Patents by Inventor Simon E Bray

Simon E Bray 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: 11717915
    Abstract: A method of friction welding a first component to a second component, the method having the steps of: rotating the first component relative to the second component about a rotation axis; and bringing the first component into contact with the second component; wherein, while the first component and the second component are in contact, a first average force is applied during a first stage of the friction welding process and a second average force is applied during a second stage of the friction welding process; and the second average force is different from the first average force.
    Type: Grant
    Filed: June 12, 2020
    Date of Patent: August 8, 2023
    Assignee: ROLLS-ROYCE PLC
    Inventors: Simon E Bray, Charlotte Gibson, Gemma A Raven, Peter A Stevens
  • Patent number: 11628514
    Abstract: A method of joining a first component to a second component at respective connection surfaces, comprising, in order, applying a local surface treatment to the connection surface of at least one of the first and second components in order to locally alter the microstructure to a depth of between 60 ?m and 10 mm below the connection surface; and joining the first component to the second component using a welding process.
    Type: Grant
    Filed: June 12, 2020
    Date of Patent: April 18, 2023
    Assignee: ROLLS-ROYCE plc
    Inventors: Andrew R Walpole, John P E Forsdike, Gavin J Baxter, Simon E Bray, Alistair J E Smith
  • Patent number: 11072037
    Abstract: A method of friction welding a first workpiece to a second workpiece, includes the first workpiece with a first faying surface having a first faying length, the second workpiece with a second faying surface having a second faying length, the second faying length greater than the first faying length; positioning the first workpiece adjacent the second workpiece; reciprocating the first workpiece and the second workpiece against one another, the first faying moves relative to the second faying by a sweep length, a temperature at the first and second faying surfaces increases to create a weld interface; each of the first and second workpieces are consumed into the weld interface, adjusting the sweep length the sweep length remains equal to a difference between the second and the first faying lengths; and stopping the reciprocating and allowing the first and second workpieces to cool to weld the first and second workpieces together.
    Type: Grant
    Filed: June 4, 2019
    Date of Patent: July 27, 2021
    Assignee: ROLLS-ROYCE plc
    Inventors: Andrew R Walpole, Simon E Bray, Robin Wilson
  • Patent number: 10632563
    Abstract: A rotary friction welding process is provided, including: providing a first axisymmetric workpiece having a first annular weld surface, and a second axisymmetric workpiece having a second annular weld surface; and rotationally welding the workpeices. On the longitudinal section through the aligned workpieces, each of the first and second annular weld surfaces is flanked by radially inner and outer side surfaces, the first weld surface and its side surfaces being shaped to thermally match the second weld surface and its side surfaces across a line of initial contact of the first and second weld surfaces such the heat flows from the weld at all the side surfaces are substantially equal.
    Type: Grant
    Filed: July 19, 2017
    Date of Patent: April 28, 2020
    Assignee: ROLLS-ROYCE PLC
    Inventors: Simon E. Bray, Andrew R. Walpole
  • Patent number: 10625370
    Abstract: The present disclosure provides a rotary friction welding process including: providing an outer axisymmetric workpiece having a front first annular weld surface at a radially inward extent and a rear first annular weld surface at a radially inward extent; providing a front inner axisymmetric workpiece, the front inner workpiece having a front second annular weld surface at a radially outward extent of the front inner workpiece; providing a rear inner axisymmetric workpiece, the rear inner workpiece having a rear second annular weld surface at a radially outward extent of the rear inner workpiece; and rotary welding the workpieces together.
    Type: Grant
    Filed: July 19, 2017
    Date of Patent: April 21, 2020
    Assignee: ROLLS-ROYCE PLC
    Inventors: Simon E. Bray, Andrew R. Walpole
  • Publication number: 20190168336
    Abstract: A workpiece for use with a friction welding process comprises a weld surface. The weld surface comprises a central ridge surface extending along the weld surface, with the central ridge surface being flanked on either side respectively by a first pyramidal surface and a second pyramidal surface. The first pyramidal surface subtends a first pyramidal angle with the central ridge surface, and the second pyramidal surface subtends a second pyramidal angle with the central ridge surface. The first pyramidal surface is further flanked by a third pyramidal surface, and the second pyramidal surface is further flanked by a fourth pyramidal surface, with the third pyramidal surface subtending a third pyramidal angle with the central ridge surface, and the fourth pyramidal surface subtending a fourth pyramidal angle with the central ridge surface. Each of the third pyramidal angle and the fourth pyramidal angle is less than 90°.
    Type: Application
    Filed: January 18, 2019
    Publication date: June 6, 2019
    Inventors: Simon E. Bray, Andrew R. Walpole, Robin Wilson
  • Patent number: 10052715
    Abstract: A method for welding together pieces which form a curved or angled end product using a friction welding process. The method includes: providing first and second pieces which together define the end product geometry, each piece including an end product geometry portion and a sacrificial weld portion, the sacrificial weld portion forming a dog-leg relative to the end product geometry portion and terminating in a planar weld interface surface. The pieces are arranged with their planar weld interface surfaces together at a weld surface interface and the sacrificial weld portions in coaxial alignment. Mechanical friction is applied between the planar weld interface surfaces sufficient to plastically deform the sacrificial weld portions. An axial force is applied along the co-axis of the sacrificial weld portions sufficient to upset the sacrificial weld portions and bring together the end product geometry portions. The sacrificial geometry portions are removed to provide the end product.
    Type: Grant
    Filed: October 19, 2016
    Date of Patent: August 21, 2018
    Assignee: ROLLS-ROYCE plc
    Inventors: Gemma Raven, Simon E Bray, Andrew R Walpole
  • Patent number: 10046414
    Abstract: A friction welding process includes: providing a first workpiece having a first weld surface, and a second workpiece having a second weld surface; aligning the workpieces with the weld surfaces facing each other, moving one workpiece relative to the other workpiece, and engaging the first and second weld surfaces such that the movement raises the temperature at the weld surfaces to create a weld interface; and ceasing the movement and allowing the weld interface to cool to weld the workpieces together at the interface. The first workpiece has a plurality of flash removal channels formed in and/or adjacent to the first weld surface. The channels provide pathways for ejection of material from the weld interface during welding.
    Type: Grant
    Filed: January 8, 2016
    Date of Patent: August 14, 2018
    Assignee: ROLLS-ROYCE plc
    Inventors: Simon E Bray, Andrew R Walpole
  • Patent number: 9248521
    Abstract: A method of linear friction welding, the method comprising: a friction phase comprising oscillating a first workpiece (2) relative to a second workpiece (4) with a surface of the first workpiece (2) being forced against a surface of the second workpiece (4), such that a plasticised layer is formed at the interface between the first and second workpieces (2, 4); wherein the friction phase is divided into a plurality of sub-phases, each sub-phase being configured to form a plasticized layer at the interface between the first and second workpieces (2, 4), each plasticized layer comprising a stagnation zone (10a, 10b); wherein the stagnation zone (10a) of one sub-phase is offset from the stagnation zone (10b) of another sub-phase.
    Type: Grant
    Filed: June 28, 2012
    Date of Patent: February 2, 2016
    Assignee: ROLLS-ROYCE plc
    Inventor: Simon E Bray
  • Patent number: 8777089
    Abstract: A method is disclosed for controlling a process in which a component 4 is moved relative to another component 6 such that at least one of the components 4, 6 experiences a reduction in magnitude in at least one dimension. Such processes may include for example friction welding. The method comprises monitoring energy input to the process and adjusting an input parameter for the process based on the monitored energy input. The monitoring of energy input is performed before any reduction in component magnitude has begun to take place.
    Type: Grant
    Filed: July 1, 2011
    Date of Patent: July 15, 2014
    Assignee: Rolls-Royce PLC
    Inventors: Stephen M. Beech, Michael D. Rowlson, Simon E. Bray, Gavin J. Baxter, Amar M. Varia
  • Patent number: 8718812
    Abstract: A method of making an aerofoil blink comprising a plurality of aerofoil blades joined to a disc to extend radially outwardly therefrom is provided. The method includes the step of: (a) modelling a linear friction welding process in which a blade member is joined to the disc, the blade member having a stub for joining to the disc, wherein the modelling provides results which are indicative of the welding power at positions along the stub during the welding process; (b) identifying adaptations to the stub using the modelling results to compensate for differences in welding power along the stub during the welding process; (c) providing a blade member having a stub with the identified adaptations; and (d) joining the provided blade member to the disc by the linear friction welding process.
    Type: Grant
    Filed: June 22, 2011
    Date of Patent: May 6, 2014
    Assignee: Rolls-Royce PLC
    Inventor: Simon E. Bray
  • Patent number: 8342382
    Abstract: A method of determining the quality of a friction weld between two components, the method comprising joining two components together using a friction welding process, measuring the loss of length of the components as a function of time during the friction welding process, determining the double differential with respect to time of the loss in length of the components as a function of time, determining the quality of the friction weld by calculating the R2 value of the linear fit to the loss in length of the components as a function of time over a defined time period, determining the end of the defined time period by identifying the start of the final positive peak of the double differential with respect to time of the loss of length of the components as a function of time, calculating R2 from the least square difference of the linear fit over the defined time period of the loss of length of the components as a function of time and comparing the calculated value of R2 with acceptable values of R2 to determine
    Type: Grant
    Filed: February 4, 2011
    Date of Patent: January 1, 2013
    Assignee: Rolls-Royce PLC
    Inventors: Gavin J Baxter, Mark G Horwell, Simon E Bray
  • Patent number: 8336755
    Abstract: A weld enclosure and welding apparatus including a weld enclosure. Also a method of welding. The apparatus has first and second opposed tooling faces adapted to receive and hold respective first and second weld elements. The weld enclosure comprises a housing that allows relative movement between the weld elements and a change in a physical dimension of at least one of the weld elements. The weld enclosure also comprises locating means for locating the housing relative to the welding apparatus and includes heating means.
    Type: Grant
    Filed: May 23, 2008
    Date of Patent: December 25, 2012
    Assignee: Rolls-Royce, PLC
    Inventors: Simon E. Bray, Tony J. Sweeting
  • Patent number: 8146795
    Abstract: A method of friction welding comprises providing a first workpiece having a first weld surface and a second workpiece having a second weld surface. The first workpiece is arranged such that it tapers away from the first weld surface, the first workpiece converges in a direction away from the first weld surface. The first and second workpieces are arranged such that the first weld surface abuts the second weld surface. The first and second workpieces are oscillated relative to each other such that at least one of the weld surfaces of at least one of the workpieces moves relative to the other weld surface of the other workpiece such that the temperature increases at the weld surfaces to create a weld interface. The oscillation is stopped and the first and second weld surfaces are allowed to cool to weld the first and second workpieces together.
    Type: Grant
    Filed: July 11, 2007
    Date of Patent: April 3, 2012
    Assignee: Rolls-Royce PLC
    Inventor: Simon E. Bray
  • Patent number: 7997473
    Abstract: A method of friction welding comprising providing a first workpiece (24) having a first weld surface (38) and a second workpiece (26) having a second weld surface (40). In a first region (42) adjacent the first weld surface (38) the first workpiece (24) is arranged at an angle (?) of substantially 90° to the first weld surface (38) and in a second region (44) adjacent to the first region (42) the first workpiece (24) tapers away from the first weld surface (38). The first workpiece (24) is arranged such that in the second region (44) the first workpiece (24) is arranged at an angle (?) greater than 90° and less than 180° to the first weld surface (38). The first and second workpieces (24, 26) are arranged such that first weld surface (38) of the first workpiece (24) abuts the second weld surface (40) of the second workpiece (26).
    Type: Grant
    Filed: July 13, 2010
    Date of Patent: August 16, 2011
    Assignee: Rolls-Royce PLC
    Inventors: Simon E. Bray, Michael D. Rowlson
  • Patent number: 7731075
    Abstract: A blade member is oscillated in the direction of arrow A-A relative to a rim of a disc; a forge force is applied radially and a weld is formed along line; the blade member is formed from a face centred cubic (FCC) nickel based single crystal alloy, such as CMSX-4 of Cannon-Muskegon Corporation; the orientation of the single crystal blade member is controlled to maximize the stress on the slip plane; by maximizing the stress on the slip plane the in-plane friction forces and the forge force are minimized; minimizing the in-plane forces enables the single crystal blade member to be successfully welded to the rim of the disc.
    Type: Grant
    Filed: May 15, 2007
    Date of Patent: June 8, 2010
    Assignee: Rolls-Royce plc
    Inventor: Simon E. Bray
  • Publication number: 20100102106
    Abstract: A weld enclosure (15) and welding apparatus (10) including a weld enclosure (15). Also a method of welding. The apparatus (10) has first (12) and second (14) opposed tooling faces adapted to receive and hold respective first (16) and second (18) weld elements. The weld enclosure (15) comprises a housing (22, 24a, 24b) that allows relative movement between the weld elements (16, 18) and a change in a physical dimension of at least one of the weld elements (16, 18). The weld enclosure (15) also comprises locating means for locating the housing (22, 24a, 24b) relative to the welding apparatus and includes heating means (20).
    Type: Application
    Filed: May 23, 2008
    Publication date: April 29, 2010
    Applicant: ROLLS-ROYCE PLC
    Inventors: Simon E. Bray, Tony J. Sweeting
  • Publication number: 20090314823
    Abstract: A method of friction welding comprises providing a first workpiece (24) having a first weld surface (38) and a second workpiece (26) having a second weld surface (40). The first workpiece (24) is arranged such that it tapers away from the first weld surface (38), the first workpiece (24) converges in a direction away from the first weld surface (38). The first and second workpieces (24, 26) are arranged such that the first weld surface (38) abuts the second weld surface (40). The first and second workpieces (24, 26) are oscillated relative to each other such that at least one of the weld surfaces (38, 40) of at least one of the workpieces (24, 26) moves relative to the other weld surface (40, 38) of the other workpiece (26, 24) such that the temperature increases at the weld surfaces (38, 40) to create a weld interface (42). The oscillation is stopped and the first and second weld surfaces (38, 40) are allowed to cool to weld the first and second workpieces (24, 26) together.
    Type: Application
    Filed: July 11, 2007
    Publication date: December 24, 2009
    Applicant: ROLLS-ROYCE PLC
    Inventor: Simon E. Bray
  • Publication number: 20090173769
    Abstract: A blade member is oscillated in the direction of arrow A-A relative to a rim of a disc; a forge force is applied radially and a weld is formed along line; the blade member is formed from a face centred cubic (FCC) nickel based single crystal alloy, such as CMSX-4 of Cannon-Muskegon Corporation; the orientation of the single crystal blade member is controlled to maximize the stress on the slip plane; by maximizing the stress on the slip plane the in-plane friction forces and the forge force are minimized; minimizing the in-plane forces enables the single crystal blade member to be successfully welded to the rim of the disc.
    Type: Application
    Filed: May 15, 2007
    Publication date: July 9, 2009
    Applicant: ROLLS-ROYCE PLC
    Inventor: Simon E. Bray
  • Patent number: 7419082
    Abstract: A friction welding process providing a workpiece having a weld surface, and a second workpiece having a weld surface. The workpieces being welded together at respective weld surfaces. Oscillatory motion is affected to the workpieces such that one weld surface moves across the other, thereby raising the temperature at the weld surfaces to create a weld interface. The oscillatory motion is ceased and the weld surfaces cool to weld the workpieces together at the interface. The workpiece has an extending portion, and the weld surface is provided on the extending portion. The extending portion includes an apex region, which engages the second workpiece's weld surface. A side face extends from the apex region to provide a gap between the side face and the second workpiece's weld surface. The gap allows weld flash material to pass from the weld interface through said gap.
    Type: Grant
    Filed: December 30, 2004
    Date of Patent: September 2, 2008
    Assignee: Rolls-Royce plc
    Inventors: John B Brownell, Jonathan P Throssell, Simon E Bray