
    Filed: August 9, 2018
    Publication date: December 6, 2018
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Steve Starr, Donald G. Godfrey, Mark C. Morris
  • Publication number: 20180347013
    Abstract: A method of manufacturing a nickel-based superalloy component includes providing or obtaining, in a powdered form, a build material alloy including, on a weight basis of the overall build material alloy: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. The method further includes subjecting the build material alloy to a high energy density beam in an additive manufacturing process to selectively fuse portions of the build material to form a built component and subjecting the built component to a finishing process to precipitate a gamma-prime phase of the nickel-based superalloy.
    Type: Application
    Filed: August 9, 2018
    Publication date: December 6, 2018
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Hallee Zox Deutchman, Brian G. Baughman, Donald G. Godfrey, Harry Lester Kington, Mark C. Morris
  • Publication number: 20180345424
    Abstract: A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.
    Type: Application
    Filed: August 9, 2018
    Publication date: December 6, 2018
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Steve Starr, Donald G. Godfrey, Mark C. Morris
  • Publication number: 20180347014
    Abstract: A nickel-based superalloy component includes a nickel-based superalloy metal. The nickel-based superalloy metal includes, on a weight basis of the overall superalloy metal: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. In some examples, the component includes a gas turbine engine component, such as a turbine blade or a turbine vane, and the metal form of the nickel-based superalloy may be used as a filler metal for welding a casting alloy, a wrought alloy, or a powder metal alloy or other wrought forms.
    Type: Application
    Filed: August 9, 2018
    Publication date: December 6, 2018
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Hallee Zox Deutchman, Brian G. Baughman, Donald G. Godfrey, Harry Lester Kington, Mark C. Morris
  • Patent number: 10105798
    Abstract: A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.
    Type: Grant
    Filed: November 5, 2015
    Date of Patent: October 23, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Steve Starr, Donald G. Godfrey, Mark C. Morris
  • Patent number: 10011892
    Abstract: Methods are provided for producing alloy forms from alloys containing one or more extremely reactive elements and for fabricating a component therefrom. The fabricating method comprises substantially removing a reactive gas from the fabrication environment. An alloy form of the alloy is formed. The alloy form is formed by melting the alloy or by melting one or more base elements of the alloy to produce a molten liquid and introducing the one or more extremely reactive elements into the molten liquid. The molten alloy is shaped into the alloy form. The component is formed from the alloy form. If the one or more extremely reactive elements are introduced into the molten liquid, such introduction occurs just prior to the shaping step.
    Type: Grant
    Filed: August 21, 2014
    Date of Patent: July 3, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Brian Hann, Mark C. Morris, Donald G. Godfrey
  • Patent number: 9914182
    Abstract: A method for transient liquid phase bonding two metallic substrate segments together including the steps of forming a joined component by bringing together the two substrate segments along a bond line with a brazing alloy comprising a melting point depressant disposed between the two segments at the bond line and performing a first thermal treatment including heating the joined component at a brazing temperature of the brazing alloy for a first period of time. The method further includes performing a second thermal treatment including heating the joined component at an intermediate temperature that is above the brazing temperature but below a gamma prime solvus temperature of the substrate segments for a second period of time and performing a third thermal treatment including heating the joined component at a super-solvus temperature that is above the gamma prime solvus temperature of the two metallic substrate segments for a third period of time.
    Type: Grant
    Filed: September 17, 2015
    Date of Patent: March 13, 2018
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Christopher David Gatto, Leticia Lara, Megan Kemp, Andy Szuromi
  • Patent number: 9782829
    Abstract: A method is provided for manufacturing a component. The method includes connecting a component comprising an internal passage and formed by an additive manufacturing process to a power supply, the component functioning as an anode, connecting a cathode to the power supply, the cathode being disposed in an electrolyte solution, the cathode being positioned externally to the internal passage of the component, contacting the internal passage of the component with the electrolyte solution, and using the power supply, applying a potential difference and current flow between the component and the cathode.
    Type: Grant
    Filed: November 26, 2013
    Date of Patent: October 10, 2017
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Mark C. Morris, Klaus Helmut Schwarz, Donald G. Godfrey, Andy Szuromi
  • Publication number: 20170129060
    Abstract: A method for improving the surface of an aluminum alloy article includes manufacturing the aluminum alloy article using an additive manufacturing technique, wherein the article as-manufactured includes one or more of cracks, roughness, or porosity at a surface of the article; coating the surface of the aluminum alloy article with a diffusion element, the diffusion element being capable of diffusing at least 0.2 mils into the article; heating the aluminum alloy article coated with the diffusion element to cause the diffusion element to diffuse the at least 0.2 mils into the article, thereby forming a diffusion layer of at least 0.2 mils in thickness comprising both aluminum alloy and diffusion element; and removing the diffusion layer from the aluminum alloy article, whereby upon the removing, a resulting improved surface of the article comprises fewer or smaller cracks, reduced roughness, or reduced porosity.
    Type: Application
    Filed: November 5, 2015
    Publication date: May 11, 2017
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Steve Starr, Donald G. Godfrey, Mark C. Morris
  • Publication number: 20170080521
    Abstract: A method for transient liquid phase bonding two metallic substrate segments together including the steps of forming a joined component by bringing together the two substrate segments along a bond line with a brazing alloy comprising a melting point depressant disposed between the two segments at the bond line and performing a first thermal treatment including heating the joined component at a brazing temperature of the brazing alloy for a first period of time. The method further includes performing a second thermal treatment including heating the joined component at an intermediate temperature that is above the brazing temperature but below a gamma prime solvus temperature of the substrate segments for a second period of time and performing a third thermal treatment including heating the joined component at a super-solvus temperature that is above the gamma prime solvus temperature of the two metallic substrate segments for a third period of time.
    Type: Application
    Filed: September 17, 2015
    Publication date: March 23, 2017
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Don Mittendorf, Christopher David Gatto, Leticia Lara, Megan Kemp, Andy Szuromi
  • Publication number: 20160348216
    Abstract: Nickel-based superalloys and additive manufacturing processes using nickel-based superalloys are disclosed herein. For example, a nickel-based superalloy includes, on a weight basis of the overall superalloy: about 9.5% to about 10.5% tungsten, about 9.0% to about 11.0% cobalt, about 8.0% to about 8.8% chromium, about 5.3% to about 5.7% aluminum, about 2.8% to about 3.3% tantalum, about 0.3% to about 1.6% hafnium, about 0.5% to about 0.8% molybdenum, about 0.005% to about 0.04% carbon, and a majority of nickel. Exemplary additive manufacturing processes include subjecting such a nickel-based superalloy in powdered build material form to a high energy density beam in an additive manufacturing process to selectively fuse portions of the build material to form a built component and subjecting the built component to a finishing process to precipitate a gamma-prime phase of the nickel-based superalloy.
    Type: Application
    Filed: December 16, 2014
    Publication date: December 1, 2016
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Hallee Zox Deutchman, Brian G. Baughman, Donald G. Godfrey, Harry Lester Kington, Mark C. Morris
  • Patent number: 9429023
    Abstract: In accordance with an exemplary embodiment, a method for manufacturing a component using additive manufacturing techniques includes providing a 3D design model for the component, adding one or more crack resistant features to the 3D design model of the component to produce an enhanced design model, and manufacturing the component using an additive manufacturing technique in accordance with the enhanced design model. The one or more crack resistant features are provided to reduce or eliminate the incidence of cracking in the manufactured component.
    Type: Grant
    Filed: January 14, 2013
    Date of Patent: August 30, 2016
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Donald G. Godfrey, Mark C. Morris, Andy Szuromi
  • Publication number: 20160053346
    Abstract: Methods are provided for producing alloy forms from alloys containing one or more extremely reactive elements and for fabricating a component therefrom. The fabricating method comprises substantially removing a reactive gas from the fabrication environment. An alloy form of the alloy is formed. The alloy form is formed by melting the alloy or by melting one or more base elements of the alloy to produce a molten liquid and introducing the one or more extremely reactive elements into the molten liquid. The molten alloy is shaped into the alloy form. The component is formed from the alloy form. If the one or more extremely reactive elements are introduced into the molten liquid, such introduction occurs just prior to the shaping step.
    Type: Application
    Filed: August 21, 2014
    Publication date: February 25, 2016
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Brian Hann, Mark C. Morris, Donald G. Godfrey
  • Publication number: 20150144496
    Abstract: A method is provided for manufacturing a component. The method includes connecting a component comprising an internal passage and formed by an additive manufacturing process to a power supply, the component functioning as an anode, connecting a cathode to the power supply, the cathode being disposed in an electrolyte solution, the cathode being positioned externally to the internal passage of the component, contacting the internal passage of the component with the electrolyte solution, and using the power supply, applying a potential difference and current flow between the component and the cathode.
    Type: Application
    Filed: November 26, 2013
    Publication date: May 28, 2015
    Inventors: Mark C. Morris, Klaus Helmut Schwarz, Donald G. Godfrey, Andy Szuromi
  • Patent number: 9039917
    Abstract: A method is provided for manufacturing a component. The method includes forming a diffusion coating on a first intermediate article formed by an additive manufacturing process. The diffusion coating is removed from the first intermediate article forming a second intermediate article. The diffusion coating is formed by applying a layer of coating material on at least one surface of the first intermediate article and diffusion heat treating the first intermediate article and the layer. The diffusion coating comprises a surface additive layer and a diffusion layer below the surface additive layer. The formation of the diffusion coating and removal thereof may be repeated at least once.
    Type: Grant
    Filed: August 12, 2013
    Date of Patent: May 26, 2015
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Andy Szuromi, Daniel Ryan, Donald G. Godfrey, Mark C. Morris
  • Publication number: 20140199175
    Abstract: In accordance with an exemplary embodiment, a method for manufacturing a component using additive manufacturing techniques includes providing a 3D design model for the component, adding one or more crack resistant features to the 3D design model of the component to produce an enhanced design model, and manufacturing the component using an additive manufacturing technique in accordance with the enhanced design model. The one or more crack resistant features are provided to reduce or eliminate the incidence of cracking in the manufactured component.
    Type: Application
    Filed: January 14, 2013
    Publication date: July 17, 2014
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Donald G. Godfrey, Mark C. Morris, Andy Szuromi
  • Patent number: 8605858
    Abstract: Embodiments of methods and systems for inspecting a structure for a crystallographic imperfection are provided. In the method, an X-ray wavelength that is particularly susceptible to diffraction by the crystallographic imperfection is identified. Then an X-ray source is provided to emit X-rays in the identified X-ray wavelength. While placing the structure at a sequence of positions relative to the X-ray source, X-rays are directed at the structure in multiple, non-parallel arrays to create sequential patterns of diffracted X-rays. The patterns of diffracted X-rays are digitally captured and communicated to a computer that compares them to locate the crystallographic imperfection. For a surface imperfection, the imperfection may be marked with a target to allow for physical removal.
    Type: Grant
    Filed: June 27, 2011
    Date of Patent: December 10, 2013
    Assignee: Honeywell International Inc.
    Inventors: Surendra Singh, Andy Szuromi, Vladimir K. Tolpygo, Andy Kinney
  • Publication number: 20130316084
    Abstract: A method is provided for manufacturing a component. The method includes forming a diffusion coating on a first intermediate article formed by an additive manufacturing process. The diffusion coating is removed from the first intermediate article forming a second intermediate article. The diffusion coating is formed by applying a layer of coating material on at least one surface of the first intermediate article and diffusion heat treating the first intermediate article and the layer. The diffusion coating comprises a surface additive layer and a diffusion layer below the surface additive layer. The formation of the diffusion coating and removal thereof may be repeated at least once.
    Type: Application
    Filed: August 12, 2013
    Publication date: November 28, 2013
    Inventors: Andy Szuromi, Daniel Ryan, Donald G. Godfrey, Mark C. Morris