Brazing (e.g., Cladding, Etc.) Patents (Class 219/615)
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Publication number: 20090001137Abstract: A brazing material for brazing tungsten/carbide/cobalt substrates (e.g., wear pads) to substrates comprising titanium or alloys thereof (e.g., fan or compressor blades). The brazing material includes gold, nickel, copper, and titanium present in respective amounts to provide a post-braze hardness of between 450 and 600 KHN to thereby increase the impact resistance of the braze joint. The substrates may be brazed by induction heating at temperatures less than about 1800° F. (982° C.).Type: ApplicationFiled: June 30, 2008Publication date: January 1, 2009Inventors: Kazim Ozbaysal, Shawn Riley
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Publication number: 20080296289Abstract: A heating system for brazing a stator bar to a clip including: a heating coil having a seat to receive the stator bar and clip; a heating mass adapted to fit into the seat of the coil, and an extendible press applying the mass to the stator bar or clip.Type: ApplicationFiled: August 18, 2008Publication date: December 4, 2008Applicant: General Electric CompanyInventors: Yu Wang, David Robert Schumacher, James Michael Fogarty, Alan Michael Iversen
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Patent number: 7414226Abstract: A method to heat a stator bar and clip assembly in a brazing chamber including: placing the stator bar and clip assembly in the brazing chamber, wherein the assembly is seated in a heating coil; positioning a conductive mass between a press and the stator bar and clip; applying the press to the assembly while the assembly is seated in the coil; heating the stator bar and clip by applying energy to the coil; brazing the stator bar to the clip with the heat from the coil, and removing the press and cooling the brazed clip.Type: GrantFiled: August 3, 2005Date of Patent: August 19, 2008Assignee: General Electric CompanyInventors: Yu Wang, David Robert Schumacher, James Michael Fogarty, Alan Michael Iversen
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Patent number: 7405379Abstract: A method of forming a brazed joint between an armature bar and a hydraulic header clip including: assembling an end of the armature bar, hydraulic header clip and a substantially phosphorus-free braze material; positioning the assembly of the armature bar, hydraulic header clip and the braze material in a braze chamber, such that the clip is seated in an induction heating coil; heating the assembly to a first temperature within 200 degrees Fahrenheit of and below a solidus temperature of the braze material by applying electrical current to the induction heat coil; heating the assembly to a second temperature above the liquidus temperature of the braze material; pooling liquid braze material on ends of the armature bar, and cooling the assembly and thereby forming a braze layer on the end of the armature bar.Type: GrantFiled: March 30, 2007Date of Patent: July 29, 2008Assignee: General Electric CompanyInventors: Jeffrey Michael Breznak, James Fredrick Hopeck, Alan Michael Iversen, Lawrence Lee Sowers
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Patent number: 7388177Abstract: An induction brazing and quenching apparatus and related method of coupling components together.Type: GrantFiled: December 29, 2004Date of Patent: June 17, 2008Assignee: Masco Corporation of IndianaInventor: Phillip Edward Coomer
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Publication number: 20080053523Abstract: A solar cell interconnect includes an elongated composite member having a nickel/iron based core of rectangular cross section peripherally metallurgically connected with a copper based covering, the core having elongated longitudinal grooves in opposed top and bottom into which the covering is mechanically swaged.Type: ApplicationFiled: August 28, 2007Publication date: March 6, 2008Inventors: Acie BROWN, Loren D. OTA, Harold R. MCCONNELL, Donald I. EDWARDS
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Patent number: 7326892Abstract: A process for heating a powder material by microwave radiation so that heating of the powder material is selective and sufficient to cause complete melting of the particles. The process entails providing a mass of powder comprising a quantity of filler particles of a metallic composition, and subjecting the mass to microwave radiation so that the filler particles within the mass couple with the microwave radiation and are completely melted. According to one aspect, the mass further contains at least one constituent that is more highly susceptible to microwave radiation than the filler particles, and the filler particles are melted as a result of heating by microwave radiation and thermal contact with the at least one constituent. According to another aspect, the powder mass is thermally pretreated to induce an irreversible increase in its dielectric loss factor prior to melting by microwave irradiation.Type: GrantFiled: September 21, 2006Date of Patent: February 5, 2008Assignee: General Electric CompanyInventors: Laurent Cretegny, David Edwin Budinger, Vasile Bogdan Neculaes, Holly Sue Shulman, Morgana Lynn Fall, Shawn Michael Allan
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Patent number: 7293689Abstract: A brazing process for joining copper and copper alloy tubes to a fitting which includes first forming a layer of a high melting temperature noble metal on one end of a copper or copper alloy tube. The plated end is then brazed to a metal ferrule to form a copper alloy-ferrule assembly. The assembly is then furnace brazed to a metal fitting.Type: GrantFiled: April 6, 2004Date of Patent: November 13, 2007Assignee: United Technologies CorporationInventor: Stephen L. Mayers
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Patent number: 7199338Abstract: A method of forming a brazed joint between an armature bar and a hydraulic header clip including: assembling an end of the armature bar, hydraulic header clip and a substantially phosphorous-free braze material; positioning the assembly of the armature bar, hydraulic header clip and the braze material in a braze chamber, such that the clip is seated in an induction heating coil; heating the assembly to a first temperature within 200 degrees F. of and below a solidus temperature of the braze material by applying electrical current to the induction heat coil; heating the assembly to a second temperature above the liquidus temperature of the braze material; pooling liquid braze material on ends of the armature bar, and cooling the assembly and thereby forming a braze layer on the end of the armature bar.Type: GrantFiled: November 19, 2004Date of Patent: April 3, 2007Assignee: General Electric CompanyInventors: Jeffrey Michael Breznak, James Fredrick Hopeck, Alan Michael Iversen, Lawrence Lee Sowers
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Patent number: 7126096Abstract: Rib and spar webs are joined in a composite wingbox to eliminate fasteners by welding the webs along bondlines defined by overlapping sections of the webs. Heat to produce the weld is generally achieved resistively by connecting a multistrip susceptor positioned along the bond line to a current source, since the geometry makes it difficult to heat these web joints inductively. The wingbox is completed without fasteners by welding skins to the rib-spar wingbox.Type: GrantFiled: June 6, 1995Date of Patent: October 24, 2006Assignee: Th Boeing CompanyInventors: Marc R. Matsen, Douglas A. McCarville, Michael M. Stepan
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Method and installation for manufacturing a metallic component and component obtained by said method
Patent number: 7064304Abstract: A heat exchanger is manufactured by assembling a bundle of pipes to a pair of header tanks by inserting the ends of the pipes into corresponding holes in the header tanks. The ends of the pipes include a brazing material. The assembled heater core is placed into an adapted enclosure, and heated, for example, by induction or laser heating, to a temperature above the melting temperature of the brazing material to mechanically fix the ends of the pipes to the holes. Subsequently, the heater is switched off and the heat exchanger is cooled within the enclosure.Type: GrantFiled: May 20, 2004Date of Patent: June 20, 2006Assignee: Delphi Technologies, Inc.Inventors: Christian Lamothe, Roger Fourile, Philippe D. Nivoix -
Patent number: 7049548Abstract: A system and method for processing a preform in a vacuum vessel to produce a structural assembly are provided. The system includes a heated die set defining a cavity in which the preform can be formed, bonded, or otherwise processed. The die set is disposed in a cavity of the vacuum vessel from which gas can be evacuated. Thus, a pressurized fluid can be provided to the preform, e.g., to an interior space of the preform to form or constrain the preform in the die cavity, and the vacuum vessel can be evacuated so that the die set, and typically the preform, are exposed to a pressure that is reduced relative to the ambient pressure. Further, the vacuum vessel can constrain the die set in the closed position during processing.Type: GrantFiled: March 21, 2005Date of Patent: May 23, 2006Assignee: The Boeing CompanyInventors: John F. Sjogren, Theodore J. Eilert, Henry D. Harkins
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Patent number: 6884976Abstract: An apparatus and a method for forming a localized joint in at least one structural member are provided. The apparatus includes a tool that corresponds to a joint portion of the structural member. An induction coil is disposed in the tool, and a power source is configured to energize the induction coil. A susceptor disposed between the tool and the structural member has a Curie temperature at which the susceptor becomes paramagnetic such that an electromagnetic field induced in the susceptor by the induction coil heats the susceptor to the Curie temperature for forming the joint.Type: GrantFiled: November 27, 2002Date of Patent: April 26, 2005Assignee: The Boeing CompanyInventors: Marc R. Matsen, Terry L. Smith
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Patent number: 6884975Abstract: A system and method inductively heats and stress relieves a weld joint area having a stress induced zone. A susceptor assembly is positioned over the stress induced zone. The susceptor assembly includes susceptor sheets manufactured to operate at different, preselected Curie temperatures. A housing is mounted over the susceptor assembly including an induction coil positioned adjacent to the susceptor assembly. An alternating electric current is applied to the induction coil. The alternating electric current causes the induction coil to generate a plurality of magnetic flux lines. The invention provides the advantage that the magnetic flux lines passing through the susceptor assembly heat the susceptor assembly providing localized and controlled temperature heat to the weld joint area to stress relieve the stress induced zone.Type: GrantFiled: November 12, 2002Date of Patent: April 26, 2005Assignee: The Boeing CompanyInventors: Marc R. Matsen, Terry L. Smith
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Patent number: 6822204Abstract: An RFID-based induction heating/vending system for quickly and efficiently heating, vending, and recollecting stadium seats (10) or other objects. The system includes a plurality of objects each including an induction-heatable body (22), a charging/vending station (12) for heating and vending the objects; a self-serve warming station (14) that may be used by consumers to reheat their objects; and a check-out station (16) that automatically collects objects from consumers after use.Type: GrantFiled: July 2, 2003Date of Patent: November 23, 2004Assignee: Thermal Solutions, Inc.Inventor: Brian L. Clothier
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Patent number: 6693263Abstract: The invention provides a convection type brazing apparatus for metal workpieces such as aluminum, copper, iron and so forth that enables uniform heating of the metal workpieces to prevent deformation of the workpieces and can shorten a heating time to achieve a higher operation efficiency. A heating medium gas heated by a tube heater 36 in a thermal medium gas heating chamber 45 is forwarded by a fan 37 to manifolds 41A and 41B located on both left and right sides, to be blown through a multitude of nozzles 43 toward workpieces W to which a brazing material and flux have been applied in advance. Once the workpieces temperature has reached a predetermined temperature for brazing, a switching valve located in an upper duct 48 is activated so that the heating medium gas is intermittently blown to the workpieces. As a result, a temperature slope of the workpieces is minimized and uniform brazing can be performed.Type: GrantFiled: November 29, 2002Date of Patent: February 17, 2004Assignee: Oak Nippon Co., Ltd.Inventor: Makoto Nishimura
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Patent number: 6689982Abstract: An apparatus and method for welding members that are formed at least in part of aluminum. A welding assembly is constructed and arranged to position a welding material in electrically conductive relation between exterior surface portions of first and second weldable members at a location where the first and second weldable members are to be joined. The welding material assembly includes at least one welding material member mounted on a flexible carrier sheet in a predetermined arrangement with each welding material member being constructed of an electrically conductive metallic welding material capable of melting when heated by application of an electrical current. A welding method includes alternatively attaching the welding material members to a weldable member without a carrier sheet, by a welding process.Type: GrantFiled: January 11, 2002Date of Patent: February 10, 2004Assignee: Magna International, Inc.Inventors: Gianfranco Gabbianelli, Richard D. Ashley, Victor J. Malczewski
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Patent number: 6649887Abstract: Apparatus for controlled-atmosphere brazing of parts or components having cross-sectional dimensions of up to twenty-four inches. The apparatus maintains the components or parts at a uniform temperature during the brazing cycle. The apparatus includes a susceptor having a physical boundary that separates an interior of the susceptor from its exterior. While there is no limitation upon the length of the parts or components that can be brazed, the wall of the susceptor formed as a physical boundary has an internal diameter that limits the maximum cross-sectional dimension of the parts or components that are to be brazed, so that the parts or components reside within the interior of the susceptor. A heating source for heating the susceptor is provided. The heating source is capable of heating the susceptor sufficiently so that the interior of the susceptor can reach a temperature sufficient to braze the components inside the susceptor.Type: GrantFiled: March 30, 2001Date of Patent: November 18, 2003Assignee: General Electric CompanyInventor: David Edwin Budinger
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Patent number: 6639194Abstract: A method for manufacturing a multiple walled tube comprising a rolling of a plated metal strip through at least two complete revolutions to form a tube having at least a double wall which has a plated layer on the inside of the tube, said rolling being followed by a heating of the tube to cause the surface of the tube walls, which are in contact with one another, to be brazed and wherein said metal strip is plated on one side, the other side being formed by the steel of the metal strip and wherein said brazing is realised by brazing directly the plated side on the steel.Type: GrantFiled: August 7, 2001Date of Patent: October 28, 2003Assignee: TI Group Automotive Systems LimitedInventors: Lamande Pascal, Pierini Vincenzo, Volvert Albert
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Publication number: 20030111459Abstract: The invention provides a convection type brazing apparatus for metal workpieces such as aluminum, copper, iron and so forth that enables uniform heating of the metal workpieces to prevent deformation of the workpieces and can shorten a heating time to achieve a higher operation efficiency.Type: ApplicationFiled: November 29, 2002Publication date: June 19, 2003Applicant: Oak Nippon Co., Ltd.Inventor: Makoto Nishimura
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Patent number: 6559428Abstract: An induction brazing tool includes a pair of induction coil components each having a linear extension and a semi-circular coil at one end. A distal end of each component remote from the semi-circular coil includes a flange for connecting the tool to an induction brazer. The components are formed of electrical conductive hollow copper tubing. The opposite end of each component includes a flange for bolting the components to one another. Nipples are provided the ends of the coil portions and a flexible hose interconnects the nipples. A braid of electrical conductive material also connects the nipples. In use, the components are opened to form a clamshell configuration, disposed about parts to be brazed and bolted together and to the brazer. By flowing electrical current and cooling water along the tool, a brazed joint is effected.Type: GrantFiled: January 16, 2001Date of Patent: May 6, 2003Assignee: General Electric CompanyInventor: Herbert Scharner Panczner
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Publication number: 20030062256Abstract: In order to make labyrinth seal lips on the periphery of a metal moving part of a turbomachine, a thick layer of refractory material that adheres to the metal is made prior to assembling the moving part, the refractory material advantageously comprising at least one metal selected for example from Fe, Co, and Ni, together with at least one ceramic selected for example from borides, nitrides, carbides, and refractory oxides. The labyrinth seal lips that are to be made are machined to their final dimensions in the deposited thick layer.Type: ApplicationFiled: September 10, 2002Publication date: April 3, 2003Applicant: SNECMA MOTEURSInventors: Gerard Gueldry, Claude Mons
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Patent number: 6476366Abstract: A device for degassing and brazing preassembled vacuum interrupters in only one brazing operation includes a base plate having at least one brazing site which features an opening of the base plate for connecting a suction pump and a bell which covers the opening and can be put on the base plate and lifted off. The bell is surrounded on the outside by an excitation coil to which medium- or high-frequency energy can be applied. The device includes a medium- or high-frequency generator for the excitation coil and with a cylindrical tubular susceptor arranged inside the bell for receiving at least one preassembled vacuum interrupter.Type: GrantFiled: April 18, 2001Date of Patent: November 5, 2002Assignee: Moeller GmbHInventor: Jerrie Lipperts
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Publication number: 20020139794Abstract: Apparatus for controlled-atmosphere brazing of parts or components having cross-sectional dimensions of up to twenty-four inches. The apparatus maintains the components or parts at a uniform temperature during the brazing cycle. The apparatus comprises a susceptor having a physical boundary that separates an interior of the susceptor from its exterior. While there is no limitation upon the length of the parts that or components that can be brazed, the wall of the susceptor formed as a physical boundary has an internal diameter that limits the maximum cross-sectional dimension of the parts or components that are to be brazed, so that the parts or components reside within the interior of the susceptor. A means for heating the susceptor is provided. The heating source is capable of heating the susceptor sufficiently so that the interior of the susceptor can reach a temperature sufficient to braze the components inside the susceptor.Type: ApplicationFiled: March 30, 2001Publication date: October 3, 2002Inventor: David Edwin Budinger
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Publication number: 20020092845Abstract: An induction brazing tool includes a pair of induction coil components each having a linear extension and a semi-circular coil at one end. A distal end of each component remote from the semi-circular coil includes a flange for connecting the tool to an induction brazer. The components are formed of electrical conductive hollow copper tubing. The opposite end of each component includes a flange for bolting the components to one another. Nipples are provided the ends of the coil portions and a flexible hose interconnects the nipples. A braid of electrical conductive material also connects the nipples. In use, the components are opened to form a clamshell configuration, disposed about parts to be brazed and bolted together and to the brazer. By flowing electrical current and cooling water along the tool, a brazed joint is effected.Type: ApplicationFiled: January 16, 2001Publication date: July 18, 2002Inventor: Herbert Scharner Panczner
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Patent number: 6359267Abstract: An induction heating system that can be used to braze metals and that overcomes many of the disadvantages of conventional brazing systems. The induction heating system improves quality and lowers production cost for many brazing requirements. The system is designed to quickly, accurately and cost effectively heat individual parts, and to replace flame brazing procedures and batch vacuum furnaces. Because the system can braze parts in an inert atmosphere or in no atmosphere (e.g., in a vacuum), no flux or acid cleaning bath is necessary and oxidation on the part is eliminated. Further, by including a gas quenching feature, the system prevents the annealing of parts and produces high quality brazed parts that meet desired hardness specifications.Type: GrantFiled: July 26, 2000Date of Patent: March 19, 2002Assignee: Ameritherm, Inc.Inventors: Dale Wilcox, Girish Dahake
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Patent number: 6333494Abstract: A method of brazing a plurality of copper strands to a buss bar includes: a) cleaning the buss bar and the copper strands; b) positioning a filler shim on the surface of the buss bar; c) placing a copper strand on the filler shim, the filler shim and the strand having substantially equal lengths; d) stacking additional copper strands on the buss bar, with a filler shim between each adjacent pair of strands; and e) heating the filler shims utilizing an induction brazing coil to a temperature sufficient to cause melting of the shims and to thereby form a brazed lap joint between the copper strands and the buss bar.Type: GrantFiled: December 4, 2000Date of Patent: December 25, 2001Assignee: General Electric CompanyInventors: Todd Joseph Fischer, Edward James Oziminski, Vladimir Pilic, David Roy Parker, Roy Cleveland Parker, Jason Stroosnyder, John Francis Nolan
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Patent number: 6270001Abstract: A method is disclosed of manufacturing a pulley with integral bearing comprising a sheet metal pulley mounted on the outer race of a bearing. The pulley is a close sliding fit on the outer race. The interstice between the pulley and the race is at least partly filled with a low-melting-point filler metal which, when heated, melts and diffuses by capillary action into the interstice between the pulley and the race, at least partly filling the interstice and fastens the pulley to the race when it solidifies. The filler metal is advantageously a brazing alloy having a melting point much lower than that of the parts to be joined together. Applications of the method include the manufacture of belt tensioning pulleys with integral bearings, as used on automobile vehicle engines, for example.Type: GrantFiled: March 9, 2000Date of Patent: August 7, 2001Assignee: SKF FranceInventors: Vedran Tadic, Manfred Brandenstein, Johannes Van De Sanden
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Patent number: 6180932Abstract: An induction brazing uses a multisheet, diaphagm retort having isolated pressure zones to control the net tooling pressure at a level that avoids core crush. The isolated chambers in the multisheet diaphragm allow us to apply controlled pressure to the braze joint, especially at the elevated brazing temperature where the honeycomb core is soft and malleable.Type: GrantFiled: December 22, 1999Date of Patent: January 30, 2001Assignee: The Boeing CompanyInventors: Marc R. Matsen, Ronald W. Brown
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Patent number: 6156134Abstract: In a method of bonding ferric and austenitic dual stainless steels, an insert material made of a Ni base alloy having a melting point below 1290.degree. C. is put between the bonding cross section faces of mother material steels comprising a dual phase stainless steel. A pressure force in the range of 3 MPa to 5 MPa is applied to a bonding area. The bonding area is heated at a temperature in the range of 1290.degree. C. to a melting point of the mother material steel. The temperature is kept for in the range of 30 second to 180 second.Type: GrantFiled: August 27, 1998Date of Patent: December 5, 2000Assignee: Daido Tokushuko Kabushiki KaishaInventors: Takao Shimizu, Hirotsugu Horio, Noboru Yamamoto, Shigeyuki Inagaki, Hiroaki Suzuki, Masaki Tsuchiya
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Patent number: 6087640Abstract: Capitalizing on the unique feature of our induction heating workcell that permits rapid and controlled heating and cooling of a workpiece within a wide temperature range permits combining several manufacturing operations into a single heating cycle to save time, energy, capital, touch labor, and factory space. For example, we can combine superplastic forming (SPF) with annealing; two operations that occur at temperatures that differ by about 150-200.degree. F. (85-105.degree. C.) or more, to produce quality parts. We mill parts flat to simplify their machining, form them to complex curvature, and anneal them.Type: GrantFiled: May 26, 1995Date of Patent: July 11, 2000Assignee: The Boeing CompanyInventors: Franna S. P. Gillespie, Marc R. Matsen
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Patent number: 6078031Abstract: A method for joining well and other oilfield tubulars by amorphous bonding comprises the steps of positioning a body of amorphous material (16) between adjacent and surfaces of a pair of oilfield tubulars (3, 4) that are to be joined and using induction heating to melt the amorphous material and create on cooling a metallurgical bond between the tubulars (3, 4). Throughout the heating and bonding process the tubulars (3, 4) are fixed in axial alignment with each other using clamp means which include a mandrel (1) which is inserted into the interior of the tubulars (3, 4) so that the bonding process can be performed in a sealed chamber (17, 18) which is filled with an inert gas.Type: GrantFiled: June 29, 1999Date of Patent: June 20, 2000Assignee: Shell Research LimitedInventors: Alan Edgar John Bliault, Francis Alexander Cumming, Mark Seth Laws
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Patent number: 6050473Abstract: A first electromagnetic induction pump system includes a first plurality of electromagnetic induction pumps, arranged in the direction parallel to the width of workpiece. The first plurality of electromagnetic induction pumps extend vertically along a first vertical plate portion at a workpiece inlet side of a single reservoir. A second electromagnetic induction pump system includes a second plurality of electromagnetic induction pumps, arranged in the direction parallel to the width of workpiece. The second plurality of electromagnetic induction pumps extend vertically extends along a second vertical plate portion at the workpiece outlet side of the reservoir. Brazing filler metal is ejected upward in waves by the electromagnetic induction pump systems to braze workpieces carried by the ejected waves into and out of the device.Type: GrantFiled: August 10, 1998Date of Patent: April 18, 2000Assignee: Kabushiki Kaisha Tamura Seisa KushoInventors: Tsugunori Masuda, Junichi Onozaki, Hiroshi Saito
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Patent number: 5981922Abstract: A single reservoir contains brazing filler metal. A first electromagnetic induction pump extends vertically along a vertical plate portion at a workpiece inlet side. A second electromagnetic induction pump extends vertically along a vertical plate portion at the workpiece outlet side. Heaters for melting the brazing filler metal are disposed between the first electromagnetic induction pump and the second electromagnetic induction pump. Each electromagnetic induction pump has a first iron core having an induction coil wound therearound disposed at the outer side of a vertical plate portion at the workpiece inlet side or the workpiece outlet side respectively. A second iron core is disposed at the inner side of the respective vertical plate portion. A brazing filler metal rising gap is disposed between the second iron cores.Type: GrantFiled: June 11, 1998Date of Patent: November 9, 1999Assignee: Kabushiki Kaisha Tamura SeisakushoInventors: Tsugunori Masuda, Junichi Onozaki, Hiroshi Saito
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Patent number: 5977527Abstract: A fixture for an induction brazing station includes a removable front plate on which is mounted a work piece holder. The base of the induction unit mounts to a back plate lying coplanar with the front plate on the work surface. The coil of the induction unit is uniquely matched to the front plate and the work piece holder. The induction coil removably mounts to the front plate when not in use such that the front plate may be removed from the work surface with the work piece holder and coil mounted thereon. A different front plate may then be mounted upon the work surface having a different coil configuration and work piece holder. The coil(s) are removed from the front plate and attached to the induction base on the back plate. The coil extends to the work piece holder on the front plate in the correct position. The invention provides for quick changeover between different induction units at a single work station.Type: GrantFiled: May 15, 1998Date of Patent: November 2, 1999Assignee: Bausch & Lomb IncorporatedInventors: Mark E. Preston, Ronald D. Spoor, Bruce F. Westphal, Tadeusz Urbanowicz
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Patent number: 5914064Abstract: Capitalizing on the unique feature of our induction heating workcell that permits rapid and controlled heating and cooling of a workpiece within a wide temperature range allows us to combine manufacturing into a single heating cycle to save time, energy, capital, touch labor, and factory space. For example, we can combine superplastic forming (SPF) with annealing two operations that occur at temperatures that differ by about 150-200.degree. F. (85-105.degree. C.) or more, to produce quality parts. We mill parts flat to simplify their machining, form them to complex curvature, and anneal them.Type: GrantFiled: July 9, 1997Date of Patent: June 22, 1999Assignee: The Boeing CompanyInventors: Franna S. P. Gillespie, Marc R. Matsen
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Patent number: 5902507Abstract: A method and apparatus for induction brazing wherein the induction coil's power is controlled by a closed loop temperature controller which is provided a temperature signal from a temperature sensor located proximate the brazed joint. Power is supplied to the induction coil until temperature reaches a specific set point corresponding to the desired brazing temperature of the alloy.Type: GrantFiled: March 3, 1997Date of Patent: May 11, 1999Assignee: Chrysler CorporationInventors: Michael F. Wiezbowski, Jack Levine, Ted J. Socha
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Patent number: 5889262Abstract: A system and a method for automatically controlling an input heat amount of a high-frequency electric resistance welding machine.Type: GrantFiled: May 15, 1997Date of Patent: March 30, 1999Assignee: Seah Steel CorporationInventors: Joo-Sup Oh, Yoo-Sup Jung, Yong-Suk Kim
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Patent number: 5886314Abstract: A profiled end cut is applied to a length of stock pipe in an apparatus wherein the pipe is rotated by a drive head with a plasma cutter moved axially on a trolley in synchrony with rotation under control of a guidance system. The guidance system follows a desired pattern to effect two adjoining end cuts in a single continuous operation. Pipe handling is effected by two sets of rollers, a support set permitting rotation and a lifting set to enable axial movement.Type: GrantFiled: May 15, 1996Date of Patent: March 23, 1999Inventor: Peter James Sims
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Patent number: 5869814Abstract: The present invention is a method for improving the strength and quality of thermoplastic welds by annealing the weld following its formation at a temperature of at least about 500.degree. F. (i.e., about 125.degree. F. below the melt) for about 20 minutes to control cooling of the weld.Type: GrantFiled: August 22, 1996Date of Patent: February 9, 1999Assignee: The Boeing CompanyInventor: Roger W. Scoles
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Patent number: 5847375Abstract: Rib and spar webs are joined in a composite wingbox to eliminate fasteners by welding the webs along bond lines defined by overlapping sections of the webs. Heat to produce the weld is generally achieved resistively by connecting a multistrip susceptor positioned along the bond line to a current source, since the geometry makes it difficult to heat these web joints inductively. The wingbox is completed without fasteners by welding skins to the rib-spar wingbox.Type: GrantFiled: July 19, 1996Date of Patent: December 8, 1998Assignee: The Boeing CompanyInventors: Marc R. Matsen, Douglas A. McCarville, Michael M. Stepan
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Patent number: 5831252Abstract: Target members of titanium or a titanium alloy with melting point M are bonded together by first forming a bonding layer with melting point J lower than M on at least one of the bonding surfaces over which the target members are to be joined together. While the target members are pressed against each other over the bonding surfaces, end parts of the target members adjacent the bonding surfaces are heated to an intermediate temperature T such that J<T<M and is kept at this intermediate temperature for a specified length of time to effect liquid-phase diffusion bonding. Alternatively, an insert member of titanium or a titanium alloy may be inserted between the bounding surfaces of the target members to form liquid-phase diffusion bonding by first forming bonding layers of the type described above on mutually opposite end surfaces of the insert member and then inserting the insert member between the target members.Type: GrantFiled: March 19, 1996Date of Patent: November 3, 1998Assignee: Daido Tokushuko Kabushiki KaishaInventor: Takao Shimizu
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Patent number: 5821506Abstract: Multisheet SPF parts with braze joints at selected locations are produced with improved energy efficiency and at lower cost. The parts include a core defined with intermittent welds between two or more core sheets and aerodynamically smooth facing sheets brazed to the core. The manufacturing process includes heating the multisheet pack to its superplastic forming range below the melting point of the braze alloy, superplastically forming the pack to define braze joints having unmelted braze alloy; increasing the temperature to the braze temperature of the braze alloy, and cooling the pack below the superplastic range to freeze the braze alloy in the braze joint.Type: GrantFiled: May 22, 1997Date of Patent: October 13, 1998Assignee: The Boeing CompanyInventor: Marc R. Matsen
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Patent number: 5808281Abstract: Sesceptor sheets are selected so that their magnetic permeability decreases to unity at approximately the desired operating temperature thereby limiting heating to this "Curie temperature" and providing substantial uniformity of temperature in the panel Preferably, the susceptor includes multiple layers, such as a first metal having a relatively lower Curie temperature, a thin foil of copper in contact with the surface of the first sheet, and a second metal having a relatively higher Curie temperature. Such a susceptor allows thermal control at two spaced set points defined by the Curie temperatures.Type: GrantFiled: June 6, 1995Date of Patent: September 15, 1998Assignee: The Boeing CompanyInventors: Marc R. Matsen, Edward J. Woods, Karl A. Hansen, deceased, John J. deJong, executor
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Patent number: 5777299Abstract: An induction heating generator is described for braze-welding metallic pipes with a continuous process under a controlled atmosphere, comprising at least one heating inductor composed of two half-inductors in series whose winding directions for their windings are one opposite to the other. The generator is further equipped with a quartz tube placed inside the inductors and in which the metallic pipes pass together with the controlled atmosphere gas. The generator further includes at least one removable sealing insert to join two contiguous inductors. For every medium- and/or high-frequency section of the generator, a load matching system is finally provided to compensate for external diameter variations of the pipes, the system being interlacedly handled by a programmable controller (P.L.C.).Type: GrantFiled: November 22, 1996Date of Patent: July 7, 1998Assignee: Emmedi, S.p.A.Inventor: Erasmo Dominici
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Patent number: 5723849Abstract: A fiber reinforcement fabric contains a metal susceptor strip paired with each warp thread and woven with the weave thread to produce a thermoplastic welding susceptor of separated and electrically isolated, longitudinal metal strips and fiber reinforcement in the weld.Type: GrantFiled: June 6, 1995Date of Patent: March 3, 1998Assignee: The Boeing CompanyInventors: Marc R. Matsen, Ronald W. Brown, James Healy, Karl A. Hansen, deceased, John J. deJong, executor
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Patent number: 5705794Abstract: Our induction heating workcell permits rapid and controlled heating and cooling of a workpiece within a wide temperature range. The induction workcell allows us to combine manufacturing operations, like SPF, brazing, and annealing, into a single heating cycle to save time, energy, capital, touch labor, and factory space. Superplastic forming (SPF) and brazing occur at temperatures that differ by about 150.degree.-200.degree. F. (85.degree.-105.degree. C.) or more as do SPF and .beta.-annealing of titanium.Type: GrantFiled: May 26, 1995Date of Patent: January 6, 1998Assignee: The Boeing CompanyInventors: Franna S. P. Gillespie, Marc R. Matsen
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Patent number: 5700995Abstract: Multisheet SPF parts with braze joints at selected locations are produced with improved energy efficiency and at lower cost by heating the multisheet pack to its superplastic forming range below the melting point of the braze alloy, superplastically forming the pack to define braze joints having unmelted braze alloy; increasing the temperature to the braze temperature of the braze alloy, and cooling the pack below the superplastic range to freeze the braze alloy in the braze joint.Type: GrantFiled: March 17, 1995Date of Patent: December 23, 1997Assignee: The Boeing CompanyInventor: Marc R. Matsen
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Patent number: 5688426Abstract: A hybrid metal webbed composite beam includes a metal I or T web section and a composite cap formed over and adhered to the I or T web. The beam incorporates advantages of metals and composites in modern aerospace construction allowing thermoplastic welding of the beam to skins while having the strength of metal.Type: GrantFiled: June 7, 1995Date of Patent: November 18, 1997Assignee: The Boeing CompanyInventors: Brad L. Kirkwood, Michael M. Stepan, Paul J. Patt
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Patent number: 5679272Abstract: When welding a series of container bodies, the welding speed is at first increased to prevent the first body from colliding with the second body at the intake to the welding machine. The welding speed is then reduced to a rated welding speed V.sub.s at which minimum gaps are maintained between successive bodies.Type: GrantFiled: January 16, 1996Date of Patent: October 21, 1997Assignee: Elpatronic AGInventor: Harry Aderhold