Patents by Inventor John A. Baumann

John A. Baumann has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11278986
    Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.
    Type: Grant
    Filed: December 4, 2019
    Date of Patent: March 22, 2022
    Assignee: The Boeing Company
    Inventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
  • Publication number: 20200101559
    Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.
    Type: Application
    Filed: December 4, 2019
    Publication date: April 2, 2020
    Applicant: The Boeing Company
    Inventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
  • Patent number: 10532425
    Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.
    Type: Grant
    Filed: October 16, 2017
    Date of Patent: January 14, 2020
    Assignee: The Boeing Company
    Inventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
  • Patent number: 10479474
    Abstract: Provided are wingtip torque boxes and methods of fabricating such boxes using friction stir welding. Specifically, a wingtip torque box may be formed by friction stir welding two monolithic clamshells along their respective spars thereby forming a new monolithic structure. Use of the friction stir welding and monolithic clamshells simplifies the overall fabrication process and yields a robust wingtip torque box that can be bolted on or otherwise attached to an aircraft wing. The wingtip torque box may include internal grid stiffeners and/or external stiffeners that may be also monolithic with other components of the box. For example, the stiffeners may be machined in spars or skin portions of the clamshells during fabrication of clamshells. The wingtip torque box may have a continuous cavity extending between the ends and, in some embodiments, between spars of the box and providing access for performing various operations inside the box.
    Type: Grant
    Filed: July 14, 2016
    Date of Patent: November 19, 2019
    Assignee: The Boeing Company
    Inventors: Michael P. Shemkunas, Kenneth D. Cominsky, Steven S. Heer, David P. Heck, Benjamin D. Smith, John A. Baumann, Matthew D. Uhlman, Burke L. Reichlinger, Eric E. Thomas, James P. Dobberfuhl
  • Publication number: 20190111513
    Abstract: Disclosed herein are systems, methods, and devices for repairing holes in weld seams created by bobbin friction stir welding tools. A hole may be created when a welding tool or, more specifically, a pin of the tool is removed or otherwise extracted from a weld seam created by the tool. The method may involve inserting a plug (e.g., a rivet) into the hole, reshaping the plug in the hole (e.g., riveting) thereby securing the plug in the component, and creating another weld seam through the plug thereby consuming the plug. In some embodiments, the hole may be reshaped prior to inserting the plug. For example, the hole may be drilled out and/or a countersink may be created on one or both ends of the hole. Furthermore, the plug may extend outside of the hole prior to its reshaping and, in some embodiments, even after reshaping.
    Type: Application
    Filed: October 16, 2017
    Publication date: April 18, 2019
    Applicant: The Boeing Company
    Inventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
  • Publication number: 20180056436
    Abstract: Systems, methods, and devices are disclosed herein that repair and fill exit holes created by welding operations on vehicle components or parts. Methods may include inserting a plug into the exit hole in one or more vehicle parts, where the exit hole is created by the welding operation performed on the one or more vehicle parts. Methods may further include positioning a first pin on the plug such that the first pin is contacting an exposed surface of the plug, and rotating the first pin while contacting the exposed surface of the plug, where the rotating generates thermal energy based on a frictional force associated with the first pin and the plug. The methods may also include filling the exit hole by heating and plasticizing the plug via the thermal energy, and consolidating a material of the plug with the one or more vehicle parts.
    Type: Application
    Filed: August 26, 2016
    Publication date: March 1, 2018
    Applicant: The Boeing Company
    Inventors: Eric E. Thomas, Sean M. Thuston, Brian J. Martinek, John A. Baumann
  • Publication number: 20180056439
    Abstract: Systems, methods, and devices are disclosed herein that repair and fill exit holes created by welding operations on vehicle components or parts. Methods disclosed herein may include inserting a plug into an exit hole in one or more vehicle parts, where the exit hole is created by a welding operation performed on the one or more vehicle parts. Methods may also include positioning a shoulder member on the plug such that the shoulder member is contacting an exposed surface of the plug. Methods may further include rotating the shoulder member while contacting the exposed surface of the plug, the rotating generating thermal energy based on a frictional force associated with the shoulder member and the plug. Methods may also include filling the exit hole by heating and plasticizing the plug via the thermal energy, and consolidating a material of the plug with the one or more vehicle parts.
    Type: Application
    Filed: February 22, 2017
    Publication date: March 1, 2018
    Applicant: THE BOEING COMPANY
    Inventors: ERIC E. THOMAS, SEAN M. THUSTON, BRIAN J. MARTINEK, JOHN A. BAUMANN
  • Publication number: 20180015996
    Abstract: Provided are wingtip torque boxes and methods of fabricating such boxes using friction stir welding. Specifically, a wingtip torque box may be formed by friction stir welding two monolithic clamshells along their respective spars thereby forming a new monolithic structure. Use of the friction stir welding and monolithic clamshells simplifies the overall fabrication process and yields a robust wingtip torque box that can be bolted on or otherwise attached to an aircraft wing. The wingtip torque box may include internal grid stiffeners and/or external stiffeners that may be also monolithic with other components of the box. For example, the stiffeners may be machined in spars or skin portions of the clamshells during fabrication of clamshells. The wingtip torque box may have a continuous cavity extending between the ends and, in some embodiments, between spars of the box and providing access for performing various operations inside the box.
    Type: Application
    Filed: July 14, 2016
    Publication date: January 18, 2018
    Applicant: The Boeing Company
    Inventors: Michael P. Shemkunas, Kenneth D. Cominsky, Steven S. Heer, David P. Heck, Benjamin D. Smith, John A. Baumann, Matthew D. Uhlman, Burke L. Reichlinger, Eric E. Thomas, James P. Dobberfuhl
  • Patent number: 9687935
    Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.
    Type: Grant
    Filed: November 18, 2015
    Date of Patent: June 27, 2017
    Assignee: THE BOEING COMPANY
    Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
  • Patent number: 9545697
    Abstract: A method for performing operations on a structure. A moveable platform may be positioned in an area relative to the structure to define a working envelope. The moveable platform may be connected to a tool that may be moved around a plurality of axes within the working envelope using the moveable platform. The tool may be moved to a plurality of locations within the working envelope using the moveable platform. An operation may be performed with the tool through the working envelope at each of the plurality of locations using the moveable platform.
    Type: Grant
    Filed: April 6, 2009
    Date of Patent: January 17, 2017
    Assignee: THE BOEING COMPANY
    Inventors: Eric Whinnem, Gary A. Lipczynski, John A. Baumann
  • Patent number: 9511461
    Abstract: A manufacturing apparatus is presented. The manufacturing apparatus comprises a tool support movable along multiple axes; a tool mounted on the tool support for performing a manufacturing operation on a workpiece; and an ancillary device releasably mounted on the tool support and used in conjunction with the tool, the ancillary device moveable along at least a first axis independent of the movement of the tool.
    Type: Grant
    Filed: May 27, 2013
    Date of Patent: December 6, 2016
    Assignee: THE BOEING COMPANY
    Inventors: John A. Baumann, Herb Bommer, Kurt A. Burton, Mike P. Matlack
  • Patent number: 9289849
    Abstract: One aspect of the disclosure relates to a friction stir welding apparatus. The friction stir welding apparatus includes a spindle housing and a pin tool concentric with an axis and rotatable relative to the spindle housing about the axis. The friction stir welding apparatus also includes a first shoulder not substantially rotatable relative to the spindle housing about the axis and a second shoulder not substantially rotatable relative to the spindle housing about the axis. The pin tool is rotatable relative to the first shoulder and the second shoulder.
    Type: Grant
    Filed: April 2, 2015
    Date of Patent: March 22, 2016
    Assignee: THE BOEING COMPANY
    Inventors: Michael P. Matlack, Amy Marie Helvey, John A. Baumann
  • Publication number: 20160067817
    Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.
    Type: Application
    Filed: November 18, 2015
    Publication date: March 10, 2016
    Inventors: Mike P. MATLACK, Kurt A. BURTON, John A. BAUMANN
  • Patent number: 9205533
    Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.
    Type: Grant
    Filed: April 21, 2014
    Date of Patent: December 8, 2015
    Assignee: The Boeing Company
    Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
  • Publication number: 20150298297
    Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.
    Type: Application
    Filed: April 21, 2014
    Publication date: October 22, 2015
    Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
  • Publication number: 20150209895
    Abstract: One aspect of the disclosure relates to a friction stir welding apparatus. The friction stir welding apparatus includes a spindle housing and a pin tool concentric with an axis and rotatable relative to the spindle housing about the axis. The friction stir welding apparatus also includes a first shoulder not substantially rotatable relative to the spindle housing about the axis and a second shoulder not substantially rotatable relative to the spindle housing about the axis. The pin tool is rotatable relative to the first shoulder and the second shoulder.
    Type: Application
    Filed: April 2, 2015
    Publication date: July 30, 2015
    Inventors: Michael P. Matlack, Amy Marie Helvey, John A. Baumann
  • Patent number: 9033328
    Abstract: The present invention is directed to apparatus and methods for clamping along a work piece. In one embodiment, a clamping system includes one or more force applying units each including a plunger or force applying member adapted to apply clamping force to the work piece, and one or more coupling units linked with the force applying units forming a chain of force applying units and coupling units. The coupling units may include a lockable pivot adapted to pivot to conform the chain to the surface of the work piece when unlocked, and adapted to be locked when at least one of the plurality of force applying units applies clamping force to the work piece. In another embodiment, a clamping system may include multi-axis pivot units. In a further embodiment, a clamping system may include length adjusting units.
    Type: Grant
    Filed: October 31, 2003
    Date of Patent: May 19, 2015
    Assignee: The Boeing Company
    Inventor: John A. Baumann
  • Patent number: 9022376
    Abstract: A reconfigurable clamping system is disclosed. An example clamping system for securing a workpiece comprises a retention assembly and an inflatable bladder. The retention assembly comprises a plurality of links, each pair of adjacent links having a pivotal connection to enable the retention assembly to be configured to the general shape of a workpiece, and each pair of adjacent links having a locking mechanism to selectively lock an angular relationship between the pair. The inflatable bladder is coupled between the retention assembly and the workpiece and is to apply a clamping force to the workpiece.
    Type: Grant
    Filed: July 1, 2013
    Date of Patent: May 5, 2015
    Assignee: The Boeing Company
    Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
  • Patent number: 9010613
    Abstract: One aspect of the disclosure relates to a friction stir welding apparatus. The friction stir welding apparatus includes a spindle housing and a pin tool concentric with an axis and rotatable relative to the spindle housing about the axis. The friction stir welding apparatus also includes a first shoulder not substantially rotatable relative to the spindle housing about the axis and a second shoulder not substantially rotatable relative to the spindle housing about the axis. The pin tool is rotatable relative to the first shoulder and the second shoulder.
    Type: Grant
    Filed: December 16, 2013
    Date of Patent: April 21, 2015
    Assignee: The Boeing Company
    Inventors: Michael P. Matlack, Amy Marie Helvey, John A. Baumann
  • Publication number: 20130292891
    Abstract: A reconfigurable clamping system is disclosed. An example clamping system for securing a workpiece comprises a retention assembly and an inflatable bladder. The retention assembly comprises a plurality of links, each pair of adjacent links having a pivotal connection to enable the retention assembly to be configured to the general shape of a workpiece, and each pair of adjacent links having a locking mechanism to selectively lock an angular relationship between the pair. The inflatable bladder is coupled between the retention assembly and the workpiece and is to apply a clamping force to the workpiece.
    Type: Application
    Filed: July 1, 2013
    Publication date: November 7, 2013
    Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann