Abstract: A hole plug that can be used during rework or repair of a composite fiber assembly includes various features that allow placement of a vacuum force to the surface being reworked or repaired. In some implementations, the hole plug can include a plurality of nubs positioned around a shank. The nubs can secure the hole plug to the composite fiber assembly until a cure of an adhesive. The hole plug can further include a plurality of longitudinally oriented grooves extending along the shank and positioned between the plurality of nubs, and can include a notch positioned circumferentially around the shank. The grooves and notch can be used as adhesive carriers that assist with dispersal of a sufficient volume of the adhesive onto other portions of the shank and the composite fiber assembly during insertion of the hole plug into a hole in the composite fiber assembly.

Abstract: A hole plug that can be used during rework or repair of a composite fiber assembly includes various features that allow placement of a vacuum force to the surface being reworked or repaired. In some implementations, the hole plug can include a plurality of nubs positioned around a shank. The nubs can secure the hole plug to the composite fiber assembly until a cure of an adhesive. The hole plug can further include a plurality of longitudinally oriented grooves extending along the shank and positioned between the plurality of nubs, and can include a notch positioned circumferentially around the shank. The grooves and notch can be used as adhesive carriers that assist with dispersal of a sufficient volume of the adhesive onto other portions of the shank and the composite fiber assembly during insertion of the hole plug into a hole in the composite fiber assembly.

Abstract: A method for repairing a composite structure using pre-cured plugs. In accordance with one method, composite material is removed from a first composite laminate to form a cavity bounded by a tapered internal surface that extends from an opening at an outer mold line surface of the first composite laminate. In addition, a second composite laminate is machined to form a plug having a tapered surface. Then the plug is placed so that the tapered surface of the plug opposes the tapered internal surface of the first composite laminate. Thereafter, the tapered surface of the plug is bonded to the tapered internal surface of the first composite laminate. Optionally, a hole is drilled in the plug for receiving a fastener.

Abstract: A method of bonding composite structures includes positioning a second structure at a bonding site on a first structure and coupling a first vacuum bag to the first structure such that the first vacuum bag covers the bonding site. The method also includes applying a vacuum to the first vacuum bag to induce a first mechanical force to the second structure via the first vacuum bag. A second vacuum bag is coupled to the first structure such that second vacuum bag covers the second structure and at least a portion of the first vacuum bag. The method further includes applying a vacuum to the second vacuum bag to induce a second mechanical force to the second structure via the second vacuum bag.

Abstract: Provided is a method a method for reworking an article. The method includes forming a patch over an area of a composite structure requiring rework. The forming includes placing a first film-adhesive over the area of the composite structure requiring rework, wherein the first film-adhesive extends over a first surface area of the structure including beyond an entirety of the area requiring rework, placing a first pre-cured ply stack over the first film-adhesive, wherein the first pre-cured ply stack extends over a second surface area of the composite structure; placing a second film-adhesive over the first pre-cured ply stack, wherein the second film-adhesive extends over a third surface area of the composite structure; and placing a second pre-cured ply stack over the second film-adhesive, wherein the second pre-cured ply stack extends over a fourth surface area of the composite structure.

Abstract: A hole plug that can be used during rework or repair of a composite fiber assembly includes various features that allow placement of a vacuum force to the surface being reworked or repaired. In some implementations, the hole plug can include a plurality of nubs positioned around a shank. The nubs can secure the hole plug to the composite fiber assembly until a cure of an adhesive. The hole plug can further include a plurality of longitudinally oriented grooves extending along the shank and positioned between the plurality of nubs, and can include a notch positioned circumferentially around the shank. The grooves and notch can be used as adhesive carriers that assist with dispersal of a sufficient volume of the adhesive onto other portions of the shank and the composite fiber assembly during insertion of the hole plug into a hole in the composite fiber assembly.

Abstract: A method of bonding composite structures includes positioning a second structure at a bonding site on a first structure and coupling a first vacuum bag to the first structure such that the first vacuum bag covers the bonding site. The method also includes applying a vacuum to the first vacuum bag to induce a first mechanical force to the second structure via the first vacuum bag. A second vacuum bag is coupled to the first structure such that second vacuum bag covers the second structure and at least a portion of the first vacuum bag. The method further includes applying a vacuum to the second vacuum bag to induce a second mechanical force to the second structure via the second vacuum bag.

Abstract: Provided is a method a method for reworking an article. The method includes forming a patch over an area of a composite structure requiring rework. The forming includes placing a first film-adhesive over the area of the composite structure requiring rework, wherein the first film-adhesive extends over a first surface area of the structure including beyond an entirety of the area requiring rework, placing a first pre-cured ply stack over the first film-adhesive, wherein the first pre-cured ply stack extends over a second surface area of the composite structure; placing a second film-adhesive over the first pre-cured ply stack, wherein the second film-adhesive extends over a third surface area of the composite structure; and placing a second pre-cured ply stack over the second film-adhesive, wherein the second pre-cured ply stack extends over a fourth surface area of the composite structure.

Abstract: A computer-implemented method includes receiving damage information by a user interface device and quantifying at least one parameter of the damage. A structural analysis is performed to determine a damage allowability based on the parameter. An output result of the structural analysis is displayed from the user interface device. The system includes a compliance system having a database of structural information relating to the structure. A computer enabled user interface device is coupled to the compliance system. The user interface device includes a processor configured to access the structural information and display a location of the damage based on the structural information. The processor is configured to quantify at least one parameter of the damage. The processor is further configured to perform a structural analysis to determine a damage allowability based on the parameter and display a maintenance instruction based on the damage allowability.