For Deposition Welding (e.g., Coating Or Building Up) Patents (Class 219/76.1)
  • Patent number: 10933493
    Abstract: An additive manufacturing system includes a build plate; a deposition system operable to dispense material as a melt pool to grow a workpiece on the build plate; a sensor system operable to determine a temperature of the workpiece being grown on the build plate adjacent to the melt pool; and a heater system operable to selectively heat the workpiece between the melt pool and the build plate.
    Type: Grant
    Filed: September 25, 2017
    Date of Patent: March 2, 2021
    Assignee: Raytheon Technologies Corporation
    Inventor: Wendell V. Twelves
  • Patent number: 10930320
    Abstract: According to one embodiment, a disk device includes a disk-shaped recording medium, a head which processes data on the recording medium, and a housing accommodating the recording medium and the head. The housing includes a base with a side wall, and a cover having a welded portion welded to the side wall by laser welding. The welded portion includes a first welded portion welded to a first region of the side wall and having weld beads with a first shape, and a second welded portion welded to a second region of the side wall and having welded beads with a second shape different from the first shape.
    Type: Grant
    Filed: April 28, 2020
    Date of Patent: February 23, 2021
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Makoto Okamoto, Yasutaka Sasaki
  • Patent number: 10919105
    Abstract: Provided is a three-dimensional laminating and shaping apparatus 100 including a column unit 200 that is configured to output an electron beam EB and deflect the electron beam EB toward the front surface of a powder layer 32, an electron detector 72 that is configured to detect electrons that may be emitted in a predetermined direction from the front surface of the powder layer 32 when the powder layer 32 is irradiated with the electron beam EB, a melting judging unit 410 that is configured to generate a melting signal based on the strength of the detection signal from the electron detector 72, and a deflection controller 420 that is configured to receive the melting signal to determine the condition of the irradiation the electron beam.
    Type: Grant
    Filed: September 4, 2018
    Date of Patent: February 16, 2021
    Assignee: ADVANTEST CORPORATION
    Inventors: Shinji Sugatani, Shigeki Nishina, Jun Matsumoto, Masahiro Takizawa, Minoru Soma, Akio Yamada
  • Patent number: 10894360
    Abstract: An additive manufacturing system including a build plate and at least two powder reservoirs. The at least two powder reservoirs including a first powder reservoir configured to store a first powder and deposit the first powder onto the build plate, wherein the first powder reservoir is configured to move relative to the build plate, and a second powder reservoir configured to store a second powder and deposit the second powder onto the build plate, wherein the second powder reservoir is configured to move relative to the build plate. The first powder has at least one predetermined characteristic that is different than that of the second powder.
    Type: Grant
    Filed: September 28, 2018
    Date of Patent: January 19, 2021
    Assignee: The Boeing Company
    Inventors: Om Prakash, Araveti Gupta
  • Patent number: 10888925
    Abstract: The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.
    Type: Grant
    Filed: March 1, 2018
    Date of Patent: January 12, 2021
    Assignee: VELO3D, INC.
    Inventors: Kimon Symeonidis, Rueben Joseph Mendelsberg, Nina Cathryn Bordeaux, Gregory Ferguson Brown, Tasso Lappas
  • Patent number: 10882140
    Abstract: The temperature of a molten pool is measured based on an image captured by an infrared camera or the like. A three-dimensional laminating and shaping apparatus include a material ejector that ejects a material of a three-dimensional laminated and shaped object. The three-dimensional laminating and shaping apparatus includes a light beam irradiator that irradiates the ejected material with a light beam. The three-dimensional laminating and shaping apparatus includes an image capturer that captures a molten pool of the material formed by irradiating the ejected material with the light beam. The three-dimensional laminating and shaping apparatus includes a temperature deriving unit that derives a temperature of the molten pool based on a luminance of an image of the molten pool captured by the image capturer.
    Type: Grant
    Filed: March 25, 2016
    Date of Patent: January 5, 2021
    Assignee: TECHNOLOGY RESEARCH ASSOCIATION FOR FUTURE ADDITIVE MANUFACTURING
    Inventors: Keiichi Noriyama, Hirohisa Kuramoto
  • Patent number: 10828832
    Abstract: An additive manufacturing system including a build plate and a powder spreading unit having a plurality of recoater blades configured to spread powder onto the build plate. The powder spreading unit including a base member, and the plurality of recoater blades is coupled to the base member and configured to spread powder onto the build plate.
    Type: Grant
    Filed: September 28, 2018
    Date of Patent: November 10, 2020
    Assignee: The Boeing Company
    Inventors: Om Prakash, Araveti Gupta
  • Patent number: 10814428
    Abstract: A method for producing a layered object includes irradiating a surface layer of the object with an energy beam to create an interaction zone on the surface layer. The method also includes providing relative motion between the energy beam and the surface layer so as to control the interaction between the energy beam and the surface layer. The method also includes introducing feedstock into the interaction zone so that the feedstock melts and forms a hot solidified surface after leaving the interaction zone. The method also includes applying mechanical energy to the hot solidified surface.
    Type: Grant
    Filed: January 10, 2018
    Date of Patent: October 27, 2020
    Assignee: General Electric Company
    Inventor: Douglas Gerard Konitzer
  • Patent number: 10814552
    Abstract: An additive manufacturing system including a build plate, at least one recoater blade configured to spread powder onto the build plate, and at least one vibration mechanism coupled to one or more of the build plate and the at least one recoater blade. A controller coupled to the at least one vibration mechanism is configured to control actuation of the at least one vibration mechanism so that vibratory pulses are induced within the powder to effect compaction of the powder on the build plate.
    Type: Grant
    Filed: September 28, 2018
    Date of Patent: October 27, 2020
    Assignee: The Boeing Company
    Inventors: Om Prakash, Araveti Gupta
  • Patent number: 10814555
    Abstract: An additive manufacturing system including a build plate, and at least one powder reservoir configured to store and deposit powder onto the build plate, the at least one powder reservoir including a powder dispensing aperture having a variable size. The powder dispensing unit includes a base member, and the least one powder reservoir coupled to the base member.
    Type: Grant
    Filed: September 28, 2018
    Date of Patent: October 27, 2020
    Assignee: The Boeing Company
    Inventors: Om Prakash, Araveti Gupta
  • Patent number: 10792766
    Abstract: The invention relates to additive manufacturing field and laser shock peening (LSP) field, in particular to a combined apparatus for layer-by-layer interactive additive manufacturing with laser thermal/mechanical effects. In the apparatus, a LSP module and a SLM module operate in alternate so as to perform LSP for the formed part in the forming process of the formed part, and thereby a better strengthening effect of the formed part is achieved. The invention effectively overcomes the challenges of “shape control” against deformation and cracking of the formed parts incurred by internal stress and “property control” against poor fatigue property of the formed parts incurred by metallurgical defects during additive manufacturing, improves fatigue strength and mechanical properties of the faulted parts, and realizes high-efficiency and high-quality holistic processing of the formed parts.
    Type: Grant
    Filed: June 8, 2017
    Date of Patent: October 6, 2020
    Assignee: JIANGSU UNIVERSITY
    Inventors: Jinzhong Lu, Haifei Lu, Jianhua Yao, Kaiyu Luo, Fangnian Lang, Liujun Wu, Yikai Shao
  • Patent number: 10780626
    Abstract: A method is described for manufacturing a three-dimensional product, in particular a hydraulic element, the method encompassing at least the following method steps: Providing a first section of the product to be manufactured, which includes at least one first connection point for a second section of the product to be manufactured; and producing the second section by an additive manufacture in which the at least one first connection point of the first section is used as a substrate for the additive manufacture of the second section.
    Type: Grant
    Filed: September 12, 2018
    Date of Patent: September 22, 2020
    Assignee: Robert Bosch GmbH
    Inventors: Johannes Rauch, Benjamin Seitz, Bertram Amrhein, Hannes Willeck, Lukas Loeber, Martin Schoepf
  • Patent number: 10773336
    Abstract: An additive manufacturing system includes at least one imaging device configured to direct electromagnetic radiation towards a build layer of a component positioned within a powder bed of the additive manufacturing system. The additive manufacturing system also includes at least one detector configured to detect the electromagnetic radiation that reflects from the build layer.
    Type: Grant
    Filed: January 10, 2018
    Date of Patent: September 15, 2020
    Assignee: General Electric Company
    Inventors: Kevin George Harding, William Robert Ross, Bryon Edward Knight, Venkata Vijayaraghava Nalladega, Clifford Bueno
  • Patent number: 10744598
    Abstract: An additive manufacturing apparatus and corresponding method for building an object by layerwise consolidation of material wherein the apparatus includes a build enclosure containing a build support for supporting the object during the build, a material source for providing material to selected locations for consolidation, a radiation device for generating and directing radiation to consolidate the material at the selected locations and an acoustic sensing system. The acoustic sensing system may be arranged to detect acoustic signals generated in the build enclosure by consolidation of the material with the radiation. The acoustic sensing system may be a passive acoustic sensing system arranged to detect acoustic signals generated in the build enclosure that are indicative of at least one condition of the building process and/or the object.
    Type: Grant
    Filed: June 10, 2016
    Date of Patent: August 18, 2020
    Assignee: RENISHAW PLC
    Inventor: Liam David Hall
  • Patent number: 10549385
    Abstract: A component is produced in layers by laser melting. A molten pool is created in a bed of powder by a working laser beam. Further auxiliary laser beams are set to a power density that merely slows down the cooling of the material in one zone, but do not cause any renewed melting. In this way, the cooling rate of the microstructure can be set so that an advantageous structural formation develops. This allows for example the mechanical properties of the component produced to be advantageously improved without downstream heat treatments.
    Type: Grant
    Filed: March 6, 2014
    Date of Patent: February 4, 2020
    Assignee: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Ursus Krüger, Olaf Rehme, Daniel Reznik, Martin Schäfer
  • Patent number: 10451174
    Abstract: A robot includes a first member, a second member provided to be capable of turning with respect to the first member, and a gear device configured to transmit a driving force from one side to the other side of the first member and the second member. The gear device includes internal teeth and external teeth provided halfway in a transmission path of the driving force and configured to mesh with each other and lubricant disposed between the internal teeth and the external teeth. An average grain size of a constituent material of the external teeth is smaller than an average grain size of a constituent material of the internal teeth.
    Type: Grant
    Filed: July 25, 2017
    Date of Patent: October 22, 2019
    Assignee: Seiko Epson Corporation
    Inventor: Masaaki Sakata
  • Patent number: 10404024
    Abstract: A method of manufacturing a terminal-formed electric wire includes a welding member placing process in which at least one welding member formed of metal having a melting point lower than that of a plurality of metal strands included in a core wire is arranged to the core wire of at least a terminal-forming target portion of the electric wire, and a terminal forming process in which the exposed terminal-forming target portion is interposed between first and second electrodes having a shape corresponding to a desired terminal shape, at least the welding member in the terminal-forming target portion is melted by electrically conducting the first and second electrodes while pressing the terminal-forming target portion with the first and second electrodes, and the melted metal is then solidified, so that the terminal-forming target portion is formed as a terminal portion having a desired terminal shape.
    Type: Grant
    Filed: May 16, 2017
    Date of Patent: September 3, 2019
    Assignee: YAZAKI CORPORATION
    Inventors: Masanobu Higashitani, Shigeo Mori, Takashi Ishihara, Shigeru Tanaka, Hiroshi Fujita, Yoshinori Yamagata
  • Patent number: 10376942
    Abstract: A water jet peening device includes a sealed vessel provided to cover a surface of a welded portion, and adapted to be in a sealed state where an internal pressure is higher than an outside, a jet nozzle adapted to jet high-pressure water to create a cavitation bubble toward the surface of the welded portion, inside the sealed vessel, and a pressure control hole adapted to be able to adjust the internal pressure of the sealed vessel. The water jet peening device can efficiently reform a tensile residual stress on the surface of the welded portion to a compressive residual stress.
    Type: Grant
    Filed: January 16, 2015
    Date of Patent: August 13, 2019
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventors: Takaharu Maeguchi, Yuichiro Nomura, Kazuya Tsutsumi, Nobuyuki Hori
  • Patent number: 10279413
    Abstract: A tool welding system is disclosed that includes a table that heats a tool. A multi-axis robot includes a welding head that is moved relative to the table in response to a command. A controller is in communication with the robot and generates the command in response to welding parameters. The weld parameters are based upon a difference between an initial tool shape and a desired tool shape. The difference between the initial tool shape and the desired tool shape corresponds to a desired weld shape. The desired weld shape is adjusted based upon initial tool shape variations, which includes thermal growth of the tool. The tool is welded to provide the desired weld shape to achieve a desired tool shape.
    Type: Grant
    Filed: August 25, 2017
    Date of Patent: May 7, 2019
    Inventor: Ariel Andre Waitzman
  • Patent number: 9737951
    Abstract: A welding wire feeder having a multiple motor drive standard is provided. The welding wire feeder may be coupled to one of a plurality of electric motor assemblies, and a user may select the electric motor assembly to be used from a menu of electric motor assemblies on a user interface or may enter customized configuration parameters for the electric motor assembly on the user interface. The control circuitry of the welding wire feeder may then be properly configured backed upon which electric motor assembly is selected or based upon the customized configuration parameters entered.
    Type: Grant
    Filed: January 12, 2011
    Date of Patent: August 22, 2017
    Assignee: ILLINOIS TOOL WORKS INC.
    Inventors: Brandon John Speilman, Peter Donald Mehn
  • Patent number: 9291062
    Abstract: Methods of forming a blade and rendering a blade resistant to erosion includes positioning a backing plate(s) or elongated backing plate(s) adjacent at least one side of a forward face of a leading edge surface of the blade. The methods include depositing an erosion resistant material in a plurality of layers by fusion bonding the erosion resistant material to the forward face of the leading edge surface of the blade. The backing plates providing a template or guide for depositing the plurality of layers of erosion resistant material. The plurality of layers of erosion resistant material form an erosion shield and a leading edge of the blade. Methods include removing the backing plate.
    Type: Grant
    Filed: September 7, 2012
    Date of Patent: March 22, 2016
    Assignee: General Electric Company
    Inventors: Michael Lewis Jones, Swami Ganesh
  • Patent number: 8987629
    Abstract: A process for closing an opening in a surface of a component, and components formed thereby. The process entails forming a channel in the component surface so that the channel at least partially surrounds an opening at the component surface. An alloy is then deposited in the channel to form a crack-free deposit in the channel. A step is then machined that intersects the opening and is at least partially formed in the deposit. The step defines a recess that is at least partially surrounded by a peripheral portion of the deposit and has a surface recessed into the component surface. A cap is placed in the recess and welded to the peripheral portion of the deposit to define a weld joint that completely closes the opening. The surface of the weld joint is then machined to form a machined surface that is substantially flush with the component surface.
    Type: Grant
    Filed: July 29, 2009
    Date of Patent: March 24, 2015
    Assignee: General Electric Company
    Inventors: Yan Cui, Gitahi Charles Mukira, Srikanth Chandrudu Kottilingam
  • Publication number: 20150069025
    Abstract: Cladding and remanufacturing a machine component includes directing cleaning and welding beams split from an incident laser beam toward the machine component, and moving the machine component relative the cleaning and welding beams such that the welding beam trails behind the cleaning beam along a common travel path. A surface of the machine component is decontaminated by the cleaning beam, whilst a cladding material is melted via the welding beam such that upon solidifying the cladding material forms a coating metallurgically bonded to base material and previously deposited cladding material of the machine component.
    Type: Application
    Filed: September 10, 2013
    Publication date: March 12, 2015
    Applicant: Caterpillar, Inc.
    Inventors: Kegan Luick, Daniel Sordelet, Daniel T. Cavanaugh, Justin Embrey
  • Publication number: 20150040364
    Abstract: A repairing method includes heating a base material by a heater, and irradiating a laser beam to a repair region of the base material by using a laser oscillator unit, after the base material is heated. In the method, generation of a crack and a break can be suppressed, and the repair region can be repaired more appropriately.
    Type: Application
    Filed: December 18, 2013
    Publication date: February 12, 2015
    Applicant: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventors: Tomoko OGASAHARA, Kosuke NISHIKAWA, Noriyuki HIRAMATSU, Akira FUKUSHIMA
  • Patent number: 8952292
    Abstract: A welding head is provided. The welding head includes a bracket and a plurality of blocks coupled to the bracket. Each of the plurality of blocks has a contact tip. The contact tips are adapted to receive an electrode. Further, at least one of the plurality of blocks is capable of variable positioning relative to the bracket.
    Type: Grant
    Filed: April 17, 2012
    Date of Patent: February 10, 2015
    Assignee: Caterpillar Inc.
    Inventors: Matthew J. Behmlander, Huijun Wang
  • Publication number: 20150037601
    Abstract: An additive layer manufacture (ALM) machine comprises an energy source (180) for selectively melting a layer of metal powder (500), and an electron beam (110) for determining the shape of the selectively melted solid layer (320) once it has solidified. The shape is determined by detecting backscattered electrons (130) from the interaction between the electron beam (110) and the solid layer (320). If the shape of the solid layer (320) is outside a determined tolerance, it may be corrected before proceeding. The process may be repeated to generate a finished component (300) with good mechanical properties and accurate geometry.
    Type: Application
    Filed: July 22, 2014
    Publication date: February 5, 2015
    Inventor: Michael Lewis BLACKMORE
  • Patent number: 8943998
    Abstract: An apparatus for cladding the interior surfaces of a curved pipe section includes a flexible track that is positioned longitudinally within the curved pipe and supported at opposite ends to corresponding opposite ends of the curved pipe. The flexible track is caused to bend and conform to the radius of curvature of an interior surface of the curved pipe. A robotic crawler is supported on the track section and carries a material applicator head. The robotic crawler is driven back-and-forth across the track section while the material applicator head applies an overlay material to the interior surface of the curved pipe. In a method, the position of the curved pipe in space, the travel direction and speed of the crawler and the position of the application head are all coordinated to maintain the application of the overlay material in the “flat plane” position.
    Type: Grant
    Filed: November 15, 2010
    Date of Patent: February 3, 2015
    Inventor: Don Gano
  • Patent number: 8938867
    Abstract: There is provided a transmission device comprising a rigid casing configured to be mounted perpendicularly on a pair of parallel rotatable driving and driven shafts. Annular driving and driven gears are provided in the casing. The annular driving gear is adapted for rotating simultaneously with the driving shaft, and is also adapted for forwarding rotational motion of the inner section to a transmission device. The annular driven gear is adapted for engaging and rotating simultaneously with the driving shaft and sliding over the same, and for forwarding to the inner section rotational motion received from the transmission device. The transmission device is rotatively connected to the annular driving and driven gears for transmitting rotational movement of the driving shaft to the driven shaft. There is also provided a portable boring-welding apparatus using this transmission device and a method for rotating a driven shaft using a parallel driving shaft.
    Type: Grant
    Filed: July 14, 2011
    Date of Patent: January 27, 2015
    Assignee: Usinage Filiatrault Inc.
    Inventors: Stéphane Filiatrault, Guy Filiatrault
  • Publication number: 20150021379
    Abstract: An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.
    Type: Application
    Filed: July 10, 2014
    Publication date: January 22, 2015
    Inventors: Bruce Patrick Albrecht, Christopher Hsu
  • Publication number: 20150001001
    Abstract: Methods and systems to manufacture gun suppressors using laser metal melting (LMM) are disclosed, together with gun suppressors manufactured according to the methods and systems. In preferred forms the LMM process involves deposition of a metal powder such as titanium oxide.
    Type: Application
    Filed: December 23, 2013
    Publication date: January 1, 2015
    Inventor: Bert John WILSON
  • Publication number: 20140363327
    Abstract: A method for forming a component includes providing a first layer of a mixture of first and second powders. The method includes determining the frequency of an alternating magnetic field to induce eddy currents sufficient to bulk heat only one of the first and second powders. The alternating magnetic field is applied at the determined frequency to a portion of the first layer of the mixture using a flux concentrator. Exposure to the magnetic field changes the phase of at least a portion of the first powder to liquid. The liquid portion couples to at least some of the second powder and subsequently solidifies to provide a composite component.
    Type: Application
    Filed: June 10, 2014
    Publication date: December 11, 2014
    Inventor: Matthew J. Holcomb
  • Patent number: 8895886
    Abstract: Disclosed is a method for affixing a metal cladding to a metal base. The method includes: heating the metal cladding and a surface of the metal base with a heating device to create a molten metal pool having molten metal cladding layered upon molten metal base material in the metal base; stabilizing a temperature gradient of the molten metal pool with a laser beam directed into the molten metal pool; and cooling the molten metal pool to affix solidified cladding to the metal base.
    Type: Grant
    Filed: March 15, 2011
    Date of Patent: November 25, 2014
    Assignee: General Electric Company
    Inventors: Dechao Lin, Yan Cui, Srikanth Chandrudu Kottilingam, David Edward Schick, Brian Lee Tollison
  • Publication number: 20140339206
    Abstract: A method for re-melting and refilling a defect (7) in a surface (19) of a substrate (4) by re-melting the defect (7) causing a hollow (28) to be produced above the re-melt, and the hollow (28) is refilled. A nickel- or cobalt-based substrate (4) is re-melted by a laser re-melting method. Subsequently, the hollow (28) that is produced is refilled by a laser application method, in particular by soldering. Also, a component having a re-melted region (25) and a solder region (31) thereover is disclosed.
    Type: Application
    Filed: September 14, 2012
    Publication date: November 20, 2014
    Applicant: SIEMENS AKTIENGESELLSCHAFT
    Inventors: Michael Ott, Sebastian Piegert, Ingo Reinkensmeier
  • Patent number: 8890020
    Abstract: A heater tube is provided for use in a method of producing a diamond or cubic boron nitride (CBN) tipped cutting tool by sintering a mass of crystalline particles to a metal carbide. The heater tube has a cylindrical shape and is comprised of a plurality of windings of an expanded graphite foil which are compressed together. In the method, a heater tube assembly is formed which comprises the metal carbide substrate positioned within the heater tube and a mass of diamond or CBN particles positioned within the heater tube adjacent the substrate. The method includes simultaneously applying sufficient levels of pressure to the heater tube assembly and sufficient levels of electrical current to the heater tube assembly for a sufficient amount of time to cause sintering of the crystalline particles and bonding to the substrate to form a diamond or CBN tipped cutting tool.
    Type: Grant
    Filed: December 20, 2013
    Date of Patent: November 18, 2014
    Inventor: Leland M. Reineke
  • Publication number: 20140331750
    Abstract: A multi-hole probe has a kernel that includes a forward surface that includes at least a first, second, and third pressure sensing ports. The multi-hole probe kernel further includes an upper surface, generally orthogonal to the forward surface, and including at least a first, second, and third stem ports. Still further, the multi-hole probe kernel includes first, second, and third tubes running between and providing a fluid connection with the first, second, and third pressure sensing ports and the first, second, and third stem ports, respectively.
    Type: Application
    Filed: May 7, 2013
    Publication date: November 13, 2014
    Applicant: Honeywell International Inc.
    Inventor: Timothy Vander Hoek
  • Patent number: 8872056
    Abstract: A method for metalworking using an adjustable vacuum and support system for evacuating particulate matter, smoke, excess gas, and molten metal from a work area during welding and for providing adjustable support to a welding head. The vacuum system has a vacuum head and a vacuum nozzle. An adjustable mounting bracket has a first portion fixed to the vacuum head and a second portion securable to the welding head. The bracket arrangement establishes pivotal and slidable couplings between the welding head and the vacuum head. The vacuum nozzle has a support surface for being rested on a surface of a workpiece to support the vacuum head and the welding head. The support surface can be a base bevel surface at the tip of the nozzle, and an opposed suction bevel surface can have a nozzle aperture interposed therealong.
    Type: Grant
    Filed: October 22, 2013
    Date of Patent: October 28, 2014
    Inventor: Charles Klangos
  • Publication number: 20140315040
    Abstract: A method of integrally forming at least one stiffener onto a sheet metal component configured to carry a load is provided including generating a stereolithography file. The stereolithography file includes a surface geometry of the at least one stiffener extending from a surface of the sheet-metal component. The surface geometry of the stereolithography file is sliced into a plurality of thin strips. The plurality of thin strips is substantially parallel to the surface of the sheet metal component. Energy from an energy source is applied to a powdered material such that the powdered material fuses to form the plurality of thin strips. One of the plurality of thin strips is integrally formed with the surface of the sheet-metal component. Each of the plurality of thin strips is integrally formed with an adjacent thin strip to create at least one stiffener.
    Type: Application
    Filed: April 19, 2013
    Publication date: October 23, 2014
    Applicant: Sikorsky Aircraft Corporation
    Inventor: Michael R. Urban
  • Publication number: 20140263193
    Abstract: A method and system to weld or overlay workpieces employing a high intensity energy source to create a puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle. The filler wire comprises a core and an electrically conductive outer matrix having particles to be deposited into the puddle.
    Type: Application
    Filed: March 15, 2013
    Publication date: September 18, 2014
    Applicant: LINCOLN GLOBAL, INC.
    Inventors: Paul E. Denney, Steven R. Peters
  • Publication number: 20140263194
    Abstract: Embodiments of the invention relate to consumables that are used with non-arc deposition processes, including hot-wire deposition processes. Exemplary embodiments of the present invention eliminate the use of arc initiators or arc stabilizers in the consumable. Other embodiments add additional amounts of carbonates in the consumable than would otherwise be present in consumables for arc welding processes. Similarly, other exemplary embodiments of the present invention include additional amounts of nitrides than would otherwise be present in arc process consumables. Other exemplary embodiments include carbides that are desired to be deposited through the non-arc processes.
    Type: Application
    Filed: March 15, 2013
    Publication date: September 18, 2014
    Applicant: Lincoln Global, Inc.
    Inventors: Badri K. NARAYANAN, Jonathan S. Ogborn, Michael Whitehead, Rajan B. Vaidyanath
  • Patent number: 8816239
    Abstract: A method of manufacturing a component. The method includes the steps of heating a working region of a substrate with a heating means; directing a material into the working region to bring the material into a temporary molten state, and depositing said material on the substrate such that when the material solidifies it forms at least part of the component. The heating means power output, stand off, orientation, speed and direction of travel relative to the substrate are adjustable and controlled throughout the material deposition process to control the shape and/or size of the working region to thereby control the distribution and rate of heat delivery to the substrate.
    Type: Grant
    Filed: April 5, 2011
    Date of Patent: August 26, 2014
    Assignee: Rolls-Royce PLC
    Inventors: Daniel Clark, Christopher A. Simmons, Mark D. Hancock
  • Patent number: 8809724
    Abstract: Process for reducing cracking in superalloy metal components by selectively growing large single grains during the casting operation at a region where fusion welding will be required.
    Type: Grant
    Filed: August 4, 2008
    Date of Patent: August 19, 2014
    Assignee: General Electric Company
    Inventors: Srikanth Chandrudu Kottilingam, Doyle Clyde Lewis, Daniel Anthony Nowak, Matthew D. Collier, Jian Zheng, Lawrence James Whims
  • Publication number: 20140190942
    Abstract: A method and apparatus for forming a layered structure. At least one raised area (202) is formed on a work piece (200), and a structure (302) is formed on the raised area using an Additive Layer Manufacturing (ALM) process.
    Type: Application
    Filed: August 8, 2012
    Publication date: July 10, 2014
    Applicant: BAE SYSTEMS PLC
    Inventors: Andrew David Wescott, Jagjit Sindhu
  • Publication number: 20140166627
    Abstract: A system for applying a target track material to an x-ray tube target includes a controller configured to direct a beam of energy toward an x-ray tube target, and direct a solid stock material toward the beam of energy to cause the solid stock material to melt and deposit as a melted material on the x-ray tube target.
    Type: Application
    Filed: February 24, 2014
    Publication date: June 19, 2014
    Applicant: General Electric Company
    Inventors: Gregory Alan Steinlage, Marshall Gordon Jones, Donald Robert Allen, Ben David Poquette
  • Publication number: 20140131338
    Abstract: Various embodiments of a metal cored wires, hardband alloys, and methods are disclosed. In one embodiment of the present invention, a hardbanding wire comprises from about from about 16% to about 30% by weight chromium; from about 4% to about 10% by weight nickel; from about 0.05% to about 0.8% by weight nitrogen; from about 1% to about 4% by weight manganese; from about 1% to about 4% by weight carbon from about 0.5% to about 5% by weight molybdenum; from about 0.25% to about 2% by weight silicon; and the remainder is iron including trace elements. The hardband alloy produced by the metal cored wire meets API magnetic permeability specifications and has improved metal to metal, adhesive wear resistance compared to conventional hardband alloys.
    Type: Application
    Filed: November 12, 2013
    Publication date: May 15, 2014
    Applicant: Postle Industries, Inc.
    Inventor: Christopher J. Postle
  • Publication number: 20140124483
    Abstract: Layered metal deposition by fusion thereof onto a surface of an engineered structural member, without degrading structural performance. The net shape of an exterior member is defined, including a fusion contact area. The structural member is preheated below its maximum operating temperature. An energy beam and feedstock are directed to a feed point in the fusion area, thereby forming a molten puddle fusing the materials together. The feed point is moved relative to the structural member, thereby advancing the molten puddle of presently fed feedstock and rapidly solidifying previously fed feedstock. The energy beam power is modulated to control the size of the molten puddle so as not to exceed a predetermined depth of penetration of the fusion region into the structural member. Advancing the feed point sequentially fuses feedstock into the defined net shape on the structural member.
    Type: Application
    Filed: November 7, 2012
    Publication date: May 8, 2014
    Inventor: David S. Henn
  • Patent number: 8715772
    Abstract: A process for the thermal deposition coating of a workpiece is provided that comprises the steps of: thermally depositing a coating on a metallic surface of a workpiece from a deposition head wherein at least one condition selected from the group of: coating deposition rate onto said surface, relative motion between the surface and said deposition head, and cryogenic coolant application rate onto said workpiece is controllable; substantially simultaneously measuring temperatures at a plurality of locations over the metallic surface of the workpiece; determining an average temperature of the temperatures measured in step (b); comparing the average temperature to a preselected minimum temperature and a preselected maximum temperature for the workpiece; and adjusting at least one of the controllable conditions if said average temperature is not between the preselected minimum temperature and the preselected maximum temperature for the workpiece.
    Type: Grant
    Filed: March 27, 2006
    Date of Patent: May 6, 2014
    Assignee: Air Products and Chemicals, Inc.
    Inventor: Zbigniew Zurecki
  • Publication number: 20140103015
    Abstract: An installation for fabricating a part by selectively melting powder, the installation including a mechanism producing a beam, for example a laser beam or an electron beam, and a mechanism moving a point of impact of the beam over a layer of powder. The installation further includes a collector element for collecting projections of molten powder produced during local melting of the powder by the beam, the collector element including an opening for passing the beam, and a mechanism configured to move the collector element jointly with the beam over the layer of powder.
    Type: Application
    Filed: May 15, 2012
    Publication date: April 17, 2014
    Applicant: SNECMA
    Inventors: Jean-Francois Castagne, Damien Hebuterne, Thomas Vilaro
  • Patent number: 8674262
    Abstract: The present invention is a device for coating surfaces of metallic work pieces with an electrically conductive material by employing short duration high current packets of pulses in which the work piece forms the cathode and the consumable coating material forms the anode, which are connected to a generator for generating pulses by charging and discharging a bank of capacitors using a MOSFET. The invention is also a device for controlling the on and off time of a metal oxide semiconductor field effect transistor (MOSFET).
    Type: Grant
    Filed: August 12, 2011
    Date of Patent: March 18, 2014
    Assignee: International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI)
    Inventors: Kalidindi Ramachandra Soma Raju, Chebrolu Sambasiva Rao, Ribalko Alexander Vasilyevich
  • Publication number: 20140061167
    Abstract: A process (and apparatus for performing the process) for layer manufacturing a three-dimensional work piece comprising the steps of: feeding raw material in a solid state to a first predetermined location; exposing the raw material to an electron beam to liquefy the raw material; depositing the raw material onto a substrate as a molten pool deposit, the deposit having a forward edge region in an x-y plane with a forward edge region width and a trailing edge region in the x-y plane with a trailing edge region width, under at least one first processing condition; monitoring the molten pool deposit for at least one preselected condition using detecting of scatter from a scanning electron beam contemporaneously with the depositing step; solidifying the molten pool deposit; automatically altering the first processing condition to a different processing condition based upon information obtained from the comparing step; and repeating steps at one or more second locations for building up layer by layer, generally alo
    Type: Application
    Filed: November 13, 2013
    Publication date: March 6, 2014
    Applicant: Sciaky, Inc.
    Inventors: Scott Stecker, Phillip Wollenhaupt
  • Publication number: 20140021171
    Abstract: Method and device for solid structure formation by localized microwaves for additive fabrication of solid bodies by use of localized microwave radiation applied to a source material, in the form of a powder, wire or other solid form, so as to generate a hotspot in a thermal-runaway process or through plasma breakdown, and melt a small portion of it (with at least one dimension smaller than the microwave wavelength) thereby consolidating small pieces of the molten source material in a stepwise manner to construct the entire body.
    Type: Application
    Filed: September 24, 2013
    Publication date: January 23, 2014
    Inventors: Eli Jerby, Alon Salzberg, Yehuda Meir, Francisco Xavier Planta Torralba, Rafael Rubio Bonilla, Benjamin Cavallini