Abstract: An anti-icing system includes a nozzle assembly, a bleed air supply, a bleed control valve assembly, and a controller. The bleed air supply is configured to direct pressurized bleed air to the nozzle assembly. The bleed air supply includes a first pressure sensor configured to measure a first pressure of the pressurized bleed air. The bleed control valve assembly includes a control valve and a valve actuator. The control valve is positionable to control a flow rate of the pressurized bleed air. The valve actuator is configured to control a position of the control valve. The controller is configured to identify a power condition of the bleed air supply as a first power condition or a second power condition and control the valve actuator to position the control valve in a fully opened position for the first power condition and in a predetermined position based on the first pressure for the second power condition.

Abstract: A center plug for attenuating noise in a gas turbine engine includes an inner skin, the inner skin having a substantially cylindrical shape and extending along an axial centerline; an outer skin positioned radially outside the inner skin; a forward bulkhead disposed proximate a forward end of the inner skin, the forward bulkhead connected to and extending radially outward from the inner skin; an aft bulkhead disposed proximate an aft end of the inner skin, the aft bulkhead connected to and extending radially outward from the inner skin; and a first resonator cavity disposed within a volume defined by the inner skin, the outer skin and the forward bulkhead and the aft bulkhead, the first resonator cavity including a first perforated disk extending between the inner skin and the outer skin and forming a first sub-cavity and a second sub-cavity.

Abstract: An end effector for the through thickness reinforcement of a fibrous preform includes a needle cleaning material configured to contact a needle to clean resin from the needle during or between through thickness reinforcement operations. The needle cleaning material may extend from a presser foot toward the needle. The needle cleaning material may slidingly engage the needle in response to movement of one of the needle or the presser foot moving (e.g., translating and/or rotating) with respect to the other of the needle or the presser foot.

Abstract: A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a support structure moveable with respect to the female forming tool, and at least one bladder coupled to the support structure and configured to be received into the die recess. The support structure is configured to move the bladder(s) with respect to the female forming tool. The bladder(s) is/are configured to be inflated to apply a compressive force to compress and form a fibrous preform between the bladder(s) and the female forming tool.

Abstract: A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is clamped to a floating plate using a bladder-activated clamp. The floating plate is translated in a first direction to tension the preform into a shaped body. A plurality of compressing bladders are activated to apply compressive forces to the preform.

Abstract: A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a first die half configured to be received by the die recess, a second die half configured to be received by the die recess, an expander tool coupled between the first die half and the second die half. The expander tool is configured to move the first die half laterally toward a first side of the female forming tool away from the second die half to compress the fibrous preform between the first die half and the female forming tool. The expander tool is further configured to move the second die half laterally toward a second side of the female forming tool away from the first die half to compress the fibrous preform between the second die half and the female forming tool.

Abstract: An end effector for needling a fibrous preform includes a body (or head), a plurality of articulating presser feet mounted to the body and moveable with respect to the body, and a plurality of articulating needles mounted to the body and moveable with respect to the body. The needles may be configured to move between an extended position and a retracted position. The presser feet may be configured to move between an extended position and a retracted position. The end effector presser feet may conform to complex geometries of a fibrous preform. The end effector may control needling depth, needling density, applied tension and/or pressure on the fibrous preform, and needle angle.

Abstract: An end effector for the through thickness reinforcement of a fibrous preform includes a plurality of spray nozzles configured to direct a needle cleaning fluid to a needle to clean resin from the needle between through thickness reinforcement operations. The plurality of spray nozzles may extend from a presser foot toward the needle. The needle cleaning fluid may contact the needle while the needle or the presser foot move (e.g., translate and/or rotate) with respect to the other of the needle or the presser foot. The plurality of spray nozzles can be incorporated into the end effector. The plurality of spray nozzles can be incorporated into a needle cleaning station into which a portion of the robotic end effector can be moved for cleaning the needles.

Abstract: A manufacturing method is provided. The manufacturing method arranges a first surface of a first composite preform component to align with a first surface of a second composite preform component; attaches the first surface of the first composite preform component to the first surface of the second composite preform component to form a complex composite structure; and densifies the complex composite structure as one, complete complex composite structure.

Abstract: A method is provided for manufacturing a container. During this method, a baffle is provided. The baffle is configured from or otherwise includes baffle thermoplastic material. A sidewall is formed using an additive manufacturing device. The sidewall is bonded to the baffle during the forming of the sidewall. The sidewall circumscribes the baffle. The sidewall is configured from or otherwise includes sidewall thermoplastic material. The container includes an internal chamber, the baffle and the sidewall. The sidewall forms an outer peripheral boundary of the internal chamber. The baffle is arranged within the internal chamber.

Abstract: An acoustic panel includes a front skin comprising a plurality of apertures, a back skin, and a core positioned between the front skin and the back skin. The core includes at least one primary core portion including a honeycomb structure defining a plurality of cavities extending from the front skin to the back skin. The core further includes a secondary core portion external to the at least one primary core portion and including a foam structure extending from the front skin to the back skin.

Abstract: An acoustic panel is provided that includes a perforated first skin, a second skin and a core. The core is between and connected to the perforated first skin and the second skin. The core includes a plurality of chambers, a first corrugated structure and a second corrugated structure. The chambers includes a first chamber. The first chamber extends from the perforated first skin, through the first corrugated structure and the second corrugated structure, to the second skin.

Abstract: A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.

Abstract: A manufacturing method is provided. A first end of a set of spars is coupled to a first skin of a flight control surface. A set of ribs is interlocked with the set of spars and a first end of the set of ribs is coupled to the first skin. A second skin is coupled to a second end of the set of spars and a second end of the set of ribs.

Abstract: An end effector for welding composite components includes an end effector housing and a welding member mounted to the end effector housing. The end effector further includes a leading roller mounted to the end effector housing forward of the welding member and at least one follower roller mounted to the end effector housing aft of the welding member. The end effector further includes at least one first cooling air jet positioned to direct a first stream of cooling air toward the at least one follower roller.

Abstract: A latch assembly includes a housing including a first housing portion and a second portion including. The latch assembly further includes a first latch member disposed within the first housing portion and configured for translation along the latch axis. The first latch member includes at least two rotatable arms configured to rotate between an arm retracted position and an arm extended position in which the at least two rotatable arms extend in a first direction away from the latch axis. The latch assembly further includes a second latch member disposed within the second housing portion and configured for translation along the latch axis. The second latch member includes a second latch member body including a base portion and at least one axially extending portion extending from the base portion in a second direction toward the interior surface of the lateral wall.

Abstract: A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. The apertured first plate is configured from or otherwise includes first plate metal. A first sheet is bonded to the apertured first plate to form a first grid structure. The first apertures extend through the apertured first plate to the first sheet. The first sheet is configured from or otherwise includes first sheet metal.

Abstract: A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.

Abstract: A method for forming a fiber-reinforced thermoplastic control surface includes forming first and second skins from a fiber-reinforced thermoplastic resin. The method further includes overmolding fiber-reinforced thermoplastic features onto the first skin and/or second skin, including stiffener structures, sidewalls, and/or hinges. The method further comprises welding or consolidating the first and second skins together, along with the associated internal features overmolded thereon to form a single-piece, stiffened, fiber-reinforced thermoplastic control surface.

Abstract: A nacelle may comprise a fixed structure and a translating structure configured to translate relative to the fixed structure. A first drive system may be operationally coupled to the translating structure. The drive system may comprise a primary actuator coupled to the fixed structure and including a primary rod and a primary gear rotationally coupled to the primary rod, a torque shaft rotationally coupled to the primary gear, and a secondary actuator operationally coupled to the primary actuator via the torque shaft.