Abstract: A thermal and vacuum assessment method includes providing a composite part having a repair area, installing a vacuum bag over the repair area, drawing a vacuum on the vacuum bag, testing for air leaks in the vacuum bag, heating the vacuum bag and obtaining a thermal image of the repair area.

Abstract: Systems and methods for configuration management in an article of manufacture disclosed. In one embodiment, a system for documenting a configuration of an article of manufacture includes an identifier positioned on the article of manufacture. A local positioning system is used to determine a positional location of the identifier on the article of manufacture. A multifunction apparatus configured to interactively communicate with the identifier and the local positioning system is present that is operable to communicate configuration information to the identifier.

Abstract: A patch for a structure has a rework area with an inconsistency formed therein. The patch comprises a patch body having at least two regions including a fail-safe region and a safe-life region encompassing the fail-safe region. The safe-life region has a mode I interlaminar fracture toughness that is less than the mode I interlaminar fracture toughness of the fail-safe region.

Abstract: A deterministic non-destructive evaluation system for composite damage assessment and repair includes structure of interest, non-destructive evaluation data and strength test data obtained on the structure of interest, finite element analysis performed on a structural model modified by the non-destructive data and the strength test data, a strength-to-indication correlation based on the finite element analysis and deterministic non-destructive evaluation predictions and recommendations based on the strength-to-indication correlation.

Abstract: A composite laminate comprises a stack of unidirectional fiber reinforced composite plies arranged in a fiber orientation sequence providing the laminate with quasi-isotropic properties.

Abstract: A patch for reworking an inconsistent area of a composite structure comprises a composite laminate patch and a bond joint between the patch and the structure. The bond joint including at least first and second regions respectively having differing properties for releasing strain energy around the inconsistent area at different rates.

Abstract: A patch for reworking an inconsistent area in a composite structure includes a composite laminate patch adapted to cover the inconsistent area and bonded to the structure by a layer of adhesive. The patch includes a plurality of composite plies having a tapered cross section, and at least first and second regions respectively having differing fracture toughnesses.

Abstract: A patch for reworking an inconsistent area in a composite structure includes a composite laminate patch and a layer of adhesive for bonding the laminate patch to the composite structure. The laminate patch has at least first and second regions for releasing strain energy around the inconsistent area respectively at different rates.

Abstract: Methods and systems for structural and component health monitoring are provided. A system includes a plurality of sensor systems positioned about an object to be monitored and a processing system communicatively coupled to at least one of said plurality of sensor systems wherein the processing system includes an ontology and reasoning module configured to model the object to be monitored, reason about the received sensor data associated with the object to be monitored and reason about the relationships between the received sensor data to fuse the data into contextual information for the overall object to be monitored and a contextual analyzer configured to transmit the received sensor data to said ontology and reasoning module and to store the information into a contextual information database.

Abstract: A system for structural assessment is described that comprises a plurality of sensors and a surface covering for at least a portion of a structure. The sensors are arranged in a pattern and attached to the surface covering. The surface covering is attached to a surface of a structure, and the sensors are configured to provide signals relating to the integrity of the structure to an external device.

Abstract: A system for structural assessment is described that comprises a plurality of sensors and a surface covering for at least a portion of a structure. The sensors are arranged in a pattern and attached to the surface covering. The surface covering is attached to a surface of a structure, and the sensors are configured to provide signals relating to the integrity of the structure to an external device.

Abstract: Methods and systems for structural and component health monitoring are provided. A system includes a plurality of sensor systems positioned about an object to be monitored and a processing system communicatively coupled to at least one of said plurality of sensor systems wherein the processing system includes an ontology and reasoning module configured to model the object to be monitored, reason about the received sensor data associated with the object to be monitored and reason about the relationships between the received sensor data to fuse the data into contextual information for the overall object to be monitored and a contextual analyzer configured to transmit the received sensor data to said ontology and reasoning module and to store the information into a contextual information database.

Abstract: Systems and methods for inspecting electrical conductivity in composite materials having conductive structures are disclosed. In one embodiment, a method for inspecting a conductive structure in a composite bonding region comprises positioning an apparatus operable to induce a current on the conductive structure. The apparatus is positioned on the conductive structure at a first selected position proximate to the bonding region. The method also comprises energizing the apparatus to provide a desired induced current in the conductive structure. The method further comprises detecting an impedance property value of the apparatus. Accordingly, the method additionally comprises positioning the apparatus at a second selected position if the impedance value is within a predetermined range of values. Alternatively, if the impedance value is not within the predetermined range, the method additionally comprises documenting the first selected position.

Abstract: Systems and methods for inspecting electrical conductivity in composite materials having conductive structures are disclosed. In one embodiment, a system of inspecting electrical conductivity in an electrical bonding region includes a coil coupled to an alternating current source that is configured to induce a current in a conductive structure within the region. A processor is coupled to the coil that is operable to detect an impedance property value from the coil that results from the current induced in the conductive structure.

Abstract: A system and method for assessing the ability to rework a composite structure with a heat induced inconsistency is provided. The method includes acquiring information related to the composite structure with a heat induced inconsistency; comparing the information of the composite structures with a heat induced inconsistency with heat induced inconsistency assessment signatures stored in a look up table; correlating the output of the compared information with material master curves; analyzing the composite structures with a heat induced inconsistency to determine the remaining structural capability; determining if the composite structures with a heat induced inconsistency requires immediate rework or replacement; and displaying the results.

Abstract: Systems and methods for inspecting electrical conductivity in composite materials having conductive structures are disclosed. In one embodiment, a system of inspecting electrical conductivity in an electrical bonding region includes a coil coupled to an alternating current source that is configured to induce a current in a conductive structure within the region. A processor is coupled to the coil that is operable to detect an impedance property value from the coil that results from the current induced in the conductive structure.

Abstract: Systems and methods for configuration management in an article of manufacture disclosed. In one embodiment, a system for documenting a configuration of an article of manufacture includes an identifier positioned on the article of manufacture. A local positioning system is used to determine a positional location of the identifier on the article of manufacture. A multifunction apparatus configured to interactively communicate with the identifier and the local positioning system is present that is operable to communicate configuration information to the identifier.

Abstract: We control the cure temperature within ±15° F. (8° C.) for organic resin matrix composites with a thermal diffusion apparatus which contains a liquid fluid transfer medium to convey heat from an immersed resistance heater to the repair site. Uniform heating of the repair site occurs despite differences in the underlying structure of the repair site, such as the location of underlying spars or other structural features or variations in the skin thickness, because of natural convection within the heat transfer fluid. The fluid transfer medium preferably is a solid, at ambient temperature, but melts at a relatively low, elevated temperature below the cure temperature. We achieve uniform heating that is necessary for suitable repairs to temperatures of at least about 350° F. (177° C.) and simplify monitoring of the repair site temperatures because of the uniform heating we naturally achieve.

Abstract: Apparatus for applying heat to a patch on a composite structure repair site includes a sealed bladder containing both a thermally conductive fluid and a heating element in thermal contact with the fluid. The heating element which comprises a flexible sheet having an electrical resistance wire uniformly placed thereon can be immersed in the fluid or otherwise in direct thermal contact therewith. Electrical power is applied to the heating element by conductors passing through the bladder surface. The heating element of disclosed structure can be attached to seal the bladder interior into two reservoirs, to permit fluid flow throughout the bladder or to form at least one outer surface of the bladder. Flexible supports can also be attached from the heating element to an interior bladder surface to maintain spacing between the heating element and the surface.

Abstract: Apparatus for applying heat to a patch on a composite structure repair site is disclosed. The apparatus includes a sealed bladder containing both a thermally conductive fluid and a heating element in thermal contact with the fluid. The heating element which comprises a flexible sheet having an electrical resistance wire uniformly placed thereon can be immersed in the fluid or otherwise in direct thermal contact therewith. Electrical power is applied to the heating element by conductors passing through the bladder surface. The heating element of disclosed structure can be attached to seal the bladder interior into two reservoirs, to permit fluid flow throughout the bladder or to form at least one outer surface of the bladder. Flexible supports can also be attached from the heating element to an interior bladder surface to maintain spacing between the heating element and the surface.