公开(公告)号：US20230201950A1

公开(公告)日：2023-06-29

申请号：US17982129

申请日：2022-11-07

Applicant: Spirit AeroSystems, Inc.

Inventor： James Michael Wagner ,  Rahbar Nasserrafi ,  Paul Ray Toivonen ,  Heath Edward Misak ,  Craig Matthew Clasper

IPC: B23K11/20 ,  B23K11/00

CPC classification number: B23K11/20 ,  B23K11/0006

Abstract: A method of bonding two or more metallic components into a single piece. The bonding surfaces of the metallic components are protected from reaction with the environment. A force is applied to the metallic components to push the bonding surfaces together. Simultaneous with applying the force, an electric current is passed through the bonding surfaces to joule heat and weld the bonding surfaces together to form the single piece. The bonding surfaces may be protected by plating with a noble metal, applying a coating, shielding with a noble gas, or placing into a vacuum. A press may be used to apply the force. The force and the electric current may be sufficient to push out metal around the joint of the bonding surfaces, and at least one of the bonding surfaces may be drafted to facilitate pushing out the metal. The electric current may be pulsed to induce electroplasticity.

公开(公告)号：US20240399461A1

公开(公告)日：2024-12-05

申请号：US18325826

申请日：2023-05-30

Applicant: Spirit AeroSystems, Inc.

Inventor： Heath Misak ,  Donald Foulk ,  Rahbar Nasserrafi ,  Paul Ray Toivonen

IPC: B22F10/73 ,  B22F12/30 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/20

Abstract: A method of managing additive manufacturing powder used for three-dimensional printing of one or more printed parts, including printing a printed part and a canister covering the printed part on a build plate using a single additive manufacturing process. The method also includes transporting the canister and the printed part, along with the build plate, to a second location. The second location may be outfitted for removal of the canister from the build plate and removal of powder left behind in the canister from the printing of the printed part and the canister. Additional or alternative method steps can include receiving the printed part into a de-powdering machine at the second location, removing the canister from the build plate in the de-powdering machine, and removing powder left behind in the canister from the printing of the printed part and the canister to be recycled for printing another printed part.

公开(公告)号：US20240279833A1

公开(公告)日：2024-08-22

申请号：US18111828

申请日：2023-02-20

Applicant: Spirit AeroSystems, Inc.

Inventor： Rahbar Nasserrafi ,  Gerald Eugene Hicks, Jr. ,  Paul Ray Toivonen ,  Ni Yen Luu ,  Shawn Douglas Vierthaler

IPC: C25D1/00 ,  C25D7/00 ,  C25D17/10

CPC classification number: C25D1/00 ,  C25D7/008 ,  C25D17/10

Abstract: A system and method for producing a rigid, heat-resistant part, such as a superalloy, via electrodeposition. The method can include the steps of coating a secondary alloy particulate with a superior alloy, forming a pre-coated particulate, dispensing a quantity of the pre-coated particulate into a container of an electrolytic solution, and applying a charge to the electrolytic solution such that the pre-coated particulate is electrodeposited onto a cathode or an external casing of the cathode. The pre-coated particulate can include particulate of non-uniform size and/or shape. The secondary alloy particulate is protected in the catalytic solution by the superior alloy coated thereon, such as nickel, iron, cobalt, and/or copper. The method also includes a step of vibrating or agitating the electrolytic solution before and/or during applying the charge to the electrolytic solution for even distribution of the pre-coated particulate onto the cathode or an external casing thereof.