The Boeing Company

Troy Allan Haworth

Cory Clawson Cunningham

Eric M Chapman

Dana A Henshaw

Russell William Waymire

Kevin Michael Mejia

Ashley Marie Jones

Christopher Perez

Matthew Thomas Hollinger

Martin R Grether

Mitchell Loren Ray Mellor

Grant C Zenkner

Rogie I Rodriguez

Gregory Robert Gleason

Stefanie Anita Meier

David Ansyl Eckols

Chul Young Park

Thomas C Wittenberg

Matthew Ryoichi Soja

Nazir M Kaabour

Peter D Wildermuth

A method includes flowing gas within a chamber for first process parameters at a predetermined point in a laser focal plane and simulating the step of flowing gas within the chamber based on the value of the flow characteristic of the gas at the predetermined point in the laser focal plane so that a value of a simulated-flow characteristic of the gas at a predetermined point away from the laser focal plane is identified. The method comprises comparing the value of the simulated-flow characteristic of gas at the predetermined point away from the laser focal plane to a desired value of the simulated-flow characteristic and flowing gas within the chamber for second differing process parameters, when the value of the simulated-flow characteristic of the gas at the predetermined point away from the laser focal plane differs from the desired value of the simulated-flow characteristic is outside a predetermined range.

Methods of configuring gas flow in additive-manufacturing machines

A method of configuring an additive-manufacturing machine comprises a chamber, a platform, movable inside the chamber and comprising a build-plane surface, and a laser, having a laser focal plane within the chamber. The method comprising steps of flowing a gas within the chamber in accordance with a first set of process parameters and identifying a value of a flow characteristic of the gas at a predetermined point in the laser focal plane while flowing the gas within the chamber in accordance with the first set of process parameters. The method also comprises additively manufacturing a test coupon using the laser while flowing the gas within the chamber in accordance with the first set of process parameters, wherein the test coupon has a test-coupon peripheral surface.

A manufacturing method that includes fabricating a component using an additive manufacturing process, and fabricating a coupon using the additive manufacturing process. The coupon includes a main portion and a grip portion. Fabrication of the coupon includes fabricating the main portion concurrently with the fabrication of the component, fabricating the grip portion dissociatedly from the fabrication of the component, and coupling a first end of the main portion with the grip portion to form the coupon.

Dissociatedly fabricated grips for additively manufactured coupons and methods

Methods of using micro-specimens for testing an additive manufactured material or a part made from the additive manufactured material. The methods include testing small and large test specimens taken from an additive manufactured part and from a blank constructed from the additive manufactured material. Correction factors based on the test specimens are calculated and applied to a calculated material property of the additive manufactured material.

Method of testing additive manufactured material and additive manufactured parts

An additive manufacturing system includes a foil supply drum, a melting energy source, and a processor. The foil supply drum is configured to be rotated for dispensing a foil sheet over a substrate surface supported by a build element. The melting energy source is configured to direct at least one melting energy beam onto a non-melted region of the foil sheet located over the substrate surface. The processor is configured to execute computable readable program instructions based on a three-dimensional digital definition of the object, and control the melting energy beam to selectively melt at least some of the non-melted region into melted portions forming a material layer of the object onto the substrate surface while separating the melted portions from non-melted portions, and command rotation of the foil supply drum for dispensing the foil sheet during manufacturing of the object in correspondence with the digital definition.

Foil fusion additive manufacturing system and method

An attachment system and method that includes first and second fittings, a first eccentric bushing positioned within the first fitting, and a second eccentric bushing positioned within the second fitting. The system may include a first friction washer positioned between the first bushing and first fitting and a second friction washer positioned between the second bushing and the second fitting. A coating on the exterior of the friction washers prohibits rotation of the bushings with respect to the fittings. The coating may be a nickel-diamond coating that prohibits rotation even in the presence of a lubricant. The first fitting may be a frame fitting connected to a fuselage of an aircraft and the second fitting may be a beam fitting connected to the floor of the aircraft. The system may include lock plates that engage lock stops to prohibit rotation of the bushings in combination with the coated friction washers.

Anti-rotation for eccentric bushings

Structural components are disclosed that are fabricated from unidirectional carbon fiber composite materials into compound contour profiles along a longitudinal axis thereof without wrinkling of composite material plies oriented in various directions relative to the longitudinal axis. Methods of stacking, sequencing, and applying the material plies to fabricate the components are also disclosed.

Compound contoured composite beams and fabrication methods

Growing community of inventors

Snohomish, WA, United States of America

Troy Allan Haworth