The Boeing Company

Other

Commonwealth Scientific and Industrial Research Organisation

Theboeing Company

Gary W Coleman

Marc Rollo Matsen

Daniel David Bloch

David S Nansen

James H Lee

David Michael Dietrich

John R Fischer

Amy Marie Helvey

Terry L Smith

Russell W Cochran

Vu Thua Nguyen

John Edward Barnes

Elizabeth M Mull

Scott W Franz

Srinivasarao Lathabai

Kevin L Nash

Warner B Vanaken

Yuqing Feng

Joseph Peter Reilley

Anthony Miller

Julius J Schaan

Daniel G Sanders

Robert David Briggs

Gregory L Ramsey

Luis R Leon

Karl J Schaefer

Frederick W Buldhaupt

Chul Young Park

Michael P Shemkunas

Ryan J Glamm

Paul D Edwards

Thanh V Duong

Gregory E Trepus

David Griffiths

Michelangelo Mortello

Robert James Scudamore

Lei Xu

Nathan A Ashmore

Catherine J Parrish

John Barnes

A method of fabricating of an object includes causing a first heat source to heat a feed material to form a melt pool of the feed material on a surface. The method further includes causing a second heat source to heat the melt pool on the surface to regulate grain formation of the feed material in the melt pool as the melt pool cools and solidifies on the surface to form at least a portion of the object. The method also includes causing the first heat source and the second heat source to move relative to the surface as the melt pool is formed and cooled.

Fabrication with regulated grain formation

A method of welding a workpiece assembly includes positioning a flange adjacent to a web to form a workpiece assembly having an interface between a flange edge surface and a web side surface, and in which a web edge portion protrudes beyond a flange front surface on a front side of the workpiece assembly. The method additionally includes constraining the flange and the web against movement, and moving a plasma arc welding (PAW) torch, located on the front side of the workpiece assembly, along a lengthwise direction of the interface, while causing a plasma arc to pass through a flange edge portion and the web side surface, and generate molten material that joins the flange to the web.

Method of welding a workpiece assembly

In one aspect, A method of forming a product using an additive-manufacturing head includes forming a new layer of material of the product with the additive-manufacturing head. Forming the new layer of material includes depositing the new layer of material on an existing layer of material and melting the new layer of material so that the new layer of material is welded to the existing layer of material. The method also includes processing at least one of the new layer of material or the existing layer of material with a laser-emitting device, coupled to the additive-manufacturing head. Processing the at least one of the new layer of material or the existing layer of material with the laser-emitting device comprises smoothing a lateral surface of at least one of the new layer of material or the existing layer of material with a laser beam, emitted from the laser-emitting device.

Additive-manufacturing systems, apparatuses and methods

A component is formed by welding a plurality of sheets of metal to form a blank with a number of weld nuggets, placing the blank between a die section and a lid section, heating the die section to heat the blank, and introducing a pressurized gas between the lid section and the die section to press the blank into a mold in the die section to form a component. The number of weld nuggets has a desired thickness ratio between about 1.1 to about 1.25 such that the plurality of sheets of metal and the component formed have a number of characteristics that are substantially the same.

Welding in preparation for superplastic forming

A method of minimising distortion in a workpiece is described that includes utilizing a computer system to carry out finite element analysis on a finite element thermo-mechanical model of the workpiece during and after fabrication by additive manufacturing to predict shape distortion and residual stress development in the workpiece, wherein the fabrication includes the fabrication step of depositing multiple layers of a material melted by a heat source along a deposit path on a substrate, and introducing alterations to the workpiece prior to or during fabrication to compensate for the predicted distortion.

Distortion prediction and minimisation in additive manufacturing

A method of minimizing distortion in a workpiece is described that includes utilizing a computer system to carry out finite element analysis on a finite element thermo-mechanical model of the workpiece during and after fabrication by additive manufacturing to predict shape distortion and residual stress development in the workpiece, wherein the fabrication includes the fabrication step of depositing multiple layers of a material melted by a heat source along a deposit path on a substrate, and introducing alterations to the workpiece prior to or during fabrication to compensate for the predicted distortion.

Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.

There are provided an apparatus and an associated method for manufacturing superplastically formed structural assemblies from preforms. The apparatus includes first and second co-operable dies structured to define a die cavity therebetween for at least partially receiving the preform, at least one heater in thermal communication with the die cavity for heating the preform to a forming temperature, and at least one injector in fluid communication with the die cavity. The injector is structured for injecting pressurized gas into the die cavity to urge the preform against one of the dies to form the preform into the structural assembly. Further, at least one of the injectors is structured for injecting a quenchant into the die cavity to thereby heat treat the structural assembly while distortion of the structural assembly is being at least partially restrained by at least one of the dies.

Apparatus for forming and heat treating structural assemblies

A device is provided for hoisting a module for mounting into an overhead space, such as the crown of an aircraft fuselage. The device includes a frame that supports the module, and a lifting device that lifts the first frame to properly place the module. The lifting device includes a frame, attachment devices that attach the frame of the lifting device to overhead support frames, and a driving device that moves the frame of the lifting device up the attachment devices. The frame of the lifting device receives the frame that supports the module as the frame of the lifting device is moved by the driving device.

Hoist for aircraft cabin construction

Method and apparatus for forming and heat treating structural assemblies

A method of manufacturing a structural assembly is provided. In one embodiment, the method includes the steps of providing first and second structural members having preselected shapes and dimensions. The first structural member defines a first raised portion and the second structural member defines a second raised portion. According to one embodiment, the providing step includes forming the first and second structural members into preselected shapes and dimensions. The first and second structural members can comprise plates, T-stiffeners or tubular members. The first raised portion of the first structural member is positioned adjacent to the second raised portion of the second structural member following the providing step to thereby define an interface therebetween and wherein the first and second raised portions define a substantially consumable weld land. Thereafter, the first and second structural members are irradiated with a high-energy source along the interface to thereby substantially consume the weld land and join the first and second structural members to form a structural assembly. The first high-energy source preferably comprises an electron beam or a laser.

Joining of structural members by welding

A visual aid device for positioning of a towing vehicle for hitching to a trailer. A vehicle-attachable sighting rod assembly co-operates with a trailer sighting target assembly to guide the vehicle rearwardly into hitching position. Sighting and target rods are so placed as to come together when the vehicle reaches the hitching position. The sighting rod may be attached to be visible along the side of the vehicle, so that an unobstructed rear window is not needed. The target rod is then placed upon the ground to the side of the trailer coupling the same distance that the vehicle sighting rod is from the vehicle coupling. The target assembly may also have another sighting rod, which with the target rod is useful for vehicle direction control, if needed. The assemblies may also be used with the rear window, if it is not visually obstructed. In this case, the target assembly then being attached to the trailer tongue with the target rod rising vertically directly from the coupling to be seen through the window.

Side vision aid for trailer hitching

Bottle bag

Growing community of inventors

Snohomish, WA, United States of America

Gary W Coleman