Abstract: The process of the present invention destroys cyanide, especially that associated with spent aluminum potliners, by reacting, in a preferred embodiment the crushed potliners with an effective amount of a mixture made from a chloride salt and bleach in cyanide destroying conditions. The chloride salty preferably is calcium chloride. The bleach is calcium or sodium hypochlorite. The reaction mixture generally also includes calcium carbonate as a source of carbon dioxide to accelerate the reaction rate.

Abstract: The life of ceramic SPF dies can be enhanced significantly by plasma spray application of a cordierite glaze on the forming surface. The preferred glaze has a coefficient of thermal expansion close to or matching with the ceramic of the die, and, typically, is a 2•2•5 MAS system including 2-10 mol % TiO2 (or above 8 wt %).

Abstract: A laminated composite (multi-ply) radius filler includes a plurality of woven fabric reinforced plies cut to fill a radius gap (including, if appropriate, intentional overfill) to increase absolute strength, to increase specific strength, or to reduce cost by reducing cracking and distortion in the radius of a composite assembly. The present invention also describes the method of manufacture and method of use for such laminated composite radius filler.

Abstract: Large machines, especially those having working envelopes in excess of fifteen feet, exhibit unacceptable errors because of thermal expansion and mechanical misalignments between the axes. The errors have traditionally been minimized by enclosing the machine in a thermal enclosure, by careful calibration, or by mounting a laser interferometer on each axis. These solutions are costly, may require frequent recalibration, and do not correct for small rotations of one axis relative to another axis due to wear etc. The present invention uses an interferometric laser tracker or a comparable 3D position sensor to measure the position of a retroreflector attached to the end effector, e.g. a machine head when the machine comes to rest. A computer compares the measured position to the desired position according to the machine media, and adds the appropriate correction with trickle feed media statements to move the machine to the correct position prior to further machining.

Abstract: An edge wrap machine for applying decorative laminate to an aircraft interior panel, particularly a stowbin door, lifts the edge to be wrapped with an actuator, wraps the edge automatically by drawing a vacuum between two silicone blankets sandwiching the panel, and lowers the actuator to achieve bonding pressure on the wrapped edge. The machine automates a hand operation that is relatively slow and potentially dangerous to the workers.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.

Abstract: Thermoplastic welding is an emerging technology targeted at significantly reducing the manufacturing cost of aerospace structure by eliminating fasteners and the touch labor associated with fasteners to prepare, install, and inspect the assemblies. Quality welds are highly dependent upon achieving appropriate temperatures everywhere along the bond line. The present invention is a system that evaluates the quality of the welds involving inputting an EM pulse to the embedded susceptor and listening to the acoustic response that the pulse generates to determine weld quality from the sound.

Abstract: A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: A surface treatment, especially for titanium and aluminum alloys, forms a pigmented sol-gel film covalently bonded on the metal surface to produce desired color, gloss, reflectivity, electrical conductivity, emissivity, or a combination thereof usable over a wide temperature range. The coating retains its characteristics and impact resistance following exposures to temperatures at least in the range from −321° F. to 750° F. An aqueous sol containing an alkoxyzirconium and an organosilane with an organic acid catalyst and zirconium stabilizer is applied to etched or grit blasted substrates by dipping, spraying, or drenching, to produce bonds in a single application comparable in strength and performance to standard anodize controls. Parameters affecting performance include the sol composition, the Si/Zr ratio, the ratio of sol ingredients, the concentration of the sol, the carrier solvent, solution age, catalysts, surface pretreatment, application method, curing process, and primer used.

Abstract: Thermoplastic welding is an emerging technology targeted at significantly reducing the manufacture of aerospace structure by eliminating fasteners and the touch labor associated with fasteners to prepare, install, and inspect the assemblies. Thermoplastic welds, however, suffer from significant residual tensile strain caused by differences in the coefficient of thermal expansion between the carbon fiber reinforced composite laminates and the unreinforced weld. We alleviate this strain by adding fiber reinforcement to the weld using a structural susceptor which is a laminate of alternating layers of thermoplastic resin and fiber reinforcement sandwiching a conventional metal susceptor. A further advantage of the structural susceptor is the ability to peel it in selected locations to fill the gap between the laminates, eliminating costly profilometry of the faying surfaces and the associated problem of resin depletion where machining occurred to match the faying surfaces.

Abstract: Cure and consolidation of a viscous thermoplastic resin, especially one that softens and melts at a high temperature, is improved by assisting autoclave pressurized momentum transport for compaction of the composite using high frequency, low amplitude acoustic vibration within the resin. The vibration induces shear thinning in the resin which promotes resin flow, achieves filling or collapse of voids, and assists consolidation of the composite preform.

Abstract: High performance polyester sulfone oligomers are prepared for aerospace applications by condensing mono- or difunctional crosslinkable end caps (i.e. unsaturated hydrocarbons having one or two crosslinking sites) with dicarboxylic acid halides and dialcohols (i.e. diols). Multidimensional oligomers have an aromatic hub from which the polyester chains radiate. Blends of the linear and multidimensional oligomers can be made using compatible, non-crosslinking polymers. Prepregs and composites are formed from the oligomers or blends.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: A laminated composite (multi-ply) radius filler includes a plurality of woven fabric reinforced plies cut to fill a radius gap (including, if appropriate, intentional overfill) to increase absolute strength, to increase specific strength, or to reduce cost by reducing cracking and distortion in the radius of a composite assembly. The present invention also describes the method of manufacture and method of use for such laminated composite radius filler.

Abstract: The present invention relates to an index/seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/seal pin seals via replaceable O-rings on the threaded stem of the pin to prevent low viscosity resin from exiting a mold cavity and invading the threads, bolts, pins, or other elements of the internal mandrel. The pin also assures accurate positioning of a mandrel in the die cavity while it allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system.

Abstract: A process is provided for preparing solid superconducting mixed-metal oxides whereby the superconductor can be formed into any predetermined shape by way of viscous sol precursors. The superconductors are also formed by this process into homogeneous phases.

Abstract: The invention is a radar decoy which electronically simulates objects by generating radar detectable signals over the entire microwave frequency range. The simulator includes a series of tuned, spaced diode networks for generating carrier suppressed doppler side bands. Each diode network operates at a single, different frequency. The diode networks are enclosed by a corner reflector which modulates the amplitude and the phase of an impinging radar signal. The diode networks are controlled by a switching network which turns the diodes on and off at a desire frequency to produce a doppler frequency shift and thereby simulate moving objects.

Abstract: Multicurved copper films having fine-line elements suitable for radome applications can be improved by cutting the elements with reproducible precision to close tolerance (typically line widths of 3-10±0.25 mil) using an etchant comprising a concentrated saline solution of CuCl2.

Abstract: Boeing achieves satellite diversity by having a large discrimination angle for a MEO constellation of communications satellites to limit interference in the Ku-band with GSO communications systems. Each satellite entering an exclusion zone over a GSO ground station terminates all transmissions to provide EPFD within acceptable limits. The Boeing MEO constellation preferably comprises 20 satellites, 5 in each orbit. The four orbits are inclined at about 57° with respect to the equator. Services include an Integrated Digital Service (IDS) and Backhaul Data Service (BDS) to accommodate the needs of different users.

Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can from under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.