Patents by Inventor Steven R. Peters

Steven R. Peters 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).

  • Publication number: 20200156171
    Abstract: A welding or additive manufacturing system includes a power supply having a controller which controls operation of the power supply. The power supply provides a current waveform to a contact tip assembly having a first bore terminating at a first exit orifice and a second bore terminating at a second exit orifice. The first exit orifice is configured to deliver a first wire electrode and said second exit orifice is configured to deliver a second wire electrode. The exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between the wire electrodes while preventing solid portions of the first wire electrode delivered through the first bore from contacting solid portions of the second wire electrode delivered through the second bore, during a deposition operation in which the current waveform is conducted to both of the wire electrodes simultaneously through the contact tip assembly.
    Type: Application
    Filed: January 27, 2020
    Publication date: May 21, 2020
    Inventors: Matthew A. Albright, Matthew A. Weeks, Steven R. Peters, Andrew R. Peters, Bruce J. Chantry
  • Publication number: 20200114452
    Abstract: A welding or additive manufacturing wire drive system includes a first drive roll having a first annular groove, a second drive roll having a second annular groove, a first welding wire located between the drive rolls in the annular grooves, and a second welding wire located between the drive rolls in the annular grooves. A biasing member biases the first drive roll toward the second drive roll to force the first welding wire to contact the second welding wire. The first welding wire contacts each of a first sidewall portion of the first annular groove, a first sidewall portion of the second annular groove, and the second welding wire. The second welding wire contacts each of a second sidewall portion of the first annular groove, a second sidewall portion of the second annular groove, and the first welding wire. The drive rolls rotate in opposite directions thereby moving the welding wires through the wire drive system.
    Type: Application
    Filed: October 15, 2018
    Publication date: April 16, 2020
    Inventors: Steven R. Peters, Alexander C. Mehlman, Matthew A. Weeks, Bradford W. Petot
  • Publication number: 20200114448
    Abstract: A welding or additive manufacturing wire drive system includes a first spindle for a first welding wire spool, a second spindle for a second welding wire spool, a first drive roll, and a second drive roll. One or both of the drive rolls has a circumferential groove. A first welding wire and a second welding wire are located between the first drive roll and the second drive roll in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove. The second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.
    Type: Application
    Filed: July 31, 2019
    Publication date: April 16, 2020
    Inventors: Bradford W. Petot, Elliott R. Ash, Kent R. Johns, Vincent D. Casella, Steven R. Peters, Alexander C. Mehlman, Matthew A. Weeks
  • Publication number: 20200047275
    Abstract: A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.
    Type: Application
    Filed: October 21, 2019
    Publication date: February 13, 2020
    Inventors: Alexander J. Stergios, Steven R. Peters, Bruce J. Chantry, Matthew A. Weeks
  • Publication number: 20200038984
    Abstract: A system and method to correct for deposition errors during a robotic welding additive manufacturing process. The system includes a welding power source to sample instantaneous parameter pairs of welding output current and wire feed speed in real time during a robotic welding additive manufacturing process while creating a current weld layer of a 3D workpiece part. An instantaneous ratio of welding output current and wire feed speed are determined for each instantaneous parameter pair. A short term running average ratio is determined based on the instantaneous ratios. A relative correction factor is generated based on at least the short term running average ratio and is used in real time while creating the current weld layer to compensate for deviations in a deposit level from a desired deposit level for the current weld layer.
    Type: Application
    Filed: October 10, 2019
    Publication date: February 6, 2020
    Inventors: Joseph A. Daniel, Steven R. Peters
  • Patent number: 10532418
    Abstract: A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.
    Type: Grant
    Filed: March 7, 2019
    Date of Patent: January 14, 2020
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: Alexander J. Stergios, Steven R. Peters, Bruce J. Chantry, Matthew A. Weeks
  • Patent number: 10464168
    Abstract: A method and system to manufacture workpieces employing a high intensity energy source that irradiates a surface of a workpiece to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets. Preferably, a wire feeding device feeds the wire to the puddle, and a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire which is deposited into the puddle.
    Type: Grant
    Filed: January 24, 2014
    Date of Patent: November 5, 2019
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: William Thomas Matthews, Paul Edward Denney, Steven R. Peters
  • Publication number: 20190321914
    Abstract: The disclosed technology generally relates to welding, and more particularly to welding multi-layered structures. In an aspect, a method of welding multi-layered metallic workpieces comprises providing a pair of multi-layered workpieces. Each of the workpieces has a base layer and an cladding layer, where the cladding layer comprises a corrosion resistant element adapted to suppress corrosion in a ferrous alloy. The method additionally comprises forming a root pass weld bead to join cladding layers of the workpieces using a first filler wire comprising the corrosion resistant element and focusing a first laser beam on the cladding layers. The method additionally comprises forming one or more weld beads to join base layers of the workpieces by resistively heating a second filler wire and directing a second laser beam over the root pass weld bead.
    Type: Application
    Filed: April 23, 2018
    Publication date: October 24, 2019
    Inventors: Paul E. Denney, Michael D. Latessa, Steven R. Peters
  • Patent number: 10399172
    Abstract: The invention described herein generally pertains to a system and method related to influencing a direction of an arc within a welding operation. Within a hot wire welding operation, an arc is generated between an electrode and a workpiece and a welding wire is energized while being supplied to a puddle formed by the electrode in order to deposit the liquefied welding wire onto the workpiece. A welder system and/or method is provided that controls a direction of the arc based on at least one of a polarity of the welding wire (via a power supply that energizes the welding wire), a location of the welding wire in proximity to the arc, a synchronization and/or de-synchronization of a polarity of the welding wire with the electrode, an activation and/or a de-activation of energizing of the welding wire, or a combination thereof.
    Type: Grant
    Filed: November 4, 2016
    Date of Patent: September 3, 2019
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: Stephen R. Cole, Steven R. Peters
  • Patent number: 10384293
    Abstract: A welding system and method is provided for welding heavy plate, where the method and device include using a laser which directs a beam to a first weld puddle to weld at least a portion of a work piece and a welding torch to direct a first welding electrode to the first weld puddle while the beam is being directed to the weld puddle. The welding torch deposits the first welding electrode to create a first weld bead. A flux nozzle is employed to deposit a welding flux onto the weld bead, and a submerged arc welding torch is used to direct a submerged arc filler metal to the weld bead to create a second weld bead through a submerged arc welding process, where the submerged arc welding process melts a portion of the first weld bead to consume the melted portion into the second weld bead.
    Type: Grant
    Filed: April 29, 2011
    Date of Patent: August 20, 2019
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: Steven R. Peters, Patrick Wahlen
  • Patent number: 10376980
    Abstract: A method of and system for controlling high frequency arc initiation in a power supply is provided. The power supply includes an output circuit that outputs at least one of a voltage waveform and a current waveform. High frequency, high voltage pulses are induced across a gap between an electrode and a workpiece to create an arc. The method and system further include monitoring at least one of a voltage reading and a current reading across the gap to determine a condition of the arc and controlling the high frequency, high voltage pulses based on the condition of the arc and the type of process, which can be, e.g., SMAW, GTAW, GMAW, FCAW, etc.
    Type: Grant
    Filed: March 8, 2013
    Date of Patent: August 13, 2019
    Assignee: Lincoln Global, INC.
    Inventor: Steven R. Peters
  • Patent number: 10369649
    Abstract: Welding circuits including superposition elements that charge and discharge to assist with re-establishing a welding arc between an electrode and a workpiece after the arc is extinguished when a welding output current polarity changes are described.
    Type: Grant
    Filed: August 4, 2015
    Date of Patent: August 6, 2019
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: Robert L. Dodge, George B. Koprivnak, Steven R. Peters
  • Publication number: 20190201997
    Abstract: A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.
    Type: Application
    Filed: March 7, 2019
    Publication date: July 4, 2019
    Inventors: Alexander J. Stergios, Steven R. Peters, Bruce J. Chantry, Matthew A. Weeks
  • Patent number: 10315268
    Abstract: A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on a desired welding temperature. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion of the welding waveform. The desired welding temperature is one of a temperature setpoint and a temperature range.
    Type: Grant
    Filed: March 11, 2013
    Date of Patent: June 11, 2019
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: Joseph A. Daniel, Steven R. Peters
  • Publication number: 20190168334
    Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.
    Type: Application
    Filed: February 5, 2019
    Publication date: June 6, 2019
    Inventors: Todd E. Kooken, Steven R. Peters, Matthew A. Weeks, Bruce J. Chantry, Alexander J. Stergios
  • Publication number: 20190160530
    Abstract: Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a metal deposition device (MDD) is configured to deposit a metal material during an additive manufacturing process. A controller is operatively coupled to the MDD and is configured to command the MDD to deposit the metal material on a base to form a contour of a part. The controller is configured to command the MDD to deposit the metal material on the base to form an infill pattern within a region outlined by the contour. The infill pattern is a wave shape having a wavelength. The controller is configured to command the metal deposition device to fuse the infill pattern to the metal contour at crossover points, where the infill pattern meets the contour, by applying energy at the crossover points and reducing a deposition rate of the metal material at the crossover points to prevent distorting the contour.
    Type: Application
    Filed: August 2, 2018
    Publication date: May 30, 2019
    Inventors: Steven R. Peters, Andrew R. Peters, William T. Matthews
  • Publication number: 20190091789
    Abstract: A system for controlling arc length by regulating short circuit events during a welding process includes a welding power supply configured to conduct a free flight transfer pulsed arc welding process between a welding electrode and a workpiece, and a controller operatively connected to the welding power supply to control a welding waveform of the free flight transfer pulsed arc welding process. The controller is configured to automatically determine whether or not tethered incipient short circuits are included in said welding waveform, monitor a short circuit event characteristic during the free flight transfer pulsed arc welding process, and automatically adjust, based on said short circuit event characteristic, at least one parameter of said welding waveform to regulate tethered incipient short circuiting of the welding electrode to the workpiece during the free flight transfer pulsed arc welding process after determining that tethered incipient short circuits are included in said welding waveform.
    Type: Application
    Filed: November 28, 2018
    Publication date: March 28, 2019
    Inventors: Steven R. Peters, Daniel P. Fleming
  • Patent number: 10239145
    Abstract: A system and method of welding is provided where a pulse welding power supply is coupled with a magnetic field power supply such that a magnetic field can be generated proximate to a welding arc during pulse welding. During pulse welding a magnetic field is used to direct the welding arc and a droplet being transferred in the arc.
    Type: Grant
    Filed: April 3, 2012
    Date of Patent: March 26, 2019
    Assignee: LINCOLN GLOBAL, INC.
    Inventors: William T Matthews, Steven R Peters, Stephen R Cole
  • Publication number: 20190072941
    Abstract: Embodiments of systems and methods to relate welding wire to a welding power source are disclosed. One embodiment is a networked system having a server computer. The server computer is configured to receive first data including at least one of an identity or a location of a consumable source of welding wire, and at least one of a weight status, indicating a change in weight, or an energization status, indicating an energization state, of the consumable source of welding wire. The server computer is configured to receive second data including at least one of an identity or a location of a welding power source, and an activation status indicating an activation state of the welding power source. The server computer is configured to match the welding power source to the consumable source of welding wire based on at least the first data and the second data.
    Type: Application
    Filed: September 6, 2017
    Publication date: March 7, 2019
    Inventors: Todd E. Kooken, Joseph A. Daniel, Matthew A. Albright, Bruce John Chantry, Steven R. Peters
  • Publication number: 20190070686
    Abstract: Embodiments of systems and methods to relate welding wire to a welding power source are disclosed. One embodiment is a wire docking station for use in a welding environment. The wire docking station includes a loading platform configured to accept a replaceable source of consumable welding wire, and a scale configured to generate a weight status of the source of consumable welding wire when docked with the loading platform. The wire docking station also includes a communication module and a contact mechanism configured to form an electrical connection between the source of consumable welding wire and the communication module. The communication module includes a transmitter configured to transmit docking station data as current draw pulses to a welding power source over the consumable welding wire of the source of consumable welding wire.
    Type: Application
    Filed: March 9, 2018
    Publication date: March 7, 2019
    Inventors: Todd E. Kooken, Joseph A. Daniel, Matthew A. Albright, Bruce J. Chantry, Steven R. Peters