Patents by Inventor Daniel Sordelet

Daniel Sordelet 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: 10669602
    Abstract: A manufacturing process includes depositing a clad layer having a thickness greater than about 0.5 mm (0.02 in) on a surface of the component by hardfacing, and creating a heat affected zone directly below the clad layer due to the depositing. The heat affected zone may be a region of the component where a lowest hardness is lower than a base hardness of the component below the heat affected zone. The method may also include heat treating the component after the deposition such that the lowest hardness in the heat affected zone is restored to within about 15% of the base hardness of the component.
    Type: Grant
    Filed: May 27, 2016
    Date of Patent: June 2, 2020
    Assignee: Caterpillar Inc.
    Inventors: Daniel Sordelet, Robert L. Meyer, Fernando Martinez Diez
  • Patent number: 10252374
    Abstract: A laser cladding system includes a laser apparatus, a chamber, and a pump system. The laser apparatus is configured to generate a laser beam. The chamber includes an interior surface that defines a cladding area comprising a sealed volume. The chamber includes a window that is made from a laser-transparent material and is configured to allow the laser beam to pass therethrough into the cladding area. The pump system has a port in communication with the cladding area. The pump system is configured to selectively generate a vacuum pressure within the cladding area sufficient to evacuate gas from within the cladding area out through the port. The laser apparatus includes a laser head from which the laser beam is emitted and a robotic laser motion system configured to selectively move the laser head such that the laser beam moves relative to a reference point within the chamber.
    Type: Grant
    Filed: January 25, 2016
    Date of Patent: April 9, 2019
    Assignee: Caterpillar Inc.
    Inventors: Daniel T. Cavanaugh, Daniel Sordelet
  • Patent number: 10000839
    Abstract: Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.
    Type: Grant
    Filed: May 24, 2016
    Date of Patent: June 19, 2018
    Assignee: Caterpillar Inc.
    Inventor: Daniel Sordelet
  • Publication number: 20170342538
    Abstract: Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.
    Type: Application
    Filed: May 24, 2016
    Publication date: November 30, 2017
    Applicant: Caterpillar Inc.
    Inventor: Daniel Sordelet
  • Publication number: 20170241007
    Abstract: A component includes a body and a wear layer. The body has a substrate surface. The wear layer is applied to the body such that the wear layer is in overlying relationship with at least a portion of the substrate surface. The wear layer is thermal-spray bonded to the body. The wear layer comprises a composite of a steel alloy and a copper alloy.
    Type: Application
    Filed: February 18, 2016
    Publication date: August 24, 2017
    Applicant: Caterpillar Inc.
    Inventor: Daniel Sordelet
  • Patent number: 9737964
    Abstract: A process of remanufacturing a component such as an attachment flange used in turbochargers is provided and includes using a steam oxidation process to form an adhesion layer on top of a sealing surface of the component. The adhesion layer is an oxidation layer that a thermal metal spray coating can be applied on top of in order to prevent spalling that can occur at high heat. Once the process is completed, the component can be inspected to ensure that it meets or exceeds the manufacturer's original specifications.
    Type: Grant
    Filed: May 18, 2015
    Date of Patent: August 22, 2017
    Assignee: Caterpillar Inc.
    Inventors: Daniel Sordelet, Thomas Clements, Robert Sharp
  • Publication number: 20170209961
    Abstract: A laser cladding system includes a laser apparatus, a chamber, and a pump system. The laser apparatus is configured to generate a laser beam. The chamber includes an interior surface that defines a cladding area comprising a sealed volume. The chamber includes a window that is made from a laser-transparent material and is configured to allow the laser beam to pass therethrough into the cladding area. The pump system has a port in communication with the cladding area. The pump system is configured to selectively generate a vacuum pressure within the cladding area sufficient to evacuate gas from within the cladding area out through the port. The laser apparatus includes a laser head from which the laser beam is emitted and a robotic laser motion system configured to selectively move the laser head such that the laser beam moves relative to a reference point within the chamber.
    Type: Application
    Filed: January 25, 2016
    Publication date: July 27, 2017
    Applicant: Caterpillar Inc.
    Inventors: Daniel T. Cavanaugh, Daniel Sordelet
  • Publication number: 20170088911
    Abstract: A manufacturing process includes depositing a clad layer having a thickness greater than about 0.5 mm (0.02 in) on a surface of the component by hardfacing, and creating a heat affected zone directly below the clad layer due to the depositing. The heat affected zone may be a region of the component where a lowest hardness is lower than a base hardness of the component below the heat affected zone. The method may also include heat treating the component after the deposition such that the lowest hardness in the heat affected zone is restored to within about 15% of the base hardness of the component.
    Type: Application
    Filed: May 27, 2016
    Publication date: March 30, 2017
    Applicant: CATERPILLAR INC.
    Inventors: Daniel Sordelet, Robert L. Meyer, Fernando Martinez Diez
  • Patent number: 9555503
    Abstract: Cladding and remanufacturing a machine component includes directing cleaning and welding beams split from an incident laser beam toward the machine component, and moving the machine component relative the cleaning and welding beams such that the welding beam trails behind the cleaning beam along a common travel path. A surface of the machine component is decontaminated by the cleaning beam, while a cladding material is melted via the welding beam such that upon solidifying the cladding material forms a coating metallurgically bonded to base material and previously deposited cladding material of the machine component.
    Type: Grant
    Filed: September 10, 2013
    Date of Patent: January 31, 2017
    Assignee: Caterpillar Inc.
    Inventors: Kegan Luick, Daniel Sordelet, Daniel T. Cavanaugh, Justin Embrey
  • Publication number: 20160339545
    Abstract: A process of remanufacturing a component such as an attachment flange used in turbochargers is provided and includes using a steam oxidation process to form an adhesion layer on top of a sealing surface of the component. The adhesion layer is an oxidation layer that a thermal metal spray coating can be applied on top of in order to prevent spalling that can occur at high heat. Once the process is completed, the component can be inspected to ensure that it meets or exceeds the manufacturer's original specifications.
    Type: Application
    Filed: May 18, 2015
    Publication date: November 24, 2016
    Applicant: CATERPILLAR INC.
    Inventors: DANIEL SORDELET, THOMAS CLEMENTS, ROBERT SHARP
  • Publication number: 20160097459
    Abstract: A valve for use in an internal combustion engine is disclosed. The valve includes a stem connected to a fillet disposed between the stem and a seat face. A thermal spray technique, such as a high velocity oxy fuel coating spray (HVOF) is applied to the seat face. A nitriding treatment that includes a nitrogen source, which may or may not contain carbon, and heat may be applied after the HVOF spray. The heat allows the nitrogen and/or carbon to penetrate the HVOF layer and the seat face to form a compound zone. The compound zone enhances the wear resistance of the surface during engine operation.
    Type: Application
    Filed: October 6, 2014
    Publication date: April 7, 2016
    Applicant: Caterpillar Inc.
    Inventors: Mark Veliz, Daniel Sordelet
  • Publication number: 20160076128
    Abstract: A method of producing a mechanical face seal, the method including a step of obtaining a cast or wrought substrate part having an inner diameter, outer diameter, and a planar surface. The method may include a rough surface treatment step to form pores, peaks, and valleys on the planar surface of the substrate part. The method may further include a spraying step to supply a spray coating material onto the substrate part to form a protective thermal spray coating layer on the substrate part.
    Type: Application
    Filed: November 10, 2015
    Publication date: March 17, 2016
    Applicant: Caterpillar Inc.
    Inventors: Daniel Sordelet, Tomasz Chojnacki, Connor Haas, Daniel Mathien, Dennis Turczyn
  • Publication number: 20160001358
    Abstract: A method of forming a layer of cladding material on a component includes performing a metal deposition process to deposit cladding material onto a surface of the component and onto a mold member. A metallurgical bond is formed between the cladding material and the component, but not between the cladding material and the mold member. The mold member may be removed after the metal deposition process, and the layer of cladding material can be processed to modify its shape.
    Type: Application
    Filed: July 2, 2014
    Publication date: January 7, 2016
    Inventors: Daniel T. Cavanaugh, Daniel Sordelet, Andrew Steinmetz
  • Publication number: 20150069025
    Abstract: Cladding and remanufacturing a machine component includes directing cleaning and welding beams split from an incident laser beam toward the machine component, and moving the machine component relative the cleaning and welding beams such that the welding beam trails behind the cleaning beam along a common travel path. A surface of the machine component is decontaminated by the cleaning beam, whilst a cladding material is melted via the welding beam such that upon solidifying the cladding material forms a coating metallurgically bonded to base material and previously deposited cladding material of the machine component.
    Type: Application
    Filed: September 10, 2013
    Publication date: March 12, 2015
    Applicant: Caterpillar, Inc.
    Inventors: Kegan Luick, Daniel Sordelet, Daniel T. Cavanaugh, Justin Embrey
  • Publication number: 20110318604
    Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.
    Type: Application
    Filed: September 2, 2011
    Publication date: December 29, 2011
    Applicant: Iowa State University Research Foundation, Inc.
    Inventors: Brian Gleeson, Daniel Sordelet, Wen Wang
  • Publication number: 20110229735
    Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.
    Type: Application
    Filed: February 23, 2011
    Publication date: September 22, 2011
    Applicant: Iowa State University Research Foundation, Inc.
    Inventors: Brian Gleeson, Daniel Sordelet, Wen Wang
  • Publication number: 20110229736
    Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.
    Type: Application
    Filed: February 23, 2011
    Publication date: September 22, 2011
    Applicant: Iowa State University Research Foundation, Inc.
    Inventors: Brian Gleeson, Daniel Sordelet, Wen Wang
  • Publication number: 20080070061
    Abstract: An alloy including a Pt-group metal, Ni and Al, wherein the concentration of Al is limited with respect to the concentration of Ni and the Pt-group metal such that the alloy includes substantiailly no ?-NiAl phase, and wherein the Pt-group metal is present in an amount sufficient to provide enhanced hot corrosion resistance.
    Type: Application
    Filed: May 4, 2007
    Publication date: March 20, 2008
    Applicant: Iowa State University Research Foundation, Inc.
    Inventors: Brian GLEESON, Daniel Sordelet
  • Publication number: 20080057340
    Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.
    Type: Application
    Filed: May 4, 2007
    Publication date: March 6, 2008
    Applicant: Iowa State University Research Foundation, Inc.
    Inventors: Brian GLEESON, Daniel Sordelet, Wen Wang
  • Publication number: 20080057338
    Abstract: An alloy including a Pt-group metal, Ni and Al in relative concentration to provide a ?-Ni+??-Ni3Al phase constitution, and a coating including the alloy.
    Type: Application
    Filed: May 4, 2007
    Publication date: March 6, 2008
    Applicant: Iowa State University Research Foundation, Inc.
    Inventors: Brian GLEESON, Daniel Sordelet, Wen Wang