Patents by Inventor Thierry Marchione

Thierry Marchione 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: 11014292
    Abstract: A hybrid method of additive manufacturing is provided. The method includes providing a powder material and fusing, by a first heat source, a portion of the powder material to form a three-dimensional structure. The three-dimensional structure can define a fill region at least partially filled with the powder material. The method further includes fusing, by a second heat source, the powder material in the fill region. Fusing the powder material in the fill region can solidify the powder material in the fill region and fuse the powder material to the three-dimensional structure for forming a solid object.
    Type: Grant
    Filed: September 17, 2018
    Date of Patent: May 25, 2021
    Assignee: Caterpillar Inc.
    Inventor: Thierry Marchione
  • Publication number: 20210138569
    Abstract: A method for manufacturing a T-shaped structure includes depositing one or more layers of weld beads over a portion of a surface of a first component such that the one or more layers of weld beads develop a metallurgical bond with the portion. Also, the method includes placing an end of a second component over the one or more layers of weld beads such that the end develops a metallurgical bond with the one or more layers of weld beads. The one or more layers of weld beads define a fully penetrated weld joint between the end and the portion to form the T-shaped structure.
    Type: Application
    Filed: November 12, 2019
    Publication date: May 13, 2021
    Applicant: Caterpillar Inc.
    Inventor: Thierry Marchione
  • Patent number: 10857599
    Abstract: A tool for a boring machine includes an elongated elongated body extending longitudinally from a proximal end to a distal end, the distal end being shaped to receive a cutting tip, and a cavity inside the body. The tool includes a lattice provided within the cavity and a powder provided in the cavity with the lattice.
    Type: Grant
    Filed: January 15, 2019
    Date of Patent: December 8, 2020
    Assignee: Caterpiller Inc.
    Inventors: Thierry A. Marchione, Kevin L. Martin, Rohit A. Bhapkar
  • Publication number: 20200368814
    Abstract: An additive manufacturing method for a part includes forming a pillar by fusing metallic material to form a hollow body portion including a wall having an inner surface and an outer surface and fusing metallic material to form a cap portion extending from a distal end of the body portion. The method includes forming the pillar by fusing metallic material to form a distal portion supported on the cap portion, supporting at least a portion of the part by the pillar, and removing the pillar from the part.
    Type: Application
    Filed: May 22, 2019
    Publication date: November 26, 2020
    Applicant: Caterpillar Inc.
    Inventors: Kevin L. MARTIN, Thierry A. Marchione
  • Patent number: 10765975
    Abstract: A filter element for the filtration of fluids can be manufactured from powdered metal using a laser manufacturing process. The powdered metal is deposited in a layer on fabrication platform and a laser beam is directed toward the layer of material so that the powdered metal granules fuse together to form a first component of the filter element. Successive layers of powdered metal can be deposited over the first component and also fused with the laser beam to form additional components. During the manufacturing process, the power or scan rate of the laser beam many be changed so that the formed layers of the filter element may have different porosity characteristics, for example, with certain portions being fluid permeable and other portions being fluid impermeable.
    Type: Grant
    Filed: July 1, 2016
    Date of Patent: September 8, 2020
    Assignee: Caterpillar Inc.
    Inventors: Thierry A. Marchione, Brent D. Widder, Rahul Gami
  • Patent number: 10746301
    Abstract: A method for manufacturing a seal is disclosed. The method includes depositing one or more layers of a first material on a metal base plate of a second material to form a main seal body of the seal. The second material is different from the first material. The method further includes separating the seal from the metal base plate such that the seal includes the main seal body and an outer seal layer retained on the main seal body to form a seal face surface of the seal. The outer seal layer is formed of a portion of the metal base plate.
    Type: Grant
    Filed: August 22, 2017
    Date of Patent: August 18, 2020
    Assignee: Caterpillar Inc.
    Inventors: Thierry Marchione, Timothy A. Thorson, Dennis Michael Turczyn
  • Publication number: 20200222990
    Abstract: A tool for a boring machine includes an elongated elongated body extending longitudinally from a proximal end to a distal end, the distal end being shaped to receive a cutting tip, and a cavity inside the body. The tool includes a lattice provided within the cavity and a powder provided in the cavity with the lattice.
    Type: Application
    Filed: January 15, 2019
    Publication date: July 16, 2020
    Applicant: Caterpillar Inc.
    Inventors: Thierry A. MARCHIONE, Kevin L. MARTIN, Rohit A. BHAPKAR
  • Publication number: 20200086555
    Abstract: A hybrid method of additive manufacturing is provided. The method includes providing a powder material and fusing, by a first heat source, a portion of the powder material to form a three-dimensional structure. The three-dimensional structure can define a fill region at least partially filled with the powder material. The method further includes fusing, by a second heat source, the powder material in the fill region. Fusing the powder material in the fill region can solidify the powder material in the fill region and fuse the powder material to the three-dimensional structure for forming a solid object.
    Type: Application
    Filed: September 17, 2018
    Publication date: March 19, 2020
    Applicant: Caterpillar Inc.
    Inventor: Thierry MARCHIONE
  • Patent number: 10569810
    Abstract: A node is disclosed. The node may have a core. The node may also have a projection extending from the core. Further the node may have a structural member attached to the projection. The node may also have a top cover having a top recess. The top recess may be configured to receive the structural member. Additionally, the node may have a bottom cover having a bottom recess. The bottom recess may be configured to receive the structural member. In addition the node may have a fastener to connect the top cover and the bottom cover.
    Type: Grant
    Filed: July 12, 2017
    Date of Patent: February 25, 2020
    Assignee: Caterpillar Inc.
    Inventors: Rahul N. Gami, Ajay Dnyandeo Yadav, Richard K. Huff, Jarrod Delane Neal, Matthew M. Robinson, Tad W. Miller, Brandon C. Brenner, David William Holthaus, Jacob Warner Bell, Michael H. Noble, Edward Patrick Ormiston, Hemant Prasad Mallampalli, Thierry A. Marchione, Michael R. Spengler
  • Patent number: 10549519
    Abstract: A system for additive manufacturing includes a laser configured to produce a laser beam having a laser spot area and configured to operate at a transverse speed. The system includes a power source configured to power the laser to selectively heat the powdered material at a configurable power level. The system includes a controller configured to determine an energy density for an ideal build for the object, the ideal build having ideal surface properties for the ideal build including a bead overlap and a build layer thickness, the energy density being based on a plurality of parameters, which include the power level, the laser spot area, the transverse speed, the bead overlap, and the build layer thickness. The controller is configured to calibrate one or both of the power source and the laser based, at least, on the energy density, and execute, after calibration, toolpath instructions to form the object.
    Type: Grant
    Filed: January 12, 2017
    Date of Patent: February 4, 2020
    Assignee: Caterpillar Inc.
    Inventor: Thierry Marchione
  • Patent number: 10413998
    Abstract: Additive manufacturing creates, repairs, or upgrades parts. Conventional manufacturing processes are used to prepare a body of the part and additive manufacturing processes are used to prepare intricate geometries of the part. A support structure is used to support the intricate features during the additive manufacturing processes. Particularly, laser sintering is used to create entire parts or to create a repaired or upgraded part by casting the body of the part and integrating the body with a build plate and using laser sintering to develop the intricate features necessary.
    Type: Grant
    Filed: October 2, 2015
    Date of Patent: September 17, 2019
    Assignee: Caterpillar Inc.
    Inventors: Thierry Marchione, Luis Vazquez
  • Patent number: 10393271
    Abstract: A method for manufacturing a seal is disclosed. The method includes coating a sealing surface substrate of an annular main seal body of the seal with a layer of Molybdenum, and melting the layer of Molybdenum to fuse the layer of Molybdenum into the sealing surface substrate to form an alloyed outer seal layer. The alloyed outer seal layer forms a sealing surface of the seal.
    Type: Grant
    Filed: June 28, 2017
    Date of Patent: August 27, 2019
    Assignee: Caterpillar Inc.
    Inventors: Thierry Marchione, Timothy A. Thorson, Dennis Michael Turczyn, Zachary Steven Birky
  • Patent number: 10384435
    Abstract: A system and method for Selective Laser Fusing of a 3D part is disclosed. The system may comprise a platform, a gantry, a dispenser, a first press, a laser configured to emit a laser beam onto powdered material, a positive pressure chamber at least partially surrounding the laser, and a controller. The controller may be configured to: (a) receive data that includes a representation of the 3D part sliced into a plurality of layers; (b) rotate on a path about an axis either the platform or simultaneously each of the dispenser, the first press, the positive pressure chamber and the laser; (c) activate the dispenser to deposit the powdered material during (b); (d) activate the laser to emit during (b) the laser beam onto the powdered material to Fuse the powdered material into a layer of the plurality of layers; and (e) repeat (b)-(d) to make the 3D part.
    Type: Grant
    Filed: January 4, 2016
    Date of Patent: August 20, 2019
    Assignee: Caterpillar Inc.
    Inventors: Timothy Thorson, Thierry A. Marchione
  • Patent number: 10352448
    Abstract: A method for manufacturing a seal is disclosed. The method includes forming a layer of a hardened metal layer on a metal base plate. Further, the method includes melting the layer of the hardened metal in a nitrogen atmosphere to form a layer of metal nitride. Furthermore, the method includes depositing a plurality of layers of a metal alloy on the layer of metal nitride to form a main seal body portion, wherein the layer of metal nitride and the main seal body portion together correspond to the seal.
    Type: Grant
    Filed: August 1, 2017
    Date of Patent: July 16, 2019
    Assignee: Caterpillar Inc.
    Inventors: Thierry Marchione, Timothy A. Thorson, Dennis Michael Turczyn
  • Publication number: 20190070685
    Abstract: A system for manufacturing a component includes a power supply unit adapted to generate welding power. The system also includes a welding system. The welding system includes a welding torch having a welding wire. The welding wire is movable in an axial direction and a radial direction with respect to a central axis of the welding torch for depositing material from the welding wire to manufacture the component. The welding system also includes a motion control assembly. The motion control assembly is adapted to move the welding wire in the radial direction. The system further includes a control unit configured to transmit control signals to the welding system for controlling at least one of a rotation speed of the welding wire, a diameter of rotation of the welding wire, a direction of rotation of the welding wire, and a iced rate of the welding wire.
    Type: Application
    Filed: October 29, 2018
    Publication date: March 7, 2019
    Applicant: Caterpillar Inc.
    Inventors: Thierry Marchione, Bradley Phillip Graham
  • Publication number: 20190063609
    Abstract: A method for manufacturing a seal is disclosed. The method includes depositing one or more layers of a first material on a metal base plate of a second material to form a main seal body of the seal. The second material is different from the first material. The method further includes separating the seal from the metal base plate such that the seal includes the main seal body and an outer seal layer retained on the main seal body to form a seal face surface of the seal. The outer seal layer is formed of a portion of the metal base plate.
    Type: Application
    Filed: August 22, 2017
    Publication date: February 28, 2019
    Applicant: Caterpillar Inc.
    Inventors: Thierry Marchione, Timothy A. Thorson, Dennis Michael Turczyn
  • Publication number: 20190040955
    Abstract: A method for manufacturing a seal is disclosed. The method includes forming a layer of a hardened metal layer on a metal base plate. Further, the method includes melting the layer of the hardened metal in a nitrogen atmosphere to form a layer of metal nitride. Furthermore, the method includes depositing a plurality of layers of a metal alloy on the layer of metal nitride to form a main seal body portion, wherein the layer of metal nitride and the main seal body portion together correspond to the seal.
    Type: Application
    Filed: August 1, 2017
    Publication date: February 7, 2019
    Applicant: Caterpillar Inc.
    Inventors: Thierry Marchione, Timothy A. Thorson, Dennis Michael Turczyn
  • Publication number: 20190003596
    Abstract: A method for manufacturing a seal is disclosed. The method includes coating a sealing surface substrate of an annular main seal body of the seal with a layer of Molybdenum, and melting the layer of Molybdenum to fuse the layer of Molybdenum into the sealing surface substrate to form an alloyed outer seal layer. The alloyed outer seal layer forms a sealing surface of the seal.
    Type: Application
    Filed: June 28, 2017
    Publication date: January 3, 2019
    Applicant: Caterpillar Inc.
    Inventors: Thierry Marchione, Timothy A. Thorson, Dennis Michael Turczyn, Zachary Steven Birky
  • Publication number: 20180193959
    Abstract: A system for additive manufacturing includes a laser configured to produce a laser beam having a laser spot area and configured to operate at a transverse speed. The system includes a power source configured to power the laser to selectively heat the powdered material at a configurable power level. The system includes a controller configured to determine an energy density for an ideal build for the object, the ideal build having ideal surface properties for the ideal build including a bead overlap and a build layer thickness, the energy density being based on a plurality of parameters, which include the power level, the laser spot area, the transverse speed, the bead overlap, and the build layer thickness. The controller is configured to calibrate one or both of the power source and the laser based, at least, on the energy density, and execute, after calibration, toolpath instructions to form the object.
    Type: Application
    Filed: January 12, 2017
    Publication date: July 12, 2018
    Applicant: Caterpillar Inc.
    Inventor: Thierry Marchione
  • Patent number: 9987683
    Abstract: A method for metallic three-dimensional (3D) printing of a part is disclosed. The method may include selecting a material for a build plate adapted to form an intermetallic phase with the part at an interface between the build plate and the part, and forming the intermetallic phase with the part at the interface.
    Type: Grant
    Filed: June 26, 2015
    Date of Patent: June 5, 2018
    Assignee: Caterpillar Inc.
    Inventor: Thierry Marchione