The Boeing Company

Ford Global Technolgoies, LLC

Northwestern University

Christopher Shane Huskamp

James B Castle

Kevin T Slattery

Brett Ian Lyons

James Maurice Boileau

David C Dunand

Keith A Young

Victor Blakemore Slaughter

Bita Ghaffari

David N Seidman

Gregg Miltenberger

Christopher Booth-Morrison

Bonnie Louise Gorsic

James William Fonda

Richard J Lederich

Kevin G Waymack

Krishnan K Sankaran

Victor Blake Slaughter

James W Fonda

Bonnie L Gorsic

James M Boileau

Materials and methods is present for manufacturing fiber reinforced parts. A powder material comprising a matrix material of a size particular distribution comprising substantially oriented fiber of a predetermined length distribution and diameter (L/D). A manufactured part that has substantially randomly oriented fiber is provided using an energy delivery system and the powder material.

Method of reinforcement for additive manufacturing

Materials and methods are presented for manufacturing fiber reinforced parts. A powder material comprising a matrix material of a particular particle size distribution comprising substantially oriented fiber of a predetermined length distribution and diameter (L/D). A manufactured part that has substantially randomly oriented fiber is provided using an energy delivery system and the powder material.

An aluminum alloy including additions of scandium, zirconium, erbium and, optionally, silicon.

Aluminum alloy with additions of scandium, zirconium and erbium

A method and apparatus for processing a sheet of material. The sheet of material may be secured relative to a tool in an incremental sheet metal forming machine. The sheet of material may be incrementally shaped into a shape of a part using a stylus. The stylus may comprise a rod having a first end and a second end, a substantially curved surface on the first end, and a texture on at least a portion of the substantially curved surface on the first end. The texture may be configured to channel a lubricant onto the first end.

Method and apparatus for incremental sheet forming

A method and apparatus for manufacturing a tool for creating composite components. A sheet metal material is secured over a forming tool in an incremental sheet metal forming machine. The sheet metal material is incrementally shaped with a stylus to form a shape for the tool. The tool is removed from the incremental sheet metal forming machine when the shape for the tool is complete. Composite materials on the tool are laid up, wherein the shape of the tool provides a desired shape for a composite component.

Formed sheet metal composite tooling

A method and apparatus for an aircraft location system comprising an aircraft structure and a number of acoustic reflectors associated with the aircraft structure. The number of acoustic reflectors is configured to generate first sound signals in response to receiving second sound signals.

Aircraft location system for locating aircraft in water environments

A non-destructive inspection apparatus, system and associated method are provided to facilitate the inspection of a workpiece. The non-destructive inspection apparatus includes an ultrasonic sensor configured to be placed in operable contact with the workpiece. The ultrasonic sensor is configured to emit ultrasonic signals into the workpiece and to receive return signals from the workpiece. The non-destructive inspection apparatus also includes a grip operably connected to the ultrasonic sensor such that the grip and the ultrasonic sensor are movable in concert. The grip is configured to support an operator's palm, such as a majority of the operator's palm, such that force applied to the ultrasonic inspection apparatus by the operator is transferred via the grip to the ultrasonic sensor. The non-destructive inspection system may also include a computer in communication with the non-destructive inspection apparatus to receive information relating to the return signals received by the ultrasonic sensor.

Non-destructive inspection apparatus having an ergonomic grip and associated method

A method and apparatus is present for manufacturing parts. A powder material is comprised of a polymer that is semi-crystalline. The powder material has an overlap between a melting temperature range and a crystallization temperature range. The powder material also has a size particular distribution that is substantially a Gaussian distribution, a particle shape that is substantially spherical, and a desired melt flow rate that is less than a temperature at which the powder material begins to chemically break down. The powder material is selected to form a selected powder material. A part is manufactured using an energy delivery system and the selected powder material.

Manufacturing aircraft parts

Any of various features of a workpiece are forged by a common set of tools. The feature is incrementally forged as the tool set is moved to successive forging locations on the surface of the workpiece. One of the tools is used to plasticize and extrude a portion of the workpiece while one or more of the other tools are used to form dams that contain and shape the extruded portions.

Incremental forging

An apparatus comprises a platform, a stylus, and a heating system. The platform is capable of holding a sheet of material. The stylus is capable of impinging the sheet of the material to incrementally form a shape for a part. The heating system is capable of heating at least a portion of the sheet of material in a location on the sheet of material prior to the stylus impinging the location.

Reducing force needed to form a shape from a sheet metal

Disclosed embodiments disclose processes for making shaped metal alloy parts, and deal more particularly with forming features and reducing residual stresses in such parts. Residual stresses introduced into a metal alloy part by heat treatment, which may include solution annealing and quenching, are reduced by processes that plastically deform the part while forming part features. An embodiment comprises: producing a metal alloy blank; subjecting the blank to a process that introduces residual stresses into the blank and plastically deforming the blank to reduce the residual stresses in the blank. Embodiments comprise: subjecting a part to a heat treatment that introduces residual stresses in the part; and age forming the part to shape the part and reduce the residual stresses, incrementally forging at least one feature into the part and reducing the residual stresses in the part, friction welding the part, or gauge rolling the cast part to desired dimensions.

Growing community of inventors

St. Louis, MO, United States of America

Christopher Shane Huskamp