Patents by Inventor Kevin Thomas Slattery
Kevin Thomas 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).
-
Patent number: 11577355Abstract: Systems and methods are provided for viscous and/or chemically erosive flow machining of work pieces. In certain examples, a tool for flow machining may be disclosed. The tool may include a cavity configured to receive a work piece and one or more inlets and outlets for viscous media flow. Viscous media and/or chemically erosive media can be flowed into the cavity and, via a media flow path, can be used to machine the work piece.Type: GrantFiled: December 29, 2017Date of Patent: February 14, 2023Assignee: The Boeing CompanyInventors: Kandaudage Channa Ruwan De Silva, Kevin Thomas Slattery
-
Patent number: 11305332Abstract: Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.Type: GrantFiled: January 22, 2021Date of Patent: April 19, 2022Assignee: The Boeing CompanyInventors: David P. Heck, Kevin Thomas Slattery, David M. Milliken
-
Patent number: 11230058Abstract: An additive manufacturing system includes a print head, a first light source array, a second light source array, and a controller. The print head includes a first rotatable reflector and a second rotatable reflector. The first light source array is configured to direct multiple first light beams toward a build medium via the first rotatable reflector. The second light source array is configured to direct multiple second light beams toward the build medium via the second rotatable reflector. The controller is coupled to the print head, the first light source array, and the second light source array. The controller is configured to control activation of the first light beams and activation of the second light beams to selectively fuse portions of the build medium to form one or more objects from the build medium.Type: GrantFiled: June 7, 2019Date of Patent: January 25, 2022Assignee: THE BOEING COMPANYInventors: David Keith Mefford, Kevin Thomas Slattery
-
Publication number: 20210138528Abstract: Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.Type: ApplicationFiled: January 22, 2021Publication date: May 13, 2021Inventors: David P. Heck, Kevin Thomas Slattery, David M. Milliken
-
Patent number: 10940523Abstract: Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.Type: GrantFiled: June 1, 2018Date of Patent: March 9, 2021Assignee: The Boeing CompanyInventors: David P. Heck, Kevin Thomas Slattery, David M. Milliken
-
Publication number: 20200384688Abstract: An additive manufacturing system includes a print head, a first light source array, a second light source array, and a controller. The print head includes a first rotatable reflector and a second rotatable reflector. The first light source array is configured to direct multiple first light beams toward a build medium via the first rotatable reflector. The second light source array is configured to direct multiple second light beams toward the build medium via the second rotatable reflector. The controller is coupled to the print head, the first light source array, and the second light source array. The controller is configured to control activation of the first light beams and activation of the second light beams to selectively fuse portions of the build medium to form one or more objects from the build medium.Type: ApplicationFiled: June 7, 2019Publication date: December 10, 2020Inventors: David Keith Mefford, Kevin Thomas Slattery
-
Patent number: 10596629Abstract: An apparatus for increasing the bulk density of metal powder includes a sealed chamber, a nozzle, and a target. The sealed chamber has an inert environment. The nozzle is coupled to an inert gas source and is configured to introduce raw metal powder into a flow of the inert gas for discharge as a cold spray mixture of the raw metal powder and the inert gas into the sealed chamber. The target is housed within the sealed chamber and is configured to receive an impact of the cold spray mixture. The nozzle and the target are configured to flatten the raw metal particles into flattened metal particles in response to the cold spray mixture impacting the target.Type: GrantFiled: December 16, 2016Date of Patent: March 24, 2020Assignee: The Boeing CompanyInventor: Kevin Thomas Slattery
-
Publication number: 20190366419Abstract: Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.Type: ApplicationFiled: June 1, 2018Publication date: December 5, 2019Inventors: David P. Heck, Kevin Thomas Slattery, David M. Milliken
-
Publication number: 20190202023Abstract: Systems and methods are provided for viscous and/or chemically erosive flow machining of work pieces. In certain examples, a tool for flow machining may be disclosed. The tool may include a cavity configured to receive a work piece and one or more inlets and outlets for viscous media flow. Viscous media and/or chemically erosive media can be flowed into the cavity and, via a media flow path, can be used to machine the work piece.Type: ApplicationFiled: December 29, 2017Publication date: July 4, 2019Inventors: Kandaudage Channa Ruwan De Silva, Kevin Thomas Slattery
-
Patent number: 10252371Abstract: 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: GrantFiled: May 19, 2017Date of Patent: April 9, 2019Assignee: THE BOEING COMPANYInventors: Kathleen Chou, Kevin Thomas Slattery
-
Patent number: 9719150Abstract: A method of forming a workpiece having an initial heat treatment and made of a naturally aging alloy to a final shape using an incremental sheet forming (ISF) machine having a coordinate system and a tool path corresponding to the final shape of the workpiece is disclosed. The method comprises positioning the workpiece in the ISF machine; performing an initial forming operation on the workpiece using the ISF machine; performing a final heat treatment on the workpiece; repositioning the workpiece in the ISF machine; and, with the workpiece in a final workpiece orientation in the ISF machine and the tool path of the ISF machine in a final tool-path orientation in the ISF machine, performing a final forming operation on the workpiece using the ISF machine to achieve the final shape of the workpiece. Intermediate heat treatments and intermediate forming operations in the ISF machine may also be performed.Type: GrantFiled: January 5, 2015Date of Patent: August 1, 2017Assignee: The Boeing CompanyInventor: Kevin Thomas Slattery
-
Publication number: 20170157673Abstract: An apparatus for increasing the bulk density of metal powder includes a sealed chamber, a nozzle, and a target. The sealed chamber has an inert environment. The nozzle is coupled to an inert gas source and is configured to introduce raw metal powder into a flow of the inert gas for discharge as a cold spray mixture of the raw metal powder and the inert gas into the sealed chamber. The target is housed within the sealed chamber and is configured to receive an impact of the cold spray mixture. The nozzle and the target are configured to flatten the raw metal particles into flattened metal particles in response to the cold spray mixture impacting the target.Type: ApplicationFiled: December 16, 2016Publication date: June 8, 2017Inventor: Kevin Thomas Slattery
-
Patent number: 9555473Abstract: An apparatus for increasing the bulk density of metal powder may include a sealed chamber, a nozzle, and a target. The sealed chamber may include an inert environment. The nozzle may be coupled to an inert gas source and may be configured to introduce raw metal powder into a flow of the inert gas for discharge as a cold spray mixture of the raw metal powder and the inert gas into the chamber. The target may be housed within the sealed chamber and may be configured to receive an impact of the cold spray mixture. The nozzle and the target may be configured to flatten the raw metal particles into flattened metal particles in response to the cold spray mixture impacting the target.Type: GrantFiled: October 8, 2011Date of Patent: January 31, 2017Assignee: The Boeing CompanyInventor: Kevin Thomas Slattery
-
Publication number: 20160194728Abstract: A method of forming a workpiece having an initial heat treatment and made of a naturally aging alloy to a final shape using an incremental sheet forming (ISF) machine having a coordinate system and a tool path corresponding to the final shape of the workpiece is disclosed. The method comprises positioning the workpiece in the ISF machine; performing an initial forming operation on the workpiece using the ISF machine; performing a final heat treatment on the workpiece; repositioning the workpiece in the ISF machine; and, with the workpiece in a final workpiece orientation in the ISF machine and the tool path of the ISF machine in a final tool-path orientation in the ISF machine, performing a final forming operation on the workpiece using the ISF machine to achieve the final shape of the workpiece. Intermediate heat treatments and intermediate forming operations in the ISF machine may also be performed.Type: ApplicationFiled: January 5, 2015Publication date: July 7, 2016Inventor: Kevin Thomas Slattery
-
Patent number: 9333702Abstract: A linear-friction-welding machine and a method of linear friction welding are provided which permit continuous clocking or angular positioning between a pair of workpieces without the complexity and cost associated with making either the weld head or the table of the friction-stir-welding machine rotatable. The linear-friction-welding machine may include a stationary or a movable table, a weld head, and a tapered cylindrical collet, adapted to engage a tapered cylindrical opening of a socket. The socket is either supported by the table or retained by the weld head, to permit controlled, continuous clocking of one of the workpieces, retained by the collet, relative to the other workpiece, which is either supported by the table or retained by the weld head such that the workpieces may be mutually biased and linearly oscillated relative each other.Type: GrantFiled: November 30, 2012Date of Patent: May 10, 2016Assignee: The Boeing CompanyInventor: Kevin Thomas Slattery
-
Publication number: 20130089749Abstract: An apparatus for increasing the bulk density of metal powder may include a sealed chamber, a nozzle, and a target. The sealed chamber may include an inert environment. The nozzle may be coupled to an inert gas source and may be configured to introduce raw metal powder into a flow of the inert gas for discharge as a cold spray mixture of the raw metal powder and the inert gas into the chamber. The target may be housed within the sealed chamber and may be configured to receive an impact of the cold spray mixture. The nozzle and the target may be configured to flatten the raw metal particles into flattened metal particles in response to the cold spray mixture impacting the target.Type: ApplicationFiled: October 8, 2011Publication date: April 11, 2013Applicant: THE BOEING COMPANYInventor: Kevin Thomas Slattery