Patents by Inventor Robert A. Hafley
Robert A. Hafley 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: 11440130Abstract: A method of controlling operation of an electron beam gun and wire feeder during deposition of pools of molten matter onto a substrate to form beads upon solidification of the molten matter. The method includes providing a substrate and a wire source. A molten pool of liquid phase metal is formed on the substrate by melting the wire utilizing an electron beam generated by an electron beam gun. The liquid metal solidifies into a solid phase. A controller utilizes data from a sensor to adjust a process perimeter based, at least in part, on data generated by the sensor.Type: GrantFiled: April 17, 2017Date of Patent: September 13, 2022Assignee: United States of America as represented by the Administrator of NASAInventors: Karen M. Taminger, Robert A. Hafley, Joseph N. Zalameda, Christopher S. Domack, Brian L. Taminger, Eric R. Burke, Richard E. Martin, William J. Seufzer, Theresa A. Butler
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Patent number: 11027332Abstract: Systems and methods are provided for the real time inspection of additive manufacturing deposits using infrared thermography. Various embodiments may enable the measurement of material properties and the detection of defects during the additive manufacturing process. Various embodiments may enable the characterization of deposition quality, as well as the detection of deposition defects, such as voids, cracks, disbonds, etc., as a structure is manufactured layer by layer in an additive manufacturing process. Various embodiments may enable quantitative inspection images to be archived and associated with the manufactured structure to document the manufactured structure's structural integrity.Type: GrantFiled: April 14, 2017Date of Patent: June 8, 2021Assignee: UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATOR OF NASAInventors: Joseph N. Zalameda, Eric R. Burke, Robert A. Hafley, Christopher S. Domack
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Publication number: 20170297095Abstract: Systems and methods are provided for the real time inspection of additive manufacturing deposits using infrared thermography. Various embodiments may enable the measurement of material properties and the detection of defects during the additive manufacturing process. Various embodiments may enable the characterization of deposition quality, as well as the detection of deposition defects, such as voids, cracks, disbonds, etc., as a structure is manufactured layer by layer in an additive manufacturing process. Various embodiments may enable quantitative inspection images to be archived and associated with the manufactured structure to document the manufactured structure's structural integrity.Type: ApplicationFiled: April 14, 2017Publication date: October 19, 2017Inventors: JOSEPH N. ZALAMEDA, ERIC R. BURKE, ROBERT A. HAFLEY, CHRISTOPHER S. DOMACK
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Publication number: 20170297140Abstract: A method of controlling operation of an electron beam gun and wire feeder during deposition of pools of molten matter onto a substrate to form beads upon solidification of the molten matter. The method includes providing a substrate and a wire source. A molten pool of liquid phase metal is formed on the substrate by melting the wire utilizing an electron beam generated by an electron beam gun. The liquid metal solidifies into a solid phase. A controller utilizes data from a sensor to adjust a process perimeter based, at least in part, on data generated by the sensor.Type: ApplicationFiled: April 17, 2017Publication date: October 19, 2017Inventors: Karen M. Taminger, Robert A. Hafley, Joseph N. Zalameda, Christopher S. Domack, Brian L. Taminger, Eric R. Burke, Richard E. Martin, William J. Seufzer, Theresa A. Butler
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Height control and deposition measurement for the electron beam free form fabrication (EBF3) process
Patent number: 9764415Abstract: A method of controlling a height of an electron beam gun and wire feeder during an electron freeform fabrication process includes utilizing a camera to generate an image of the molten pool of material. The image generated by the camera is utilized to determine a measured height of the electron beam gun relative to the surface of the molten pool. The method further includes ensuring that the measured height is within the range of acceptable heights of the electron beam gun relative to the surface of the molten pool. The present invention also provides for measuring a height of a solid metal deposit formed upon cooling of a molten pool. The height of a single point can be measured, or a plurality of points can be measured to provide 2D or 3D surface height measurements.Type: GrantFiled: March 15, 2013Date of Patent: September 19, 2017Assignee: The United States of America as represented by the Administrator of NASAInventors: William J. Seufzer, Robert A. Hafley -
Patent number: 8452073Abstract: A closed-loop control method for an electron beam freeform fabrication (EBF3) process includes detecting a feature of interest during the process using a sensor(s), continuously evaluating the feature of interest to determine, in real time, a change occurring therein, and automatically modifying control parameters to control the EBF3 process. An apparatus provides closed-loop control method of the process, and includes an electron gun for generating an electron beam, a wire feeder for feeding a wire toward a substrate, wherein the wire is melted and progressively deposited in layers onto the substrate, a sensor(s), and a host machine. The sensor(s) measure the feature of interest during the process, and the host machine continuously evaluates the feature of interest to determine, in real time, a change occurring therein. The host machine automatically modifies control parameters to the EBF3 apparatus to control the EBF3 process in a closed-loop manner.Type: GrantFiled: March 31, 2010Date of Patent: May 28, 2013Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Karen M. Taminger, Robert A. Hafley, Richard E. Martin, William H. Hofmeister
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Patent number: 8344281Abstract: A method for controlling an electron beam process wherein a wire is melted and deposited on a substrate as a molten pool comprises generating the electron beam with a complex raster pattern, and directing the beam onto an outer surface of the wire to thereby control a location of the wire with respect to the molten pool. Directing the beam selectively heats the outer surface of the wire and maintains the position of the wire with respect to the molten pool. An apparatus for controlling an electron beam process includes a beam gun adapted for generating the electron beam, and a controller adapted for providing the electron beam with a complex raster pattern and for directing the electron beam onto an outer surface of the wire to control a location of the wire with respect to the molten pool.Type: GrantFiled: March 31, 2010Date of Patent: January 1, 2013Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Karen M. Taminger, William H. Hofmeister, Robert A. Hafley
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Publication number: 20100270274Abstract: A method for controlling an electron beam process wherein a wire is melted and deposited on a substrate as a molten pool comprises generating the electron beam with a complex raster pattern, and directing the beam onto an outer surface of the wire to thereby control a location of the wire with respect to the molten pool. Directing the beam selectively heats the outer surface of the wire and maintains the position of the wire with respect to the molten pool. An apparatus for controlling an electron beam process includes a beam gun adapted for generating the electron beam, and a controller adapted for providing the electron beam with a complex raster pattern and for directing the electron beam onto an outer surface of the wire to control a location of the wire with respect to the molten pool.Type: ApplicationFiled: March 31, 2010Publication date: October 28, 2010Applicant: USA as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Karen M. Taminger, William H. Hofmeister, Robert A. Hafley
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Publication number: 20100260410Abstract: A closed-loop control method for an electron beam freeform fabrication (EBF3) process includes detecting a feature of interest during the process using a sensor(s), continuously evaluating the feature of interest to determine, in real time, a change occurring therein, and automatically modifying control parameters to control the EBF3 process. An apparatus provides closed-loop control method of the process, and includes an electron gun for generating an electron beam, a wire feeder for feeding a wire toward a substrate, wherein the wire is melted and progressively deposited in layers onto the substrate, a sensor(s), and a host machine. The sensor(s) measure the feature of interest during the process, and the host machine continuously evaluates the feature of interest to determine, in real time, a change occurring therein. The host machine automatically modifies control parameters to the EBF3 apparatus to control the EBF3 process in a closed-loop manner.Type: ApplicationFiled: March 31, 2010Publication date: October 14, 2010Applicants: Space AdministrationInventors: Karen M. Taminger, Robert A. Hafley, Richard E. Martin, William H. Hofmeister
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Patent number: 7168935Abstract: An apparatus for formation of a three dimensional object comprising a sealed container; an electron beam subsystem capable of directing energy within said container; a positioning subsystem contained within said container; a wire feed subsystem contained within said container; an instrumentation subsystem electronically connected to said electron beam subsystem, positioning subsystem, and wire feed subsystem; and a power distribution subsystem electrically connected to said electron beam subsystem, positioning subsystem, wire feed subsystem, and said instrumentation subsystem.Type: GrantFiled: August 1, 2003Date of Patent: January 30, 2007Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Karen M. Taminger, J. Kevin Watson, Robert A. Hafley, Daniel D. Petersen