Abstract: An improved anti-icing system for a nose cowl of an aircraft jet engine. An improved injection nozzle is provided to passively enhance the injection of hot, pressure gas from the engine into the ambient air within the nose cowl to entrain such air and cause the entrained mass to rotate within the nose cowl in swirling rotational motion and thereby cause the temperature of the skin of the nose cowl to rise sufficiently to preclude the formation of ice thereon during flight. A plurality of spaced circumferentially arranged tab members, that are preferably triangularly shaped, are canted inwardly slightly to create large scale longitudinal vortices and transverse stirring during the introduction of hot gas and thereby enhance its mixture with the ambient air within the nose cowl and thereby preclude any tendency for the formation of an area of elevated temperature in the skin of the nose cowl downstream of the position of the injection nozzle under certain severe design conditions.

Abstract: An arrangement for an aircraft propulsion system to determinably reduce or eliminate inlet cowl induced bending of a turbofan aircraft jet engine case during certain flight conditions. The arrangement includes a turbofan aircraft jet engine having an engine case with a fan case portion, a nacelle structure housing the engine and having a forward nacelle portion and a rearward nacelle portion, and a pylon structure to support the engine and the nacelle structure while permitting the forward nacelle structure to be translated forwardly from an operational position to a servicing position to permit access to the engine and its components. The forward nacelle portion is independently supported from the pylon and has an inner skin portion that sealingly engages the fan case portion of the engine case and an outer skin portion that is determinably locked to the rearward nacelle portion.

Abstract: A strain compatible attachment arrangement for releasably securing a plurality of metallic thermal protection system (TPS) panels to a space vehicle substructure to provide an outer mold line of the aeroshell of the vehicle. The TPS panels are spaced from the substructure to support aerodynamic loading on the TPS outer panel surface while isolating the outer panel surface from strains in the substructure and to isolate the vehicle substructure from direct thermal energy conductance though the outer TPS panel surface of the space vehicle. The attachment arrangement provides for a stand-off leg member to be secured at an inner end to the substructure and at its outer end to be releasably secured to a corner of a TPS panel, such panels being arranged in an edge abutting relationship.

Abstract: An improved pivoting door thrust reverser system for a turbofan aircraft jet engine having a non-translatable housing and at least one thrust reverser door being pivotable between a stowed forward thrust position and a deployed reverse thrust position. The thrust reverser door is pivotable about a first axis and a kicker plate is hinged to the door at a second axis. As the door is deployed by an actuator a spring loaded roller clamp means keeps the kicker plate clamped to the actuator body until a portion of the kicker plate positively engages the thrust reverser door and the roller clamp means is then disengaged from the actuator body.

Abstract: A translating sleeve structure for a cascade type thrust reverser system for controlling fan air for a turbofan aircraft gas turbine jet engine, such translating sleeve having a plurality of circumferentially arranged spaced blocker doors, each of which is hingedly connected to a door receptacle bonded into a single layer honeycomb panel inner wall of the sleeve at a longitudinal position which is aft of bleed ports positioned in the core cowl of the engine for periodically expelling gases from the engine at elevated temperatures and pressures. Positioning such blocker doors aft of the bleed ports precludes injury to the blocker doors or to their hinged connections to the core cowl and permits smaller uniformly sized doors to be used.

Abstract: An enhanced electrical harness arrangement for an aircraft engine that is arranged to provide optimum protection of the electrical conductors from extreme thermal, EMI, vibration and chafing problems encountered in service. The harness arrangement provides a high degree of repairability thereby ensuring a long service life for the harness wile also minimizing the time required for necessary repairs to the electrical conductor terminals. A repair splice member has an electrical conductor bundle inserted through it and is spaced from a connection of the electrical conductor bundle to an aircraft gas turbine engine.

Abstract: An automatic machine for rapidly fabricating a continuous length of metallic honeycomb core having a finite width and a precise height for use, substantially as fabricated, in bonding in a honeycomb core panel structure from a continuous strip of preformed metal foil having spaced crest and trough sections. The machine includes a fixed central foil guide that directs a continuous strip of metallic foil to a horizontally translatable guide that positions the foil strip between two banks of vertically biased banks of individual weld blocks having sets of vertically disposed weld pin electrodes. A spreader carriage that is horizontally translatable in synchronism with the translatable guide momentarily spreads individual opposed biased weld blocks to permit the foil strip to be laid against a previously received portion of such foil strip in horizontal and vertical registry of the crests and troughs of the preformed strip.

Abstract: A light weight composite layer arrangement for providing protection for a metal surface from a fire for a predetermined period of time in compliance with Federal Airworthiness Regulation 25. The arrangement which may be easily installed on a metal surface, which typically is an aluminum alloy, includes a silicone rubber sealant layer that is applied to the metal surface in an uncured non-flowing state. A layer of ceramic fiber fabric is then applied to the first silicone rubber sealant layer and due to its inherent flexibility easily conforms to the contours of the underlying metal surface. A second silicone rubber sealant layer may then be applied in its uncured non-flowing state over the ceramic fiber layer to essentially embed the ceramic fabric layer between the two silicone rubber layers. The silicone rubber sealant layers may then be cured at room temperature.

Abstract: An improvement in the translating cowl of a cascade type thrust reverser for a high bypass aircraft jet engine that provides a novel blocker door frame arrangement for the inner panel of such cowl. A plurality of forwardly opening spaced circumferentially arranged apertures are provided in the inner panel of the translating cowl and an outer edge portion of a one piece imperforate blocker door frame is sealingly inserted in each such opening by extending the edge portion between the facing sheets of the inner panel for bonding thereto. Each blocker door frame is configured to receive a blocker door that is hinged to such frame at the forward portion of the frame and which is connected by a drag link to a core cowl of the aircraft engine. An annular reinforcing section is secured to the inner surfaces of the blocker door frames and to an end slider portion of the translating cowl for longitudinal reciprocal motion.

Abstract: A novel pivoting door thrust reverser which provides a nozzle for the exhaust of a bypass engine that ensures a smooth continuous flow path for the exhaust without leakage around the pivoted upper and lower reverser doors. The upper reverser door is provided with a pair of biased cooperating crescent shaped kicker members that are biased outwardly in a controlled movement when the doors are deployed to deflect the upper portion of the reversed exhaust efflux forwardly in a predetermined direction to avoid interference with the control surfaces of the aircraft. The lower reverser door is provided with pivoted splitter plates that are biased outwardly when the door is deployed to abut and form a unitary splitter element that divides the lower exhaust efflux into two portions that are directed forwardly and away from the inlet of the engine to preclude foreign object damage to the engine.

Abstract: An actuator and safety lock system for a pivoting door thrust reverser for an aircraft jet engine. An actuator having a plunger upon which an integral carriage is secured is slidably disposed upon a central guide rod which extends from the actuator. An over center link mechanism is pivotally secured to the carriage and to the thrust reverser doors so that upon movement from an extended position that locks the associated reverser doors in a locked position to a retracted position the doors are rotated to an open, deployed position. An actuator is positioned in each side beam of the fixed structure of a thrust reverser and provides a simple mechanism to operate a target type pivoting door thrust reverser and significantly reduces the bulk of such side beam and reduces the weight and aerodynamic drag of such side beam and contained mechanisms.

Abstract: A method and product for repairing a sound attenuation structure for aircraft jet engine noise that includes a central honeycomb core having an imperforate facing sheet adhesively bonded thereto and a perforated facing sheet adhesively bonded to the opposing surface of the core with a woven wire cloth media adhesively bonded to the outer surface of the perforated sheet. The wire cloth is subject to deterioration and disbonding in service use. The method provides for the removal of the deteriorated wire cloth that has disbanded or deteriorated and, after cleaning of the perforated sheet and the associated honeycomb core area, and priming of the cleaned area of the perforated sheet replacement with a polymer film that is precoated with a pressure sensitive adhesive so that the film may be easily applied to the exposed perforated sheet area in place of the removed wire cloth.

Abstract: A structure to provide a variable nozzle for the fan air flow of a turbofan aircraft gas turbine engine with the nozzle being defined by the exit throat area defined by the aft edge of a trailing edge portion of the fan cowl and the core engine housing. A trailing edge cowl portion is slidably positioned in a rearwardly opening annular cavity in the aft end of the fan cowl for reciprocal axial translation between a deployed position to provide an enlarged exit throat area to provide enhanced performance of the aircraft engine during take off and climb to a cruising altitude and a stowed position to provide an optimum exit throat area for cruise condition of the engine. The trailing edge portion is sealably secured within the core cowl cavity to preclude any air leakage from the fan air stream of the fan duct around the trailing edge portion.

Abstract: A method and product for repairing sound attenuation structure for aircraft jet engine noise that includes a central honeycomb core having an imperforate facing sheet adhesively bonded thereto and a perforated facing sheet adhesively bonded to the opposing surface of the core with a woven wire cloth media adhesively bonded to the outer surface of the perforated sheet. The wire cloth is subject to deterioration and disbonding in service use. The method provides for the removal of the deteriorated wire cloth that has disbonded or deteriorated and, after cleaning of the perforated sheet and the associated honeycomb core area, and priming of the cleaned area of the perforated sheet replacement with a polymer film that is precoated with a pressure sensitive adhesive so that the film may be easily applied to the exposed perforated sheet area in place of the removed wire cloth.

Abstract: An improved method of anodizing aluminum which produces an oxide surface receptive to the formation of strong and durable bonds with epoxy adhesives and coatings with underlying bulk properties providing dissimilar metal separation and basic corrosion protection. The invention provides a two step electrolytic process which includes, firstly, anodizing the aluminum with a phosphoric acid solution and then, secondly, further anodizing the aluminum with a sulfuric and boric acid solution. A product is provided that has a final coating having two anodized regions. The first outer region produced by the phosphoric acid solution is about 3000 angstroms thick and is characterized by open pores which is particularly well suited for the establishment of stable, strong and durable bonds with epoxy primers and adhesives. The second base region produced by the sulfuric/boric acid solution provides a thick, tough, corrosion resistant region about 15,000 angstroms thick.

Abstract: A system for eliminating turbulence in aerodynamic surfaces, such as engine nacelles, resulting from air passing over joints and gaps in the aerodynamic surface. Basically, this system includes a suction chamber within the nacelle and extending along the inner skin wall adjacent to gaps or joints, such as around access doors, at the interface between the nose cowl and the fan cowl door, etc. Typically, a series of apertures extend through a top portion of the suction chamber below the gap to permit air to pass from the gap to the suction chamber. At least one duct communicates with the chamber and extends to a suction pump. In operation, the pump sucks air through the duct, suction chamber, apertures and gap, to prevent the formation of a transition from low drag laminar flow to high drag turbulent flow at the gap.

Abstract: A laminar flow control arrangement for use in a nacelle for an aircraft turbine engine. The nacelle has a microporous outer skin in the area where air flow over the skin is to be maintained in laminar flow. A honeycomb core is bonded to the inner surface of the nacelle skin. A perforated back skin is bonded to the inner surface of the core. Several closely spaced circumferential flutes open to the back skin are fastened to the back skin. At least one collector duct is connected to the flutes and a suction pump. In operation, the suction pump pulls air through the ducts and flutes, causing air to be sucked inwardly through the microporous skin thereby maintaining laminar, rather than turbulent, flow over a large part of the nacelle during aircraft take-off and cruise operation. In addition, a chamber is preferably provided in communication with any gaps in the nacelle skin in the area where laminar flow is desired.

Abstract: A method of producing laminated plastic tooling suitable for use in forming sheet material by techniques such as stretch forming, hydroforming, etc. The detailed overall method comprises the steps of designing the desired tool configuration (typically by computer-aided design), machining a suitable tool baseplate, cutting plastic boardstock into suitably sized boards, trial stacking the boards to the general tool configuration, determine that stack has the correct dimensions, unstacking and cleaning the board surfaces, restacking with an adhesive between all abutting boards with clamping as necessary, curing the adhesive, machining the stack to the required configuration under numerical control, sand the shaped tool to the desired surface smoothness, check the tool with a coordinate measuring machine and coat the tool with any desired surface coating, such as an anti-chafe coating. The resulting tool is highly accurate and is capable of long-term production use.

Abstract: A method and apparatus for expanding and contouring honeycomb preforms into compound curved honeycomb core sheets. Honeycomb preforms are provided having a plurality of face to face, contiguous, strips bonded together at selected narrow areas such that when strips along opposite edges are moved away from each other a sheet having a repeating array of regular hexagonal cells results. Opposite edge strips are secured to two spaced arms located adjacent to a freely rotatable crowned drum having a surface contour corresponding to the desired honeycomb sheet configuration. One of said arms is pivoted about the drum axis. As the arms are moved apart, a flat partially expanded honeycomb sheet initially develops. As arm movement continues, the sheet then comes into sliding contact with the drum surface. When cell expansion is completed, during the final shaping and setting phase, the honeycomb core sheet is in full contact with the drum surface.

Abstract: A thrust reverser for use with fan jet type aircraft gas turbine engines. A ring around the aft edge of the nacelle is translatable aft to uncover a series of cascade sets, each of which includes a plurality of turning vanes that direct air passing through the cascades in a reverse direction. The actuation system includes a hydraulic cylinder or the like in islands between cascade sets. A blocker door assembly is positioned within the nacelle adjacent to each cascade set during normal engine operation, with the blocker door forming a portion of the inner streamlined wall of the nacelle. The forward end of the door is hingedly secured to a cascade door support and does not move during deployment of the ring. The aft end of the door is hingedly secured to a link, the other end of which is secured to the moving ring. As the ring is translated aft, the door pivots to a position blocking at least part of the air flow through the duct between nacelle and engine core and directs it outwardly though the cascade set.