Donald A Deuser

US Patent:

60859652, Jul 11, 2000

Filed:

Feb 4, 1997

Appl. No.:

8/794835

Inventors:

Daniel S. Schwartz - University City MO
Donald A. Deuser - Florissant MO
Rick L. Martin - St. Peters MO

Assignee:

McDonnel & Douglas Corporation - St. Louis MO

International Classification:

B23K 2002
B23K 20233

US Classification:

228190

Abstract:

A novel method of forming low density core metal parts by pressure bonding face sheets to a porous foam metal core and simultaneously densifying the core is disclosed. In particular, low density core aluminum and aluminum alloy parts can be formed according to the method of the invention. The method of forming low density core metal parts generally comprises the steps of providing a porous, foam metal core and simultaneously pressure bonding first and second solid metal face sheets directly to opposite sides of the core and densifying the core by applying heat and uniaxial forge pressure to the first and second face sheets and to the core for a predetermined period of time. The method of the invention can therefore produce LDC parts having a predetermined shape and density. Furthermore, the LDC parts are less subject to interfacial oxidation and delamination than conventional LDC parts made by brazing.

US Patent:

61680729, Jan 2, 2001

Filed:

Oct 21, 1998

Appl. No.:

9/176424

Inventors:

Daniel S. Schwartz - University City MO
Donald A. Deuser - Florissant MO

Assignee:

The Boeing Company - St. Louis MO

International Classification:

B23K 2000
B23K 2800
B23K 3102
C22B 100
C22B 114

US Classification:

2282351

Abstract:

The present invention provides a method of diffusion bonding a first article containing a thermally activated expansion agent to a second article. The first article and the second article are placed adjacent to each other at a bonding area. The first article and the second article are constrained such that contact is maintained between the first article and the second article at the bonding area. The constrained articles are then heated at a temperature that causes the first article to expand, creating pressure between the articles at the bonding area.

US Patent:

59392134, Aug 17, 1999

Filed:

Jun 6, 1995

Appl. No.:

8/471940

Inventors:

David Michael Bowden - St. Louis MO
Donald Albert Deuser - Florissant MO

Assignee:

McDonnell Douglas

International Classification:

C22C 109
B32B 502

US Classification:

428608

Abstract:

A titanium matrix composite laminate (42) includes alternating layers of a titanium matrix foil (12) and a fiber mat (14). The titanium matrix foil (12) is formed from a super alpha titanium alloy having a beta phase stabilizer equivalency of at least thirteen. The beta phase stabilizer is selected from the elements molybdenum, vanadium, niobium, tantalum, halfnium, tungsten or some combination thereof. The fiber mat (14) is formed of silicon carbide (SiC) and has a carbon coating. Once a layup (16) of the alternating layers is formed, it is placed in a mold (22). Heat and pressure are then applied in a step called consolidation (40). The result is a titanium matrix composite laminate (42).

US Patent:

59725214, Oct 26, 1999

Filed:

Oct 1, 1998

Appl. No.:

9/164781

Inventors:

Christopher S. Huskamp - Columbia IL
Donald A. Deuser - Florissant MO
Daniel S. Schwartz - University City MO

Assignee:

McDonnell Douglas Corporation - St. Louis MO

International Classification:

B22F 300

US Classification:

428547

Abstract:

The present invention provides a method of forming a continuous one-piece structural porous metal (SPM) structure having a predetermined geometry. The method the invention includes the steps of preparing a metal billet comprising a metal core formed of a metal and a gas, and solid metal face sheets bonded to opposite sides of the metal core; placing the metal billet in a mold cavity having a predetermined geometry defined by opposing inner surfaces of the mold with at least one of the opposing inner surfaces contacting at least a portion of the metal billet and spaced apart from at least a portion of the metal billet; and heating the metal billet to expand the metal core to form the expanded metal structure. The portion of the metal billet in contact with the inner surfaces of the mold cavity is constrained by these surfaces while the remainder of the metal billet that is spaced apart from at least one of the inner surfaces of the mold is allowed to expand resulting in a one-piece expanded metal structure having a geometry corresponding generally to the geometry of the mold cavity with the constrained portion of the metal structure having a higher density than the remainder of the expanded metal structure. The present invention also includes a continuous one-piece expanded metal structure.

US Patent:

58553134, Jan 5, 1999

Filed:

Apr 8, 1997

Appl. No.:

8/835257

Inventors:

James L. McAfee - Ferguson MO
Donald A. Deuser - Florissant MO
John T. Niemann - O'Fallon MO
Daniel S. Schwartz - U-City MO

Assignee:

McDonnell Douglas Corporation - St. Louis MO

International Classification:

B23K 120

US Classification:

2281241

Abstract:

A two-step process for joining a first part to a second part, the first part having a coefficient of thermal expansion lower than the coefficient of thermal expansion of the second part. An anchor layer is then brazed at a lower temperature to the first part having a high thermal expansion coefficient. The anchor layer has a thickness such that upon cooling it will yield to relieve stress build up resulting from the differing thermal expansion coefficients between it and the first part. The anchor layer is then brazed to the part having a high thermal expansion coefficient. The process is particularly useful for joining carbon-carbon composite parts to copper substrates for use in the manufacture of high temperature heat exchangers as used, for example, in nuclear fusion reactors.