Patents by Inventor Murray W. Mahoney

Murray W. Mahoney 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: 6994242
    Abstract: A rotatable tool for friction stir welding a workpiece and an associated apparatus and method are provided. The tool includes a first pin portion that extends from a shoulder and defines a contour surface opposite the shoulder. A second pin portion extends from the contour surface of the first pin portion. The contour surface, which mixes the material of the workpiece during welding, can increase the mixing of the material at the interface, thereby increasing the strength of the joint.
    Type: Grant
    Filed: December 9, 2003
    Date of Patent: February 7, 2006
    Assignee: The Boeing Company
    Inventors: Christian B. Fuller, Murray W. Mahoney, William H. Bingel
  • Patent number: 6926970
    Abstract: The welding apparatus and associated method are provided. The welding apparatus includes a welding tool for forming a weld joint along the surface of at least one workpiece. The welding apparatus also includes a compression tool for selectively inducing a layer of residual compressive stress in at least a portion of the surface of the weld joint and the surface of the at least one workpiece to thereby improve the material properties of the workpiece, including corrosion resistance and fatigue strength.
    Type: Grant
    Filed: November 1, 2002
    Date of Patent: August 9, 2005
    Assignees: The Boeing Company, Lambda Research, Inc.
    Inventors: Michael Royston James, Murray W. Mahoney, Douglas J. Waldron, Paul S. Prevey, III
  • Patent number: 6866180
    Abstract: Friction stir processing (FSP) modifies the surface microstructure of metals so that thick-section metal workpieces can be bent over large angles without formation of surface cracks. A thick 2519-T8 aluminum plate (25.4 mm thick and 50.8 mm wide) was friction stir processed across the pre-tensile surface to a depth of 6.3 mm, and was then bent at room temperature over a punch with radius 38.1 mm into a v-shaped die to an 80° bend angle. Whereas unprocessed workpieces of this type exhibited surface cracking at 31° bend angle and failed at 40° bend angle, no cracking was evident for the friction stir processed workpiece up to 80° bend angle.
    Type: Grant
    Filed: February 18, 2003
    Date of Patent: March 15, 2005
    Assignee: Rockwell Scientific Licensing, LLC
    Inventors: Murray W. Mahoney, William H. Bingel
  • Publication number: 20040159696
    Abstract: Friction stir processing (FSP) modifies the surface microstructure of metals so that thick-section metal workpieces can be bent over large angles without formation of surface cracks. A thick 2519-T8 aluminum plate (25.4 mm thick and 50.8 mm wide) was friction stir processed across the pre-tensile surface to a depth of 6.3 mm, and was then bent at room temperature over a punch with radius 38.1 mm into a v-shaped die to an 80° bend angle. Whereas unprocessed workpieces of this type exhibited surface cracking at 31° bend angle and failed at 40° bend angle, no cracking was evident for the friction stir processed workpiece up to 80° bend angle.
    Type: Application
    Filed: February 18, 2003
    Publication date: August 19, 2004
    Applicant: Innovative Technology Licensing, LLC
    Inventors: Murray W. Mahoney, William H. Bingel
  • Patent number: 6712916
    Abstract: A shaped metallic component is formed by friction stirring at least a segment of a single piece of bulk metal to impart superplasticity thereto and thereby yield a single superplastic metal blank from the single piece of bulk metal. The metal blank is then deformed by a metal deformation process such as forging, rolling, drawing, bending, extruding, gas forming, punching, and stamping.
    Type: Grant
    Filed: December 21, 2001
    Date of Patent: March 30, 2004
    Assignees: The Curators of the University of Missouri
    Inventors: Rajiv S. Mishra, Murray W. Mahoney
  • Publication number: 20030085257
    Abstract: The welding apparatus and associated method are provided. The welding apparatus includes a welding tool for forming a weld joint along the surface of at least one workpiece. The welding apparatus also includes a compression tool for selectively inducing a layer of residual compressive stress in at least a portion of the surface of the weld joint and the surface of the at least one workpiece to thereby improve the material properties of the workpiece, including corrosion resistance and fatigue strength.
    Type: Application
    Filed: November 1, 2002
    Publication date: May 8, 2003
    Applicant: The Boeing Company
    Inventors: Michael Royston James, Murray W. Mahoney, Douglas J. Waldron, Paul S. Prevey
  • Patent number: 6543670
    Abstract: The present invention provides a structural assembly comprising a first workpiece and a second workpiece. The second workpiece at least partially underlies the first workpiece so as to define an interface therebetween. The assembly includes a friction stir weld joint joining the first and second workpieces. The assembly also includes an interface layer positioned between the first and second workpieces. The interface layer comprises a material having a melting temperature lower than the solidus temperatures of the first and second workpieces. The interface layer at least partially fills the interface proximate to the friction stir weld joint to thereby increase the strength and fracture toughness of the weld joint, as well as other mechanical and chemical properties, including resistance to crack growth and corrosion resistance.
    Type: Grant
    Filed: August 29, 2001
    Date of Patent: April 8, 2003
    Assignee: The Boeing Company
    Inventor: Murray W. Mahoney
  • Publication number: 20030042291
    Abstract: The present invention provides a structural assembly comprising a first workpiece and a second workpiece. The second workpiece at least partially underlies the first workpiece so as to define an interface therebetween. The assembly includes a friction stir weld joint joining the first and second workpieces. The assembly also includes an interface layer positioned between the first and second workpieces. The interface layer comprises a material having a melting temperature lower than the solidus temperatures of the first and second workpieces. The interface layer at least partially fills the interface proximate to the friction stir weld joint to thereby increase the strength and fracture toughness of the weld joint, as well as other mechanical and chemical properties, including resistance to crack growth and corrosion resistance.
    Type: Application
    Filed: August 29, 2001
    Publication date: March 6, 2003
    Applicant: INTERFACE PREPARATION FOR WELD JOINTS
    Inventor: Murray W. Mahoney
  • Publication number: 20020079351
    Abstract: A shaped metallic component is formed by friction stirring at least a segment of a single piece of bulk metal to impart superplasticity thereto and thereby yield a single superplastic metal blank from the single piece of bulk metal. The metal blank is then deformed by a metal deformation process such as forging, rolling, drawing, bending, extruding, gas forming, punching, and stamping.
    Type: Application
    Filed: December 21, 2001
    Publication date: June 27, 2002
    Inventors: Rajiv S. Mishra, Murray W. Mahoney
  • Patent number: 6206268
    Abstract: A friction stir welding pin having internal flow cavities. The pin is adapted to be driven by a conventional friction stir welding machine, and may include external threads for forcing plasticized material toward the weld root. An internal cavity located along the centerline and open to the distal end facilitates deformation of the workpiece material at the weld root. One or more flow channels extending from the sidewall of the pin to the internal flow cavity induce a continuous path of plasticized metal through the pin. The internal cavity may include internal threads to further help force plasticized material toward the root weld. The pin is particularly useful in welding aluminum work pieces where the tolerance of the workpiece thickness is not critical.
    Type: Grant
    Filed: July 13, 2000
    Date of Patent: March 27, 2001
    Inventor: Murray W. Mahoney
  • Patent number: 5975406
    Abstract: The present invention provides a method to repair a void in an aluminum alloy, particularly a void resulting from an exit hole left from friction stir welding (FSW). The method includes machining the void to provide a tapered bore (34) through a parent metal, i.e., the aluminum alloy (30), providing grooves and ridges (36) on a sidewall of the tapered bore, inserting into the bore a consumable tapered plug (38) having an included angle less than, or equal to, that of the tapered bore, and rotating the plug inside the bore under an applied load to plasticize both its surface and the ridges on the parent metal tapered bore. The tapered plug is preferably attached at its proximal end to a nonconsumable heat sink (40) to remove excessive heat generated during rotation of the plug. Also, a support bracket is temporarily attached to the aluminum alloy adjacent the tapered bore to receive a distal end of the plug (38) and to react to the applied load.
    Type: Grant
    Filed: February 27, 1998
    Date of Patent: November 2, 1999
    Assignee: The Boeing Company
    Inventors: Murray W. Mahoney, Norman G. Taylor, William H. Bingel, Frederick E. Long, Robert A. Spurling, Gerald S. Steele
  • Patent number: 5725698
    Abstract: A friction boring process creates a corrosion resistant fine grain microstructure in the wall surfaces of holes bored in aluminum alloy materials. A rotating tool is inserted directly into the aluminum material, or into a pre-drilled pilot hole, at a sufficient rotational velocity and feed rate to cause working that extends beyond the diameter of the tool, frictional heating, and extraction of aluminum material by metal deformation rather than cutting action as with a conventional drill bit. Burring, smoothing, and otherwise removing aluminum material extracted from the hole may be performed by a finishing segment that limits insertion depth of the tool. Frictional heating generates a temperature sufficient for rapid recrystallization of the remaining worked metal to form a fine grain microstructure to a depth of about 2.5 mm in the hole surfaces. Corrosion protection is retained even if some fine grain material is removed during a subsequent reaming operation.
    Type: Grant
    Filed: April 15, 1996
    Date of Patent: March 10, 1998
    Assignee: Boeing North American, Inc.
    Inventor: Murray W. Mahoney
  • Patent number: 5549768
    Abstract: A process of cold working followed by rapid recrystallization imparts a localized fine grain morphology in and around surfaces of fastener holes and edges in aluminum materials. A peening tool that may be employed for surface cold working includes a hollow housing with openings for retaining a plurality of ball peens that may be driven by rotating cams or an oscillating tapered piston operating within the housing to force the ball peens to impact the surfaces of an edge, cavity, or fastener hole to which the tool is applied. The tool may be shaped to accommodate straight bored, counter bored, countersunk, and/or edge surfaces and may be applied manually or automatically for cold working over substantially the entire surface area of the edge or cavity. The peening tool effects localized cold working to a predetermined and controlled depth to break up the existing large pancake-shaped grain structure in the surface of the aluminum alloy.
    Type: Grant
    Filed: September 19, 1995
    Date of Patent: August 27, 1996
    Assignee: Rockwell International Corporation
    Inventor: Murray W. Mahoney
  • Patent number: 5364008
    Abstract: An apparatus and a method for measuring the temperature of a reactive metallic workpiece sealed within a retort prior to and during diffusion bonding of the workpiece. The apparatus includes temperature measuring instruments disposed adjacent preselected portions of the workpiece within the retort, thermal conducting means connecting the instruments with display devices located outside the retort, conduits coupled with the interior of the retort and with the display devices, each of the conduits including a first end portion communicating the interior of the retort with vacuum generating means and a second end portion including at least one tubular region through which the thermal conducting means pass to connect with the display devices, and means for sealing the first and second end portions to maintain an evacuated state within the retort after a vacuum is applied thereto.
    Type: Grant
    Filed: April 12, 1993
    Date of Patent: November 15, 1994
    Assignee: Rockwell International Corporation
    Inventors: George W. Stacher, Murray W. Mahoney
  • Patent number: 5277045
    Abstract: A method and apparatus for effecting superplastic forming of metal workpieces at temperatures greater than 1000.degree. C., wherein both oxidation and creep deformation of the tooling are minimized. The process is achieved by heating forming surfaces of ceramic forming dies to temperatures in excess of 1000.degree. C., and using metal housings to impart high loading conditions to seal the workpiece within a chamber for superplastic forming. More specifically, the metal housings are used not only for load bearing purposes, but also for creating an evacuated chamber within which superplastic forming can take place. The ceramic dies, on the other hand, are positioned on opposing sides of the workpiece region to be superplastically formed, and are insulated from, while being contained within, the metallic dies.
    Type: Grant
    Filed: May 8, 1992
    Date of Patent: January 11, 1994
    Assignee: Rockwell International Corp.
    Inventors: Murray W. Mahoney, Clifford C. Bampton
  • Patent number: 5263640
    Abstract: A method is provided for joining Be-Al alloy structural members to yield a high shear strength at the interface. Surface oxides are first removed from the Be-Al alloy members. Aluminum is then selectively etched from the bonding surfaces to allow the flow of braze alloy into high aspect ratio capillary sites. A discontinuous ceramic reinforcing material, such as Al.sub.2 O.sub.3 or SiC in particulate or whisker form, is added in small quantities to a braze foil, such as Al-Si, to create a composite at the bond interface. The braze foil and reinforcing material are sandwiched between the Be-Al alloy members, and the joint is heated to above the liquidus temperature of the braze alloy but below the melting point of aluminum. The resulting interface shear strength of the Be-Al alloy bond has been tested to an average of about 60% of the parent alloy shear strength.
    Type: Grant
    Filed: October 7, 1992
    Date of Patent: November 23, 1993
    Assignee: Rockwell International Corporation
    Inventors: Murray W. Mahoney, William H. Bingel, Michael Calabrese
  • Patent number: 5207848
    Abstract: A method is provided for fabricating a fiber reinforced metal tube. A first, thin walled metal tube, such as a copper tube, is wrapped with layers of reinforcing fibers, such as copper coated graphite fibers. Layers of fibers aligned in the longitudinal direction of the tube, for example, may be alternated with layers of fibers aligned in the circumferential direction. The fiber wrapped tube is inserted into a second, thick walled metal tube having an inside diameter slightly larger than the outside diameter of the fiber wrapped tube. A vacuum may be formed in the fiber wrapped region between the two metal tubes. The fiber wrapped inner tube is then expanded radially against the inside of the thick walled tube with hot isostatic pressure to consolidate the reinforcing fibers into the metal, thereby forming the fiber reinforced metal tube.
    Type: Grant
    Filed: October 18, 1989
    Date of Patent: May 4, 1993
    Assignee: Rockwell International Corporation
    Inventors: Murray W. Mahoney, Milan G. Metcalf
  • Patent number: 5007265
    Abstract: A monitor is provided for measuring and controlling the strain rate of a blank during forming. A light source directs light against the blank and a video camera is positioned and focused to view the light reflected from the blank while it is being formed. A video monitor and an image processor receive the signal from the camera. This signal is used to determine the strain rate based upon the dimensional change in reference marks on the blank. The image processor provides an output signal which can be used to control the strain rate in accordance with a predetermined strain rate profile for the particular part being formed.
    Type: Grant
    Filed: December 19, 1988
    Date of Patent: April 16, 1991
    Assignee: Rockwell International
    Inventors: Murray W. Mahoney, Amit K. Ghosh
  • Patent number: 4919323
    Abstract: Nickel base alloy sheets are diffusion bonded together at a temperature which is low enough to retain the superplastic properties of the nickel base alloy. A foil and a screen of type 300 series stainless steel are placed between the sheets in the area to be bonded. This assembly is sealed in an envelope and maintained in a vacuum to protect the surfaces from oxidation, and placed within the heated platens of a press. The assembly is heated to a temperature below which rapid grain growth occurs, and sufficient pressure is applied by the press to deform the screen to create continuous contact between the surfaces to be bonded. Diffusion causes bonding of the sheets in less than six hours at temperature, without destroying the superplasticity of the nickel base alloy. In an embodiment of the invention, gas pressure is applied between the sheets in a location away from the bond to superplastically form the sheets during the bonding process.
    Type: Grant
    Filed: June 5, 1989
    Date of Patent: April 24, 1990
    Assignee: Rockwell International Corporation
    Inventors: Murray W. Mahoney, Leslie M. Holmes, Jr.
  • Patent number: 4799974
    Abstract: An aluminum alloy is provided which has a surface with a fine grain structure. It is produced by overaging an aluminum alloy and then cold working only the surface by shot peening or other surface working technique. The alloy is then heated so that the overaged, cold-worked surface recrystallizes into a fine grain structure.
    Type: Grant
    Filed: May 27, 1987
    Date of Patent: January 24, 1989
    Assignee: Rockwell International Corporation
    Inventors: Murray W. Mahoney, Amit K. Ghosh