Patents by Inventor Stephen J. Hales
Stephen J. Hales 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: 11578395Abstract: The present invention provides a process for suppressing abnormal grain growth in friction stir welded aluminum alloys by inserting an intermediate annealing treatment (“IAT”) after the welding step on the article. The IAT may be followed by a solution heat treatment (SHT) on the article under effectively high solution heat treatment conditions. In at least some embodiments, a deformation step is conducted on the article under effective spin-forming deformation conditions or under effective superplastic deformation conditions. The invention further provides a welded article having suppressed abnormal grain growth, prepared by the process above. Preferably the article is characterized with greater than about 90% reduction in area fraction abnormal grain growth in any friction-stir-welded nugget.Type: GrantFiled: July 23, 2018Date of Patent: February 14, 2023Assignee: UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATION OF NASAInventors: Stephen J. Hales, Harold D Claytor, Joel A. Alexa
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Publication number: 20210360841Abstract: Aspects relate to building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the invention provides methods of improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade than the enclosure.Type: ApplicationFiled: July 27, 2021Publication date: November 18, 2021Inventors: DONALD L. THOMSEN, III, ROBERTO J. CANO, BRIAN J. JENSEN, STEPHEN J. HALES, JOEL A. ALEXA
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Patent number: 11076516Abstract: Aspects relate to methods of building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the invention provides methods of improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade than the enclosure.Type: GrantFiled: July 27, 2018Date of Patent: July 27, 2021Assignee: UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATOR OF NASAInventors: Donald L. Thomsen, III, Roberto J. Cano, Brian J. Jensen, Stephen J. Hales, Joel A. Alexa
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Publication number: 20200124071Abstract: Systems, methods, and devices of the various embodiments may provide a joint suitable for use with space systems, such as robotic space systems, (e.g., Extra Vehicular Activity (EVA) space systems, Intra Vehicular Activity (IVA) space systems, etc.), etc. Various embodiments provide a joint configured to enable structural connection of structural elements, such as trusses, antenna boom sections, beams, etc., including cantilevered elements. Various embodiments provide a joint configured to enable connection of truss structure sections. Various embodiments may provide a robotic erectable joint including an active joint half and a passive joint half configured to connect to the active joint half to thereby form the robotic erectable joint when so connected, wherein the robotic erectable joint has a noncircular cross section (e.g., polygon (e.g., square, triangle, hexagon, etc.) cross section, oval cross section, ellipse cross section, etc.).Type: ApplicationFiled: October 22, 2019Publication date: April 23, 2020Inventors: William R. Doggett, BRUCE D. KING, JOHN T DORSEY, STEPHEN J. HALES, CHRISTOPHER S. DOMACK
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Publication number: 20190053407Abstract: Disclosed are methods of building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the invention provides methods of improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade than the enclosure.Type: ApplicationFiled: July 27, 2018Publication date: February 14, 2019Inventors: DONALD L. THOMSEN, III, ROBERTO J. CANO, BRIAN J. JENSEN, STEPHEN J. HALES, JOEL A. ALEXA
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Publication number: 20190017157Abstract: The present invention provides a process for suppressing abnormal grain growth in friction stir welded aluminum alloys by inserting an intermediate annealing treatment (“TAT”) after the welding step on the article. The TAT may be followed by a solution heat treatment (SHT) on the article under effectively high solution heat treatment conditions. In at least some embodiments, a deformation step is conducted on the article under effective spin-forming deformation conditions or under effective superplastic deformation conditions. The invention further provides a welded article having suppressed abnormal grain growth, prepared by the process above. Preferably the article is characterized with greater than about 90% reduction in area fraction abnormal grain growth in any friction-stir-welded nugget.Type: ApplicationFiled: July 23, 2018Publication date: January 17, 2019Inventors: Stephen J. Hales, Harold D. Claytor, Joel A. Alexa
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Patent number: 10039217Abstract: Disclosed are methods of building Z-graded radiation shielding and covers. In one aspect. the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the invention provides methods of improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade than the enclosure.Type: GrantFiled: August 9, 2013Date of Patent: July 31, 2018Assignee: THE UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATOR OF NASAInventors: Donald Laurence Thomsen, III, Roberto J. Cano, Brian J. Jensen, Stephen J. Hales, Joel A. Alexa
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Patent number: 9963345Abstract: A method of fabricating a composite material includes utilizing a radio frequency plasma process to form a plasma plume comprising nanoparticles. The nanoparticles may comprise boron nitride nanoparticles, silicon carbide nanoparticles, beryllium oxide nanoparticles, or carbon nanoparticles. The nanoparticles may comprise nanotubes or other particles depending on the requirements of a particular application. The nanoparticles are deposited on a substrate by directing a plasma plume towards the substrate. The nanoparticles are formed in the plasma plume immediately prior to being deposited on the substrate. The nanoparticles may form a mechanical bond with the fibers in addition to a chemical bond in the absence of a catalyst. The substrate may comprise a fiber fabric that may optionally be coated with a thin layer of metal. Alternatively, the substrate may comprise a solid material such as a metal sheet or plate.Type: GrantFiled: March 14, 2014Date of Patent: May 8, 2018Assignee: The United States of America as represented by the Administrator of NASAInventors: Stephen J. Hales, Joel A. Alexa, Brian J. Jensen, Roberto J. Cano, Peter T. Lillehei
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Publication number: 20150329948Abstract: The present invention provides a process for suppressing abnormal grain growth in friction stir welded aluminum alloys by inserting an intermediate annealing treatment (“IAT”) after the welding step on the article. The IAT may be followed by a solution heat treatment (SHT) on the article under effectively high solution heat treatment conditions. In at least some embodiments, a deformation step is conducted on the article under effective spin-forming deformation conditions or under effective superplastic deformation conditions. The invention further provides a welded article having suppressed abnormal grain growth, prepared by the process above. Preferably the article is characterized with greater than about 90% reduction in area fraction abnormal grain growth in any friction-stir-welded nugget.Type: ApplicationFiled: July 28, 2015Publication date: November 19, 2015Inventors: Stephen J. Hales, Harold D. Claytor, Joel A. Alexa
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Patent number: 9090950Abstract: The present invention provides a process for suppressing abnormal grain growth in friction stir welded aluminum alloys by inserting an intermediate annealing treatment (“IAT”) after the welding step on the article. The IAT may be followed by a solution heat treatment (SHT) on the article under effectively high solution heat treatment conditions. In at least some embodiments, a deformation step is conducted on the article under effective spin-forming deformation conditions or under effective superplastic deformation conditions. The invention further provides a welded article having suppressed abnormal grain growth, prepared by the process above. Preferably the article is characterized with greater than about 90% reduction in area fraction abnormal grain growth in any friction-stir-welded nugget.Type: GrantFiled: October 12, 2011Date of Patent: July 28, 2015Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Stephen J Hales, Harold Dale Claytor, Joel A. Alexa
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Publication number: 20140272170Abstract: A method of fabricating a composite material includes utilizing a radio frequency plasma process to form a plasma plume comprising nanoparticles. The nanoparticles may comprise boron nitride nanoparticles, silicon carbide nanoparticles, beryllium oxide nanoparticles, or carbon nanoparticles. The nanoparticles may comprise nanotubes or other particles depending on the requirements of a particular application. The nanoparticles are deposited on a substrate by directing a plasma plume towards the substrate. The nanoparticles are formed in the plasma plume immediately prior to being deposited on the substrate. The nanoparticles may form a mechanical bond with the fibers in addition to a chemical bond in the absence of a catalyst. The substrate may comprise a fiber fabric that may optionally be coated with a thin layer of metal. Alternatively, the substrate may comprise a solid material such as a metal sheet or plate.Type: ApplicationFiled: March 14, 2014Publication date: September 18, 2014Inventors: Stephen J. Hales, Joel A. Alexa, Brian J. Jensen, Roberto J. Cano, Peter T. Lillehei, Robert G. Bryant
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Patent number: 8661653Abstract: Methods of building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the methods include improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade from the enclosure.Type: GrantFiled: July 27, 2011Date of Patent: March 4, 2014Assignee: United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Donald Laurence Thomsen, III, Roberto J. Cano, Brian J Jensen, Stephen J Hales, Joel A Alexa
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Publication number: 20120090738Abstract: The present invention provides a process for suppressing abnormal grain growth in friction stir welded aluminum alloys by inserting an intermediate annealing treatment (“IAT”) after the welding step on the article. The IAT may be followed by a solution heat treatment (SHT) on the article under effectively high solution heat treatment conditions. In at least some embodiments, a deformation step is conducted on the article under effective spin-forming deformation conditions or under effective superplastic deformation conditions. The invention further provides a welded article having suppressed abnormal grain growth, prepared by the process above. Preferably the article is characterized with greater than about 90% reduction in area fraction abnormal grain growth in any friction-stir-welded nugget.Type: ApplicationFiled: October 12, 2011Publication date: April 19, 2012Applicant: USA as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Stephen J. Hales, Harold Dale Claytor, Joel A. Alexa
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Publication number: 20120023737Abstract: Disclosed are methods of building Z-graded radiation shielding and covers. In one aspect, the method includes: providing a substrate surface having about medium Z-grade; plasma spraying a first metal having higher Z-grade than the substrate surface; and infusing a polymer layer to form a laminate. In another aspect, the method includes electro/electroless plating a first metal having higher Z-grade than the substrate surface. In other aspects, the invention provides methods of improving an existing electronics enclosure to build a Z-graded radiation shield by applying a temperature controller to at least part of the enclosure and affixing at least one layer of a first metal having higher Z-grade than the enclosure.Type: ApplicationFiled: July 27, 2011Publication date: February 2, 2012Inventors: Donald L. Thomsen, III, Roberto J. Cano, Brian J. Jensen, Stephen J. Hales, Joel A. Alexa
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Patent number: 8017190Abstract: A metal/fiber laminate has a plurality of adjacent layers. Each layer is porous and includes an arrangement of fibers. At least one of the layers has its fibers coated with a metal. A polymer matrix permeates each such arrangement.Type: GrantFiled: October 18, 2010Date of Patent: September 13, 2011Assignee: United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Stephen J. Hales, Joel A. Alexa, Brian J. Jensen, Roberto J. Cano, Erik S. Weiser
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Publication number: 20110070793Abstract: A metal/fiber laminate has a plurality of adjacent layers. Each layer is porous and includes an arrangement of fibers. At least one of the layers has its fibers coated with a metal. A polymer matrix permeates each such arrangement.Type: ApplicationFiled: October 18, 2010Publication date: March 24, 2011Applicants: United States of America as represented by the Administrator of the National AeronauticsInventors: Stephen J. Hales, Joel A. Alexa, Brian J. Jensen, Roberto J. Cano, Erik S. Weiser
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Patent number: 7851062Abstract: A metal/fiber laminate has a plurality of adjacent layers. Each layer is porous and includes an arrangement of fibers. At least one of the layers has its fibers coated with a metal. A polymer matrix permeates each such arrangement.Type: GrantFiled: May 21, 2008Date of Patent: December 14, 2010Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space AdministrationInventors: Stephen J. Hales, Joel A. Alexa, Brian J. Jensen, Roberto J. Cano, Erik S. Weiser
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Publication number: 20090022975Abstract: A metal/fiber laminate has a plurality of adjacent layers. Each layer is porous and includes an arrangement of fibers. At least one of the layers has its fibers coated with a metal. A polymer matrix permeates each such arrangement.Type: ApplicationFiled: May 21, 2008Publication date: January 22, 2009Applicant: U.S.A. as represented by the administrator of the National Aeronautics and Space AdministrationInventors: Stephen J. Hales, Joel A. Alexa, Brian J. Jensen, Roberto J. Cano, Erik S. Weiser