Abstract: An apparatus and method for electroplating a graphite-epoxy workpiece in-situ. An electroplating assembly includes a rigid base that is retained a fixed distance about the surface region by insulated standoff legs. A flexible vacuum bag is coupled to the graphite-epoxy workpiece with a fluid-tight seal. The vacuum bag surrounds the surface region and encloses the rigid base to form a plating chamber. A supply chamber, containing a plating fluid, is coupled to the plating chamber by a fluid-tight tubing. A storage chamber is coupled to the plating chamber by a fluid-tight tubing. A vacuum source is coupled by tubing to the supply chamber and to the storage chamber. Valves in each tubing permit the selective coupling of the vacuum source and plating chamber to either the supply chamber or the storage chamber. Electroplating is carried out while plating fluid is drawn by the vacuum, from the supply chamber into the plating chamber and into the storage chamber.

Abstract: A rope saw cutting apparatus is partially insertable through a bore in a composite panel to scarf the panel without access to the blind side of the panel. The same apparatus can also be used to prepare a tapered repair plug to close tolerance to repair the scarfed panel. The apparatus preferably uses a rope saw blade to perform a plunge cut followed by a circumferential cut which has a desired taper or scarf angle.

Abstract: A method and apparatus for producing a controlled tapered cut on a curved surface in preparation for repairing a damaged area on the surface. The apparatus includes a cutting tool which is revolved around the damaged area at incrementally smaller radii until the entire damaged area and the periphery thereof has been machined. The cutting tool is maintained in a position such that the surface of the workpiece is machined along a tapered plane which is disposed at a predetermined angle with respect to the tangent to the surface of the workpiece. As the normal to the workpiece surface changes its angular orientation, the position of the cutting tool is correspondingly adjusted to machine the workpiece. The cutting tool is disposed in a channel member extending normal to the surface in such a manner that the angular position thereof can be adjusted.

Abstract: Material is removed from a panel (10) in the region surrounding an undesired opening (12) caused by damage or incorrect forming or wear of a fastener hole. The resulting prepared opening (21) has a bearing load transmitting sidewall surface that is substantially perpendicular to the outer surface (11) of the panel (10) and tapers slightly in an inward direction relative to the surface (11). The prepared opening (21) may extend all the way through the panel (10) or only part way through. A prefabricated insert (22) is positioned in the prepared opening (21) and bonded to the load transmitting surface. The bonding may be accomplished by applying an adhesive or using a fusing procedure. The insert (22) may have a constant angle of taper, preferably about two degrees, or may be concavely curved in the direction of taper. The insert (22) may be trimmed prior to and/or following the bonding procedure. A new fastener hole may be drilled through the bonded insert (22).

Abstract: The present invention contemplates an apparatus for producing a controlled taper cut in a workpiece. The apparatus includes a plurality of horizontal support members for supporting a slidable gantry member and a rotatable support member disposed within the gantry member in a substantially vertical position. The rotatable vertical support member is adjustable in a vertical direction within the gantry member. A router support beam is pivotally attached to the distal end of the vertical support member at the approximate midsection of the router support beam. The apparatus also includes a cutting tool slidably mounted from the support beam.

Abstract: A method and apparatus for a containment for treating a surface, such as on an aircraft, in-situ. A treating compartment having a conductive screen and an insulating fiber member therein is held in place on the surface by a retaining membrane attached around the periphery of the treating compartment. The treating fluid is held in a separate container that is coupled to the treating compartment. A suction is placed on the treating compartment which pulls the membrane, screen and fiber against the surface and into contact with each other. The suction also pulls the treating fluid into the treating compartment. The fluid spreads evenly along the insulating member disposed between the screen and the surface under treatment. A voltage potential difference is placed between the conductive screen and the surface, causing current to run through the treating fluid to provide treatment of the surface.

Abstract: A hole (12) in a panel (10) of composite material is cut by a router or the like to dress it into a rounded hole (12'). A cavity is routed or otherwise formed in the panel (10) to extend across the dressed hole (12') in the direction of maximum tension loads in the panel (10). An insert (16) is secured in the cavity (18). The insert (16) and the cavity (18) have matching plan forms and each has a relatively narrow central portion and enlarged end portions (42, 44). The end portions (42, 44) of the insert interlock with end portions of the cavity (18) such that tension loads will be carried by the insert (16) from a region of the wall (10) on one side of the hole (12') across the hole (12') to a region of the wall (10) on the opposite side of the hole (12').

Abstract: A hole (12) in a panel (10) of composite material is cut by a router or the like to dress it into a rounded hole (12'). A cavity is routed or otherwise formed in the panel (10) to extend across the dressed hole (12') in the direction of maximum tension loads in the panel (10). An insert (16) is secured in the cavity (18). The insert (16) and the cavity (18) have matching plan forms and each has a relatively narrow central portion and enlarged end portions (42, 44). The end portions (42, 44) of the insert interlock with end portions of the cavity (18) such that tension loads will be carried by the insert (16) from a region of the wall (10) on one side of the hole (12') across the hole (12') to a region of the wall (10) on the opposite side of the hole (12').

Abstract: A method and apparatus for a containment for treating a surface, such as on an aircraft, in-situ. A treating compartment having a conductive screen and an insulating fiber member therein is held in place on the surface by a retaining membrane attached around the periphery of the treating compartment. The treating fluid is held in a separate container that is coupled to the treating compartment. A suction is placed on the treating compartment which pulls the membrane, screen and fiber against the surface and into contact with each other. The suction also pulls the treating fluid into the treating compartment. The fluid spreads evenly along the insulating member disposed between the screen and the surface under treatment. A voltage potential difference is placed between the conductive screen and the surface, causing current to run through the treating fluid to provide treatment of the surface.

Abstract: A bolted repair for curved surfaces of an aircraft structure includes a plurality of relatively thin, flexible plates that are bent to conform to the surface, either individually or as a group. After the plates have been bent to conform to the surface, layers of adhesive are applied between adjacent plates to bond the plates to each other. The resulting stack of bonded plates is then secured to the structure with fasteners extending through attachment holes in the stack and structure. The plates may be bent by first securing a portion of a stack of plates to the structure and then bending the stack of plates so that the plates progressively conform to the surface of the structure. As areas of the stack of plates conform to the surface of said structure, the areas are temporarily secured to the structure with temporary fasteners until the entire surface of the stack of plates has been bent to conform to the surface of the structure.