Patents by Inventor Kevin T. Slattery
Kevin T. Slattery 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: 20200016831Abstract: An additive manufacturing system and method includes a powder bed, an additive manufacturing head that is configured to emit a first energy into the powder bed to form at least one layer of a component, a part exposing mechanism that is configured to operate so that the component is in a first position at a first time within the powder bed, and a second position at a second time in which a portion of the component is exposed outside of the powder bed, and a surface smoothing head that is configured to emit a second energy onto the portion of the component in the second position to smooth the portion of the component.Type: ApplicationFiled: July 16, 2018Publication date: January 16, 2020Applicant: THE BOEING COMPANYInventor: Kevin T. Slattery
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Publication number: 20170361396Abstract: A method includes disposing a hydride of a transition metal on a first metallic material, where at least one of the first metallic material or a second metallic material includes a surface oxide layer. The method includes performing a diffusion bonding operation to bond the first metallic material to the second metallic material. During the diffusion bonding operation, the hydride of the transition metal chemically reacts with the surface oxide layer.Type: ApplicationFiled: May 19, 2017Publication date: December 21, 2017Inventors: Kathleen Chou, Kevin T. Slattery
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Patent number: 9682445Abstract: A method includes disposing ZrH2 nanoparticles on a first metallic material. The method includes performing a diffusion bonding operation to bond the first metallic material to a second metallic material. At least one of the first metallic material or the second metallic material includes a surface oxide layer. During the diffusion bonding operation, the ZrH2 nanoparticles chemically react with the surface oxide layer.Type: GrantFiled: February 12, 2016Date of Patent: June 20, 2017Assignee: The Boeing CompanyInventors: Kathleen Chou, Kevin T. Slattery
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Patent number: 8852365Abstract: An aluminum alloy comprises aluminum, magnesium, scandium, and an enhancing system. The magnesium is from about 0.5 percent to about 10.0 percent by weight based on the aluminum alloy. The scandium is from about 0.05 percent to about 10.0 percent by weight based on the aluminum alloy. The enhancing system is from about 0.05 percent to about 1.5 percent by weight based on the aluminum alloy.Type: GrantFiled: January 7, 2009Date of Patent: October 7, 2014Assignee: The Boeing CompanyInventors: Krishnan K. Sankaran, Kevin T. Slattery
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Patent number: 8844796Abstract: Disclosed herein is a method of making a structure by ultrasonic welding and superplastic forming. The method comprises assembling a plurality of workpieces comprising a first workpiece including a first material having superplastic characteristics; ultrasonically welding the first workpiece to a second workpiece, to form an assembly; heating the assembly to a temperature at which the first material having superplastic characteristics is capable of superplastic deformation, and injecting a fluid between the first workpiece and the second workpiece to form a cavity between the first workpiece and the second workpiece.Type: GrantFiled: March 5, 2013Date of Patent: September 30, 2014Assignee: The Boeing CompanyInventor: Kevin T. Slattery
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Patent number: 8601850Abstract: Any of various features of a workpiece are forged by a common set of tools. The feature is incrementally forged as the tool set is moved to successive forging locations on the surface of the workpiece. One of the tools is used to plasticize and extrude a portion of the workpiece while one or more of the other tools are used to form dams that contain and shape the extruded portions.Type: GrantFiled: September 25, 2012Date of Patent: December 10, 2013Assignee: The Boeing CompanyInventors: Kevin T. Slattery, James B. Castle, Christopher S. Huskamp
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Patent number: 8506201Abstract: A preform for use in forming a structural assembly is provided. The preform can be formed by linear friction welding structural members to a base member and friction welding each structural member to at least one of the other structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly.Type: GrantFiled: April 26, 2007Date of Patent: August 13, 2013Assignee: The Boeing CompanyInventor: Kevin T. Slattery
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Publication number: 20130019649Abstract: Any of various features of a workpiece are forged by a common set of tools. The feature is incrementally forged as the tool set is moved to successive forging locations on the surface of the workpiece. One of the tools is used to plasticize and extrude a portion of the workpiece while one or more of the other tools are used to form dams that contain and shape the extruded portions.Type: ApplicationFiled: September 25, 2012Publication date: January 24, 2013Inventors: Kevin T. Slattery, James B. Castle, Christopher S. Huskamp
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Patent number: 8323427Abstract: Disclosed embodiments disclose processes for making shaped metal alloy parts, and deal more particularly with forming features and reducing residual stresses in such parts. Residual stresses introduced into a metal alloy part by heat treatment, which may include solution annealing and quenching, are reduced by processes that plastically deform the part while forming part features. An embodiment comprises: producing a metal alloy blank; subjecting the blank to a process that introduces residual stresses into the blank and plastically deforming the blank to reduce the residual stresses in the blank. Embodiments comprise: subjecting a part to a heat treatment that introduces residual stresses in the part; and age forming the part to shape the part and reduce the residual stresses, incrementally forging at least one feature into the part and reducing the residual stresses in the part, friction welding the part, or gauge rolling the cast part to desired dimensions.Type: GrantFiled: September 14, 2009Date of Patent: December 4, 2012Assignee: The Boeing CompanyInventors: Kevin T. Slattery, Krishnan K. Sankaran, James B. Castle, Christopher S. Huskamp
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Patent number: 8316687Abstract: A method is provided for making a composite part layup tool. A surface of a base is shaped and used as a tool to incrementally form a metal sheet. The formed metal sheet is friction plug welded to the shaped surface on the base to form a metal tool surface of the layup tool.Type: GrantFiled: August 12, 2009Date of Patent: November 27, 2012Assignee: The Boeing CompanyInventor: Kevin T. Slattery
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Patent number: 8302450Abstract: Any of various features of a workpiece are forged by a common set of tools. The feature is incrementally forged as the tool set is moved to successive forging locations on the surface of the workpiece. One of the tools is used to plasticize and extrude a portion of the workpiece while one or more of the other tools are used to form dams that contain and shape the extruded portions.Type: GrantFiled: August 13, 2009Date of Patent: November 6, 2012Assignee: The Boeing CompanyInventors: Kevin T. Slattery, Christopher S. Huskamp, James B. Castle
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Patent number: 8177113Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a frame defining an aperture therein, and at least one structural member positioned within the aperture. The assembly also includes at least one spacer positioned within the aperture such that the spacer and structural member substantially fill the aperture to secure the structural member within the frame, as well as a substrate secured to the frame and positioned adjacent to the structural member in an overlapping configuration to define an interface between the substrate and structural member. In this configuration, the substrate and structural member are capable of being friction stir welded together.Type: GrantFiled: November 21, 2006Date of Patent: May 15, 2012Assignee: The Boeing CompanyInventor: Kevin T. Slattery
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Patent number: 7946469Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.Type: GrantFiled: November 1, 2010Date of Patent: May 24, 2011Assignee: The Boeing CompanyInventors: Kevin T. Slattery, Christopher H. Swallow
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Publication number: 20110042445Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.Type: ApplicationFiled: November 1, 2010Publication date: February 24, 2011Inventors: Kevin T. Slattery, Christopher H. Swallow
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Patent number: 7891535Abstract: A method of making a tailored blank comprising the following steps: (a) friction welding first and second structural members together at a substantially right angle with respect to each other to form an intersection comprising a first joining surface formed by adjoining bottom faces of the first and second structural members, and a second joining surface formed by an angled face of the first structural member that is disposed at a first oblique angle relative to the bottom face of the first structural member; (b) friction welding the first joining surface of the intersection to a first portion of a surface of a base member; and (c) concurrently linear friction welding first and second joining surfaces of a third structural member to the second joining surface of the intersection and to a second portion of the surface of the base member respectively.Type: GrantFiled: October 13, 2005Date of Patent: February 22, 2011Assignee: The Boeing CompanyInventors: Kevin T. Slattery, Christopher H. Swallow, Loren J. Strahm
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Publication number: 20110036139Abstract: A method is provided for making a composite part layup tool. A surface of a base is shaped and used as a tool to incrementally form a metal sheet. The formed metal sheet is friction plug welded to the shaped surface on the base to form a metal tool surface of the layup tool.Type: ApplicationFiled: August 12, 2009Publication date: February 17, 2011Inventor: Kevin T. Slattery
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Publication number: 20110036141Abstract: Any of various features of a workpiece are forged by a common set of tools. The feature is incrementally forged as the tool set is moved to successive forging locations on the surface of the workpiece. One of the tools is used to plasticize and extrude a portion of the workpiece while one or more of the other tools are used to form dams that contain and shape the extruded portions.Type: ApplicationFiled: August 13, 2009Publication date: February 17, 2011Inventors: Kevin T. Slattery, Christopher S. Huskamp, James B. Castle
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Patent number: 7854363Abstract: A preform and method for forming a structural assembly are provided. The preform can be formed by friction welding structural members to a base member and subsequently providing a connection material to join the structural members. The resulting preform can be formed with dimensions and a configuration that approximate the dimensions and configuration of the structural assembly. Thus, the structural assembly can be formed by joining multiple members that are generally smaller than the finished assembly.Type: GrantFiled: July 7, 2008Date of Patent: December 21, 2010Assignee: The Boeing CompanyInventors: Kevin T. Slattery, Keith A. Young
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Patent number: 7841504Abstract: An assembly for positioning a structural assembly for friction stir welding, and a system and method for friction stir welding the structural assembly are provided. The assembly includes a substrate defining a recessed pattern therein, and at least one structural member positioned within the recessed pattern to at least partially secure the structural member therein. The structural member is positioned adjacent to the substrate and within the recessed pattern such that the substrate and structural member are formed of materials capable of being friction stir welded together.Type: GrantFiled: September 21, 2004Date of Patent: November 30, 2010Assignee: The Boeing CompanyInventors: Kevin T. Slattery, Christopher H. Swallow
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Publication number: 20100170996Abstract: An aluminum alloy comprises aluminum, magnesium, scandium, and an enhancing system. The magnesium is from about 0.5 percent to about 10.0 percent by weight based on the aluminum alloy. The scandium is from about 0.05 percent to about 10.0 percent by weight based on the aluminum alloy. The enhancing system is from about 0.05 percent to about 1.5 percent by weight based on the aluminum alloy.Type: ApplicationFiled: January 7, 2009Publication date: July 8, 2010Inventors: Krishnan K. Sankaran, Kevin T. Slattery