Patents by Inventor Donald J. Spinella
Donald J. Spinella 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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Patent number: 10293428Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.Type: GrantFiled: June 26, 2014Date of Patent: May 21, 2019Assignee: Arconic Inc.Inventors: Donald J. Spinella, Daniel Bergstrom
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Publication number: 20190134738Abstract: An apparatus and method for fastening layers of non-ferrous alloys, like aluminum, magnesium and copper utilizes a steel fastener and a spot welding machine. The fastener and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the fastener to penetrate the aluminum. A weld zone between the fastener and the various layers creates an internal weld. The fastener has a rough shaft that is coated by the molten weld zone and is hard to withdraw on solidification. Layers of non-conductive materials like plastics and ceramics may also be affixed to a conductive layer using a fastener made from a compatible material that extends through a pilot hole and welds to or penetrates a conductive layer. The fastener may have projections that initially reduce contact area with the stack.Type: ApplicationFiled: December 5, 2018Publication date: May 9, 2019Inventors: Donald J. Spinella, Daniel Bergstrom
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Publication number: 20190109388Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.Type: ApplicationFiled: December 5, 2018Publication date: April 11, 2019Inventors: Donald J. Spinella, Daniel Bergstrom
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Patent number: 9927367Abstract: An apparatus and method for measuring broken spot weld artifacts has a framework for supporting a light and a plurality of cameras for acquiring controlled images of a specimen with minimal distortion and parallax. The framework holds the specimen flat and in a reproducible position, controlling movement while imaging. The image data is received in a computer programmed with image processing software capable of isolating and measuring the artifacts. A calibration standard is used to correct for aberrations.Type: GrantFiled: May 1, 2015Date of Patent: March 27, 2018Assignee: ARCONIC INC.Inventors: Wei Huang, Michael Globig, Donald J. Spinella, K. Rao Vemuri
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Publication number: 20170326690Abstract: The present disclosure relates to new metal powders, wires and other physical forms for use in additive manufacturing, welding and cladding, and multi-component alloy products made from such metal powders, wires and forms via additive manufacturing, welding and cladding. The composition(s) and/or physical properties of the metal powders, wires or forms may be tailored. In turn, additive manufacturing, welding and cladding may be used to produce a tailored multi-component alloy product.Type: ApplicationFiled: May 16, 2017Publication date: November 16, 2017Inventors: David W. Heard, Gen Satoh, Cagatay Yanar, Vivek M. Sample, Jen C. Lin, Andreas Kulovits, Raymond J. Kilmer, Sherri McCleary, Donald J. Spinella, Kyle L. Williams
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Publication number: 20170316556Abstract: An apparatus and method for method for joining materials includes a rivet that may extend through a first sheet to be resistance welded to a second sheet. The head of the rivet has a cavity and vents allowing adhesive extruded from a pilot hole to be received in the cavity and vented in a direction parallel to the first sheet. The rivet is deformed to an hourglass shape that fills the pilot hole and displaces the first sheet into the cavity. Rivet dimension allow for holding with a robotic gripper that can be withdrawn before welding. Methods of monitoring joint quality include comparing welding parameter profiles and images of good and discrepant joints.Type: ApplicationFiled: March 24, 2017Publication date: November 2, 2017Applicant: Arconic Inc.Inventors: Donald J. Spinella, Daniel Bergstrom, Stanley E. Wojciechowski, Robert Wilcox, Justin K. Williams
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Patent number: 9766169Abstract: An apparatus and method for separating welded multi-layered samples has a slotted engine-driven spindle that twists and pulls a layer from the sample, breaking the welds as the layer winds around the spindle. The sample is held between two clamps and a tensioning cylinder pulls a movable first clamp against the second stationery clamp. Sensors may sense the force required to break the welds and the data may be stored and analyzed in a computer.Type: GrantFiled: May 15, 2015Date of Patent: September 19, 2017Assignee: Arconic Inc.Inventors: Donald J. Spinella, Justin K. Williams, Robert J. Speer, Sean Kelly, Richard S. Dulski
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Publication number: 20160167158Abstract: An apparatus and method for fastening layers of non-ferrous alloys, like aluminum, magnesium and copper utilizes a steel fastener and a spot welding machine. The fastener and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the fastener to penetrate the aluminum. A weld zone between the fastener and the various layers creates an internal weld. The fastener has a rough shaft that is coated by the molten weld zone and is hard to withdraw on solidification. Layers of non-conductive materials like plastics and ceramics may also be affixed to a conductive layer using a fastener made from a compatible material that extends through a pilot hole and welds to or penetrates a conductive layer. The fastener may have projections that initially reduce contact area with the stack.Type: ApplicationFiled: December 14, 2015Publication date: June 16, 2016Inventors: Donald J. Spinella, Daniel Bergstrom
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Publication number: 20150330884Abstract: An apparatus and method for separating welded multi-layered samples has a slotted engine-driven spindle that twists and pulls a layer from the sample, breaking the welds as the layer winds around the spindle. The sample is held between two clamps and a tensioning cylinder pulls a movable first clamp against the second stationery clamp. Sensors may sense the force required to break the welds and the data may be stored and analyzed in a computer.Type: ApplicationFiled: May 15, 2015Publication date: November 19, 2015Inventors: Donald J. Spinella, Justin K. Williams, Robert J. Speer, Sean Kelly, Richard S. Dulski
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Publication number: 20150317786Abstract: An apparatus and method for measuring broken spot weld artifacts has a framework for supporting a light and a plurality of cameras for acquiring controlled images of a specimen with minimal distortion and parallax. The framework holds the specimen flat and in a reproducible position, controlling movement while imaging. The image data is received in a computer programmed with image processing software capable of isolating and measuring the artifacts. A calibration standard is used to correct for aberrations.Type: ApplicationFiled: May 1, 2015Publication date: November 5, 2015Inventors: Wei Huang, Michael Globig, Donald J. Spinella, K. Rao Vemuri
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Publication number: 20150217395Abstract: An apparatus and method for fastening dissimilar materials like steel, plastic and aluminum. A resistance welding fastener having multiple layers may be used with or without a sealant. The fastener may be used to form an aluminum covered steel laminate via a hemming pattern of attachment. The fastener may have a solid shaft or have an extended reach and have features for interacting with the welding electrode. A variety of electrode tips may be employed to cooperate with the fastener.Type: ApplicationFiled: February 2, 2015Publication date: August 6, 2015Inventors: Donald J. Spinella, Daniel Bergstrom
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Publication number: 20150001187Abstract: An apparatus is provided including: at least one first sheet comprising a first material; at least one second sheet comprising a second material, wherein the first material comprises at least one of: a thermal conductivity and an electrical conductivity that is at least 10% lower than that of the second material; and a joint comprising at least one resistance spot weld (RSW), wherein the first sheet is at least about 1.5 times the thickness of the second sheet. Methods are also provided.Type: ApplicationFiled: September 16, 2014Publication date: January 1, 2015Inventor: Donald J. Spinella
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Publication number: 20150000956Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a spot welding machine. The metals are stacked with an aluminum body captured between steels. Heat from the welder's electric current softens the lower melting point aluminum allowing an indentation of the steel layer to penetrate the aluminum and weld to an opposing steel layer. The process may be used to join stacks with several layers of different materials and for joining different structural shapes.Type: ApplicationFiled: June 26, 2014Publication date: January 1, 2015Inventor: Donald J. Spinella
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Publication number: 20150001189Abstract: An apparatus and method for fastening dissimilar metals like steel and aluminum utilizes a steel rivet and a spot welding machine. The rivet and metals are stacked and the heat from the welder's electric current softens the lower melting point aluminum allowing the rivet to penetrate the aluminum and weld to the steel layer. The fastener may be used to join stacks with several layers of different materials and may be used to apply a threaded socket or stud made from steel or titanium to an aluminum or magnesium alloy structure. Layers of non-conductive materials like plastic and ceramics may also be affixed to a conductive layer using the fastener made from a compatible material that extends through a pilot hole.Type: ApplicationFiled: June 26, 2014Publication date: January 1, 2015Inventors: Donald J. Spinella, Daniel Bergstrom
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Patent number: 7793816Abstract: Portable friction stir welding apparatus having a crawler which supports a motor for rotating a Friction Stir Welding tool and is coupled to a drive mechanism for urging the crawler along a predefined weld path on work pieces. The crawler can comprise one member or a set of two or three physically separated members each rotatably coupled to the friction stir welding tool. The friction stir welding tool for making the weld is rotatably coupled to each member and restricts axial displacement of the physically separate members relative to each other. The members are adapted to engage rails on the work pieces which provide at least one of guiding, alignment, fixturing, torque compensation for the members as the friction stir welding tool is rotated and the crawler is moved along a joint.Type: GrantFiled: September 7, 2007Date of Patent: September 14, 2010Assignee: Alcoa Inc.Inventors: James T. Burg, Israel Stol, Donald J. Spinella, John W. Cobes
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Patent number: 7718918Abstract: A production line method of resistance welding comprising the steps of contacting a metal sheet with an electrode having an initial contact surface area at a force to provide a pressure to the metal sheet; applying a current though the electrode to the metal sheet; measuring dimensional changes of the electrode; correlating dimensional changes in the electrode to changes in the initial contact surface area; and adjusting the force to compensate for the changes in the initial contact surface area of the electrode to maintain pressure to the metal sheet. The force may be adjusted by stepping the force to maintain pressure to the faying surface of the metal sheet to be welded. By maintaining the pressure at the faying surface the life cycle of the electrodes may be increased without forming discrepant welds.Type: GrantFiled: October 7, 2008Date of Patent: May 18, 2010Assignee: Alcoa IncInventors: Donald J. Spinella, John R. Brockenbrough, Joseph M. Fridy
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Publication number: 20090084763Abstract: The present invention provides a production line method of resistance welding comprising the steps of contacting a metal sheet with an electrode having an initial contact surface area at a force provide a pressure to the metal sheet; applying a current though the electrode to the metal sheet; measuring dimensional changes of the electrode; correlating dimensional changes in the electrode to changes in the initial contact surface area; and adjusting the force to compensate for the changes in the initial contact surface area of the electrode to maintain pressure to the metal sheet. The force may be adjusted by stepping the force to maintain pressure to the flaying surface of the metal sheet to be welded. By maintaining the pressure at the faying surface the life cycle of the electrodes may be increased without forming discrepant welds.Type: ApplicationFiled: October 7, 2008Publication date: April 2, 2009Applicant: Alcoa Inc.Inventors: Donald J. Spinella, John R. Brockenbrough, Joseph M. Fridy
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Publication number: 20090065553Abstract: Portable friction stir welding apparatus having a crawler which supports a motor for rotating a Friction Stir Welding tool and is coupled to a drive mechanism for urging the crawler along a predefined weld path on work pieces. The crawler can comprise one member or a set of two or three physically separated members each rotatably coupled to the friction stir welding tool. When one member is used to make a weld, it is located on top of the work pieces. When two members are used to make a weld, one member is located on the top of the work pieces and the second member is located on bottom of the work pieces. When three members are used to make two welds simultaneously on an upper work piece and a lower work pieces, one member of the crawler is located on the top surface of the upper work piece, a second member is located between the two work pieces, and a third member is located on the bottom surface of the lower work piece.Type: ApplicationFiled: September 7, 2007Publication date: March 12, 2009Inventors: James T. Burg, Israel Stol, Donald J. Spinella, John W. Cobes
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Patent number: 7432466Abstract: A method of resistance welding comprising the steps of contacting a metal sheet with an electrode having an initial contact surface area at a force to provide a pressure to the metal sheet applying a current through the electrode to the metal sheet; measuring dimensional changes of the electrode; correlating dimensional changes in the electrode to changes in the initial contact surface area; and adjusting the force to compensate for the changes in the initial contact surface area of the electrode to maintain pressure to the metal sheet. The force may be adjusted by stepping the force to maintain pressure to the faying surface of the metal sheet to be welded. By maintaining the pressure at the faying surface the life cycle of the electrodes may be increased without forming discrepant welds. The current may also be stepped to further extend electrode life.Type: GrantFiled: December 9, 2005Date of Patent: October 7, 2008Assignee: Alcoa Inc.Inventors: Donald J. Spinella, John R. Brockenbrough, Joseph M. Fridy
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Patent number: 6791056Abstract: A projection coined onto a metal sheet, preferably an aluminum sheet, for projection welding the sheet to an adjacent metal sheet. The projection has a thickness greater than the thickness of the sheet on which it is formed. The wall of the projection surrounds a first recess and a second recess is formed in a side of the sheet opposite the projection from which the metal cold flows to form the projection. A welding gun assembly having an improved low interia, fast response to the collapse of the projection welding the sheet having the projection to the adjacent sheet.Type: GrantFiled: November 27, 2002Date of Patent: September 14, 2004Assignees: Newcor, Inc., Alcoa Inc.Inventors: Robert G. VanOtteren, Edward P. Patrick, Donald J. Spinella