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).
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Patent number: 11278986Abstract: 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: GrantFiled: December 4, 2019Date of Patent: March 22, 2022Assignee: The Boeing CompanyInventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
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Publication number: 20200101559Abstract: 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: ApplicationFiled: December 4, 2019Publication date: April 2, 2020Applicant: The Boeing CompanyInventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
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Patent number: 10532425Abstract: 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: GrantFiled: October 16, 2017Date of Patent: January 14, 2020Assignee: The Boeing CompanyInventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
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Patent number: 10479474Abstract: 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: GrantFiled: July 14, 2016Date of Patent: November 19, 2019Assignee: The Boeing CompanyInventors: 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
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Publication number: 20190111513Abstract: 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: ApplicationFiled: October 16, 2017Publication date: April 18, 2019Applicant: The Boeing CompanyInventors: Scott A. Rose, Sean M. Thuston, Brian J. Martinek, John A. Baumann
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Publication number: 20180056436Abstract: 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: ApplicationFiled: August 26, 2016Publication date: March 1, 2018Applicant: The Boeing CompanyInventors: Eric E. Thomas, Sean M. Thuston, Brian J. Martinek, John A. Baumann
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Publication number: 20180056439Abstract: 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: ApplicationFiled: February 22, 2017Publication date: March 1, 2018Applicant: THE BOEING COMPANYInventors: ERIC E. THOMAS, SEAN M. THUSTON, BRIAN J. MARTINEK, JOHN A. BAUMANN
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Publication number: 20180015996Abstract: 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: ApplicationFiled: July 14, 2016Publication date: January 18, 2018Applicant: The Boeing CompanyInventors: 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
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Patent number: 9687935Abstract: 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: GrantFiled: November 18, 2015Date of Patent: June 27, 2017Assignee: THE BOEING COMPANYInventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Patent number: 9545697Abstract: 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: GrantFiled: April 6, 2009Date of Patent: January 17, 2017Assignee: THE BOEING COMPANYInventors: Eric Whinnem, Gary A. Lipczynski, John A. Baumann
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Patent number: 9511461Abstract: 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: GrantFiled: May 27, 2013Date of Patent: December 6, 2016Assignee: THE BOEING COMPANYInventors: John A. Baumann, Herb Bommer, Kurt A. Burton, Mike P. Matlack
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Patent number: 9289849Abstract: 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: GrantFiled: April 2, 2015Date of Patent: March 22, 2016Assignee: THE BOEING COMPANYInventors: Michael P. Matlack, Amy Marie Helvey, John A. Baumann
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Publication number: 20160067817Abstract: 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: ApplicationFiled: November 18, 2015Publication date: March 10, 2016Inventors: Mike P. MATLACK, Kurt A. BURTON, John A. BAUMANN
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Patent number: 9205533Abstract: 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: GrantFiled: April 21, 2014Date of Patent: December 8, 2015Assignee: The Boeing CompanyInventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Publication number: 20150298297Abstract: 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: ApplicationFiled: April 21, 2014Publication date: October 22, 2015Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Publication number: 20150209895Abstract: 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: ApplicationFiled: April 2, 2015Publication date: July 30, 2015Inventors: Michael P. Matlack, Amy Marie Helvey, John A. Baumann
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Patent number: 9033328Abstract: 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: GrantFiled: October 31, 2003Date of Patent: May 19, 2015Assignee: The Boeing CompanyInventor: John A. Baumann
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Patent number: 9022376Abstract: 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: GrantFiled: July 1, 2013Date of Patent: May 5, 2015Assignee: The Boeing CompanyInventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Patent number: 9010613Abstract: 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: GrantFiled: December 16, 2013Date of Patent: April 21, 2015Assignee: The Boeing CompanyInventors: Michael P. Matlack, Amy Marie Helvey, John A. Baumann
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Publication number: 20130292891Abstract: 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: ApplicationFiled: July 1, 2013Publication date: November 7, 2013Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann