Patents by Inventor David Henry Abbott
David Henry Abbott 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: 20220362886Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.Type: ApplicationFiled: August 1, 2022Publication date: November 17, 2022Inventors: Todd Jay Rockstroh, Michael Francis Xavier Gigliotti, William Thomas Carter, David Henry Abbott, Rajendra Madhukar Kelkar
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Patent number: 11446766Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.Type: GrantFiled: February 24, 2020Date of Patent: September 20, 2022Inventors: Todd Jay Rockstroh, Michael Francis Xavier Gigliotti, William Thomas Carter, David Henry Abbott, Rajendra Madhukar Kelkar
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Patent number: 11426792Abstract: A method of manufacturing a three-dimensional target object may include forming a shell from loose machining powder using an additive manufacturing process and subjecting the shell to a densification process to form a target object. The shell may define an enclosure that contains additional machining powder. The densification process may include causing metallurgical bonding between the shell and additional machining powder contained in the enclosure defined by the shell and shrinking and/or distorting the shape of the shell to conform the target object to a three-dimensional model for the target object. The shell may include a plurality of layers and/or parts that differ at least in respect of density. The plurality of layers and/or parts may be configured based at least in part on the shrinking and/or distorting to the shape of the shell needed to conform the target object to the three-dimensional model for the target object.Type: GrantFiled: August 24, 2020Date of Patent: August 30, 2022Assignee: GENERAL ELECTRIC COMPANYInventors: Zhiwei Wu, Yanmin Li, David Henry Abbott, Xiaobin Chen, Thomas Froats Broderick, Judson Sloan Marte, Andrew Philip Woodfield, Eric Allen Ott
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Publication number: 20210039169Abstract: A method of manufacturing a three-dimensional target object may include forming a shell from loose machining powder using an additive manufacturing process and subjecting the shell to a densification process to form a target object. The shell may define an enclosure that contains additional machining powder. The densification process may include causing metallurgical bonding between the shell and additional machining powder contained in the enclosure defined by the shell and shrinking and/or distorting the shape of the shell to conform the target object to a three-dimensional model for the target object. The shell may include a plurality of layers and/or parts that differ at least in respect of density. The plurality of layers and/or parts may be configured based at least in part on the shrinking and/or distorting to the shape of the shell needed to conform the target object to the three-dimensional model for the target object.Type: ApplicationFiled: August 24, 2020Publication date: February 11, 2021Inventors: Zhiwei Wu, Yanmin Li, David Henry Abbott, Xiaobin Chen, Thomas Froats Broderick, Judson Sloan Marte, Andrew Philip Woodfield, Eric Allen Ott
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Publication number: 20200298341Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.Type: ApplicationFiled: February 24, 2020Publication date: September 24, 2020Inventors: Todd Jay Rockstroh, Michael Francis Xavier Gigliotti, William Thomas Carter, David Henry Abbott, Rajendra Machukar Kelkar
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Patent number: 10780501Abstract: A method for manufacturing a three-dimensional part. The method includes: performing partial densification processing on loose machining powder, to form a densified and sealed enclosure, where there is still loose machining powder accommodated inside the enclosure; and performing overall densification processing on the enclosure and the machining powder inside the enclosure, so as to implement metallurgical bonding between the machining powder inside the enclosure and the enclosure during the densification, thereby forming a target three-dimensional part.Type: GrantFiled: February 24, 2015Date of Patent: September 22, 2020Assignee: General Electric CompanyInventors: Zhiwei Wu, Yanmin Li, David Henry Abbott, Xiaobin Chen, Thomas Froats Broderick, Judson Sloan Marte, Andrew Philip Woodfield, Eric Allen Ott
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Patent number: 10703086Abstract: A system and method for authenticating an additively manufactured component is provided. The method includes locating an identifying region of the component that includes localized density variations that define a component identifier. The method further includes interrogating the identifying region of the component using a scanning device such as an x-ray computed tomography device to obtain the component identifier. The method further includes obtaining a reference identifier from a database, comparing the component identifier to the reference identifier, and determining that the component is authentic if the component identifier matches the reference identifier.Type: GrantFiled: April 5, 2017Date of Patent: July 7, 2020Assignee: GENERAL ELECTRIC COMPANYInventors: Scott Alan Gold, Thomas Graham Spears, David Henry Abbott
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Patent number: 10569362Abstract: A method of making a component includes depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.Type: GrantFiled: November 12, 2014Date of Patent: February 25, 2020Assignee: General Electric CompanyInventors: Todd Jay Rockstroh, Michael Francis Xavier Gigliotti, William Thomas Carter, David Henry Abbott, Rajendra Machukar Kelkar
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Publication number: 20190145263Abstract: A turbine component includes: a metallic wall having opposed interior and exterior surfaces, the wall configured for directing a combustion gas stream in a gas turbine engine; and a metallic negative CTE structure rigidly attached to one of the surfaces.Type: ApplicationFiled: December 31, 2018Publication date: May 16, 2019Inventors: Todd Jay ROCKSTROH, Michael Francis Xavier GIGLOTTI, JR., William Thomas CARTER, David Henry ABBOTT
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Publication number: 20180292331Abstract: A system and method for authenticating an additively manufactured component is provided. The method includes locating an identifying region of the component that includes localized density variations that define a component identifier. The method further includes interrogating the identifying region of the component using a scanning device such as an x-ray computed tomography device to obtain the component identifier. The method further includes obtaining a reference identifier from a database, comparing the component identifier to the reference identifier, and determining that the component is authentic if the component identifier matches the reference identifier.Type: ApplicationFiled: April 5, 2017Publication date: October 11, 2018Inventors: Scott Alan Gold, Thomas Graham Spears, David Henry Abbott
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Publication number: 20180290396Abstract: A method for additively manufacturing a component is provided. The method includes additively manufacturing an identifying region of the component including localized density variations that define a component identifier of the component. The localized density variations may be formed using two materials having different densities, by manipulating an energy source to underexpose or overexpose a layer of powder, or by laser shock peening the component during the additive manufacturing process. This method generates a three-dimensional unique component identifier that may be invisible to the naked eye and detectable only through interrogation by a scanning device, such as an x-ray computed tomography device. The component identifier may be stored in a database as a reference identifier and may be used for authenticating components.Type: ApplicationFiled: April 5, 2017Publication date: October 11, 2018Inventors: Scott Alan Gold, Thomas Graham Spears, David Henry Abbott
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Patent number: 9989482Abstract: The present disclosure generally relates to methods for radiographic and computed tomography (CT) inspection of workpieces having increasingly complicated internal geometry. The disclosed methods are capable of distributing a contrast agent within the detailed internal geometry of, for example, an AM workpiece or precision cast turbine blade, followed by complete removal of the contrast agent and all residues thereof after inspection.Type: GrantFiled: February 16, 2016Date of Patent: June 5, 2018Assignee: General Electric CompanyInventors: David Henry Abbott, Nicolas Kristopher Sabo
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Publication number: 20170234812Abstract: The present disclosure generally relates to methods for radiographic and computed tomography (CT) inspection of workpieces having increasingly complicated internal geometry. The disclosed methods are capable of distributing a contrast agent within the detailed internal geometry of, for example, an AM workpiece or precision cast turbine blade, followed by complete removal of the contrast agent and all residues thereof after inspection.Type: ApplicationFiled: February 16, 2016Publication date: August 17, 2017Inventors: David Henry ABBOTT, Nicolas Kristopher Sabo
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Publication number: 20160288266Abstract: A method of making a component includes depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.Type: ApplicationFiled: November 12, 2014Publication date: October 6, 2016Inventors: Todd Jay Rockstroh, Michael Francis Xavier Gigliotti, William Thomas Carter, David Henry Abbott, Rajendra Machukar KELKAR
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Publication number: 20160281510Abstract: A turbine component includes: a metallic wall having opposed interior and exterior surfaces, the wall configured for directing a combustion gas stream in a gas turbine engine; and a metallic negative CTE structure rigidly attached to one of the surfacesType: ApplicationFiled: November 12, 2014Publication date: September 29, 2016Inventors: Todd Jay ROCKSTROH, Michael Francis Xavier GIGLIOTTI, JR., William Thomas CARTER, David Henry ABBOTT
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Publication number: 20150283614Abstract: A method for manufacturing a three-dimensional part. The method includes: performing partial densification processing on loose machining powder, to form a densified and sealed enclosure, where there is still loose machining powder accommodated inside the enclosure; and performing overall densification processing on the enclosure and the machining powder inside the enclosure, so as to implement metallurgical bonding between the machining powder inside the enclosure and the enclosure during the densification, thereby forming a target three-dimensional part.Type: ApplicationFiled: February 24, 2015Publication date: October 8, 2015Inventors: Zhiwei Wu, Yanmin Li, David Henry Abbott, Xiaobin Chen, Thomas Froats Broderick, Judson Sloan Marte, Andrew Philip Woodfield, I, Eric Allen Ott
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Publication number: 20100140236Abstract: A laser machining system comprises a laser configured to generate a laser output for forming a molten pool on a substrate, a nozzle configured to supply a growth material to the molten pool for depositing the material on the substrate, and an optical unit configured to capture a plurality of grayscale images comprising temperature data during the laser deposition process, wherein the grayscale images correspond to respective ones of a plurality of radiation beams with different desired wavelengths. Further, the laser machining system comprises an image-processing unit configured to process the grayscale images to retrieve the temperature data according to linear relationships between temperatures in the laser deposition process and the corresponding grayscales of the respective images. A laser machining method is also presented.Type: ApplicationFiled: December 4, 2008Publication date: June 10, 2010Applicant: GENERAL ELECTRIC COMPANYInventors: Guoshang Cai, Kevin George Harding, Magdi Naim Azer, Yong Liu, Sudhir Kumar Tewari, Robert William Tait, Xiaobin Chen, Yanmin Li, Huan Qi, David Henry Abbott
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Publication number: 20090165988Abstract: A method for making a turbine airfoil includes: (a) providing a mold having: (i) a core; (ii) an outer shell surrounding the core such that the core and the outer shell cooperatively define a cavity in the shape of an airfoil having at least one outer wall; and (iii) a core support extending from the core to the outer shell through a portion of the cavity that defines the at least one sidewall; (b) introducing molten metal alloy into the cavity and surrounding the core support; (c) solidifying the alloy to form an airfoil casting having at least one outer wall which has at least one core support opening passing therethrough; (d) removing the mold so as to expose the airfoil; and (e) sealing the at least one core support opening in the airfoil with a metal alloy metallurgically bonded to the at least one outer wall.Type: ApplicationFiled: December 31, 2007Publication date: July 2, 2009Applicant: GENERAL ELECTRIC COMPANYInventors: Todd Jay Rockstroh, Sudhir K. Tewari, Joseph Giancarlo Sabato, Donald Brett Desander, David Henry Abbott, Mark Douglas Gledhill
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Patent number: 6103402Abstract: A containerless method of producing a crack free metallic article of near-net shape includes melting a filler material into a metallic substrate or seed under conditions chosen to preclude cracking. In a preferred embodiment of the invention, a laser beam is operated at a relatively low power density and at a relatively large beam diameter at the substrate surface for an extended length of time to produce a molten pool with a low aspect ratio. Near-net shape is achieved by applying the process in a closed-loop, multi-axis material deposition system.Type: GrantFiled: November 21, 1997Date of Patent: August 15, 2000Assignee: United Technologies CorporationInventors: John Joseph Marcin, Jr., Justin Andreas Neutra, David Henry Abbott, James Peter Aduskevich, Dilip M. Shah, Dorothea Nadette Carraway, Raymond Paul Langevin, Marc R. Sauerhoefer, Richard Alan Stone
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Patent number: 5914059Abstract: A filler material is melted into a metallic substrate having a defect under conditions chosen to preclude cracking. In a preferred embodiment of the invention, a laser beam is operated at a relatively low power density and at a relatively large diameter for an extended length of time to produce a molten pool with a low aspect ratio.Type: GrantFiled: March 22, 1996Date of Patent: June 22, 1999Assignee: United Technologies CorporationInventors: John Joseph Marcin, Jr., Justin Andreas Neutra, David Henry Abbott, James Peter Aduskevich, Dilip M. Shah, Dorothea Nadette Carraway, Raymond Paul Langevin, Marc R. Sauerhoefer, Richard Alan Stone