Patents by Inventor Daniel G. Sanders
Daniel G. Sanders 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: 20230383412Abstract: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.Type: ApplicationFiled: August 2, 2023Publication date: November 30, 2023Applicant: The Boeing CompanyInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, Daniel G. Sanders
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Patent number: 11753723Abstract: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.Type: GrantFiled: June 2, 2020Date of Patent: September 12, 2023Assignee: THE BOEING COMPANYInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, Daniel G. Sanders
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Publication number: 20230278696Abstract: A metallic structure includes a metallic sheet, including a metallic-sheet first surface and a metallic-sheet second surface. The metallic structure includes a metallic doubler, extending from the metallic-sheet first surface, and a first junction between the metallic-sheet first surface and the metallic doubler. The metallic structure includes a metallic article, extending from the metallic-sheet second surface, and a second junction between the metallic-sheet second surface and the metallic article. The first junction has a first-junction boundary. The second junction has a second-junction boundary. When viewed at any point along the second-junction boundary in a direction, perpendicular to the metallic-sheet first surface, the second-junction boundary does not extend outside of the first-junction boundary.Type: ApplicationFiled: March 7, 2022Publication date: September 7, 2023Applicant: The Boeing CompanyInventors: Daniel G. Sanders, Justin L′Hote, Eric D. Bol, Cory C. Cunningham
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Patent number: 11633835Abstract: Systems for managing abrasive media in cavitated fluid include a set of sensors in communication with cavitated fluid in a processing tank and a processor coupled to the set of sensors. The processor is configured to determine a density of an abrasive media in the cavitated fluid in the processing tank and facilitate maintaining the density of abrasive media in the cavitated fluid in the processing tank at a level that is greater than or equal to a threshold level of abrasive media. The processor is further configured to command the abrasive media addition device to add the recycled abrasive media to the processing tank to increase the density of abrasive media in the cavitated fluid in response to determining that an average density of abrasive media is less than the threshold density of abrasive media.Type: GrantFiled: December 14, 2018Date of Patent: April 25, 2023Assignee: The Boeing CompanyInventor: Daniel G. Sanders
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Publication number: 20230029286Abstract: Disclosed herein is a system for surface treating an internal surface of a part. The system comprises a tank within which the part is locatable. The system also comprises a fluid within the tank and capable of submersing the part when the part is located within the tank. The system further comprises a nozzle submersed in the fluid and configured to generate a stream of cavitated fluid directed in a first direction. The system additionally comprises a deflection tool submersed in the fluid and comprising a deflection surface that redirects the stream of cavitated fluid from the first direction to a second direction. The first direction is away from the internal surface of the part and the second direction is toward the internal surface of the part.Type: ApplicationFiled: October 4, 2022Publication date: January 26, 2023Inventors: Daniel G. Sanders, Amanda J. Wickramaratne, Hali T. Diep, Gregory L. Ramsey
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Patent number: 11465259Abstract: Disclosed herein is a system for surface treating an internal surface of a part. The system comprises a tank within which the part is locatable. The system also comprises a fluid within the tank and capable of submersing the part when the part is located within the tank. The system further comprises a nozzle submersed in the fluid and configured to generate a stream of cavitated fluid directed in a first direction. The system additionally comprises a deflection tool submersed in the fluid and comprising a deflection surface that redirects the stream of cavitated fluid from the first direction to a second direction. The first direction is away from the internal surface of the part and the second direction is toward the internal surface of the part.Type: GrantFiled: February 13, 2019Date of Patent: October 11, 2022Assignee: The Boeing CompanyInventors: Daniel G. Sanders, Amanda J. Thoreson, Hali T. Diep, Gregory L. Ramsey
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Publication number: 20210371986Abstract: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.Type: ApplicationFiled: June 2, 2020Publication date: December 2, 2021Inventors: Bruno Zamorano Senderos, Dennis Lynn Coad, Daniel G. Sanders
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Patent number: 10871471Abstract: A system and method for inspecting an additively manufactured component include an additive manufacturing head configured to form a component layer-by-layer, and an electromagnetic acoustic transducer (EMAT) configured to inspect one or more layers of the component.Type: GrantFiled: January 2, 2020Date of Patent: December 22, 2020Assignee: THE BOEING COMPANYInventors: Daniel G. Sanders, John R. Hull, Gary E. Georgeson
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Patent number: 10843291Abstract: A component is formed by welding a plurality of sheets of metal to form a blank with a number of weld nuggets, placing the blank between a die section and a lid section, heating the die section to heat the blank, and introducing a pressurized gas between the lid section and the die section to press the blank into a mold in the die section to form a component. The number of weld nuggets has a desired thickness ratio between about 1.1 to about 1.25 such that the plurality of sheets of metal and the component formed have a number of characteristics that are substantially the same.Type: GrantFiled: November 12, 2009Date of Patent: November 24, 2020Assignee: The Boeing CompanyInventors: Daniel G. Sanders, Luis R. Leon, Paul D. Edwards, Gregory L. Ramsey, Gary W. Coleman
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Publication number: 20200254586Abstract: Disclosed herein is a system for surface treating an internal surface of a part. The system comprises a tank within which the part is locatable. The system also comprises a fluid within the tank and capable of submersing the part when the part is located within the tank. The system further comprises a nozzle submersed in the fluid and configured to generate a stream of cavitated fluid directed in a first direction. The system additionally comprises a deflection tool submersed in the fluid and comprising a deflection surface that redirects the stream of cavitated fluid from the first direction to a second direction. The first direction is away from the internal surface of the part and the second direction is toward the internal surface of the part.Type: ApplicationFiled: February 13, 2019Publication date: August 13, 2020Inventors: Daniel G. Sanders, Amanda J. Thoreson, Hali T. Diep, Gregory L. Ramsey
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Publication number: 20200189068Abstract: Disclosed herein are systems, methods, and apparatuses for managing abrasive media in cavitated fluid. One system includes a set of sensors in communication with the cavitated fluid in the processing tank and a processor coupled to the set of sensors. The processor is configured to determine a density of an abrasive media in the cavitated fluid in the processing tank and facilitate maintaining the density of abrasive media in the cavitated fluid in the processing tank at a level that is greater than or equal to a threshold level of abrasive media. A method includes determining a density of abrasive media in the cavitated fluid in the processing tank and maintaining the density of abrasive media in the cavitated fluid in the processing tank at a level that is greater than or equal to a threshold density of abrasive media. One apparatus includes modules for performing the method.Type: ApplicationFiled: December 14, 2018Publication date: June 18, 2020Inventor: Daniel G. Sanders
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Patent number: 10294815Abstract: A propulsion system comprises a turbine engine, and an engine nacelle including an SPF/DB inner wall having a hot side face sheet against the engine and a cold side face sheet that has noise attenuation openings.Type: GrantFiled: March 1, 2012Date of Patent: May 21, 2019Assignee: The Boeing CompanyInventors: Max R. Runyan, Daniel G. Sanders, Larry D. Hefti, David R. Papenfuss, Jack W. Mauldin, Luis R. Leon
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Patent number: 9623977Abstract: A hybrid structure comprises a metallic built-up sandwich structure, and a monolithic superplastic formed and diffusion bonded structure joined to the built-up sandwich structure.Type: GrantFiled: March 20, 2014Date of Patent: April 18, 2017Assignee: The Boeing CompanyInventors: Max R. Runyan, Daniel G. Sanders, Jack W. Mauldin, Brent C. Ludwig, John M. Comfort, Larry D. Hefti, Jason F. Joel
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Publication number: 20160193645Abstract: A ceramic refractory insulation block for a hot press is provided that is reinforced in a manner that reduces the likelihood of cracking and, once cracked, reduces the rate at which the crack will propagate through the ceramic refractory insulation block. The ceramic refractory insulation block includes a ceramic body defining a plurality of outer surfaces. Each of the surfaces is a planar surface. The ceramic body also defines a centerline about which the ceramic body is subjected to a bending moment. The ceramic refractory insulation body also includes a plurality of reinforcing rods extending through the ceramic body. The reinforcing rods have a greater flexural strength than the ceramic body. One or more of the plurality of reinforcing rods extend through the ceramic body on each of the opposed sides of the centerline about which the ceramic body is subjected to the bending moment.Type: ApplicationFiled: January 6, 2015Publication date: July 7, 2016Inventors: Daniel G. Sanders, Larry D. Hefti, Mark T. Schergen, James Philp, Peter N. Comley
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Publication number: 20150266586Abstract: A hybrid structure comprises a metallic built-up sandwich structure, and a monolithic superplastic formed and diffusion bonded structure joined to the built-up sandwich structure.Type: ApplicationFiled: March 20, 2014Publication date: September 24, 2015Applicant: The Boeing CompanyInventors: Max R. Runyan, Daniel G. Sanders, Jack W. Mauldin, Brent C. Ludwig, John M. Comfort, Larry D. Hefti, Jason F. Joel
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Patent number: 8991683Abstract: A method of forming a pack in a die by superplastic formation and diffusion bonding comprises applying a forming pressure within the pack to expand the pack within the die; and supplying gas between the die and the pack to apply a back pressure around an outside of the pack while the pack is being expanded to counteract the forming pressure to reduce surface mark off.Type: GrantFiled: September 10, 2012Date of Patent: March 31, 2015Assignee: The Boeing CompanyInventors: Daniel G. Sanders, Larry D. Hefti, Gregory L. Ramsey
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Publication number: 20130251510Abstract: A propulsion system comprises a turbine engine, and an engine nacelle including an SPF/DB inner wall having a hot side face sheet against the engine and a cold side face sheet that has noise attenuation openings.Type: ApplicationFiled: March 1, 2012Publication date: September 26, 2013Applicant: THE BOEING COMPANYInventors: Max R. Runyan, Daniel G. Sanders, Larry D. Hefti, David R. Papenfuss, Jack W. Mauldin, Luis R. Leon
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Publication number: 20130240609Abstract: A component is formed by welding a plurality of sheets of metal to form a blank with a number of weld nuggets, placing the blank between a die section and a lid section, heating the die section to heat the blank, and introducing a pressurized gas between the lid section and the die section to press the blank into a mold in the die section to form a component. The number of weld nuggets has a desired thickness ratio between about 1.1 to about 1.25 such that the plurality of sheets of metal and the component formed have a number of characteristics that are substantially the same.Type: ApplicationFiled: November 12, 2009Publication date: September 19, 2013Applicant: THE BOEING COMPANYInventors: Daniel G. Sanders, Luis R. Leon, Paul D. Edwards, Gregory L. Ramsey, Gary W. Coleman
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Publication number: 20130001276Abstract: A method of forming a pack in a die by superplastic formation and diffusion bonding comprises applying a forming pressure within the pack to expand the pack within the die; and supplying gas between the die and the pack to apply a back pressure around an outside of the pack while the pack is being expanded to counteract the forming pressure to reduce surface mark off.Type: ApplicationFiled: September 10, 2012Publication date: January 3, 2013Applicant: THE BOEING COMPANYInventors: Daniel G. Sanders, Larry D. Hefti, Gregory L. Ramsey
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Patent number: 8329312Abstract: A superplastically formed structural assembly is provided, as is an associated preform and method for forming such an assembly. The assembly includes a skin member and a support member that are joined to define a space between the members and between the joints. The assembly can be produced by joining the members in a flat configuration, and then forming the resulting preform to a predetermined shape of the structural assembly. The support member defines at least one aperture in communication with the space between the members. Thus, the skin member can be formed by delivering a pressurized fluid through the support member to the skin member, e.g., to superplastically form the skin member against a die that defines a contour surface corresponding in shape to the predetermined configuration of the assembly. The support member can extend in a substantially direct configuration between opposing portions of the skin member.Type: GrantFiled: June 27, 2011Date of Patent: December 11, 2012Assignee: The Boeing CompanyInventors: Daniel G. Sanders, David W. Foutch, Jeff D. Will, Luis Leon, Gregory L. Ramsey, Garry A. Booker