Abstract: A composite fastener, preferably in the form of a rivet, which comprises a shank having a first head integrally formed on one end thereof, the shank and head formed of a high temperature thermoplastic matrix material selected from the group consisting of a polyether ether ketone resin and a polyamide imide resin, and having continuous reinforcing fibers, such as graphite fibers, axially oriented in substantially parallel relation throughout the shank, the fibers being flared and extending continuously into the head and substantially evenly flared and swaged therein, thereby forming a fastener having high shear and high tensile characteristics.

Abstract: Process for producing a cap flange structure, particularly a sinewave I-beam structure comprises joining together a pair of metal sheets in a predetermined area spaced from the opposite outer edge portions of the sheets, and leaving the area between the adjacent sheets along the two opposite edge portions unattached. The joined together portion of the resulting assembly is formed into a sinewave configuration which forms the web of the I-beam structure. The unattached edge portions of the assembly of adjacent sheets is introduced into a die cavity and the die cavity is heated and a gas under pressure is inserted into the area between the sheets of the unattached edge portions, and expanding the sheets of the unattached edge portions into the shape of the die cavity against the wall of the cavity by an accordion expansion without any substantial stretching or thinning of the sheets, while simultaneously moving such sheets in the die cavity.

Abstract: A clamp assembly for efficient mounting of wire bundles, hydraulic tubing and other extended service conduits is comprised of a unitary support plate having a triad of support clamp elements formed of strong, resilient metal or plastic with appropriately sized securable openings and means for attaching it to structure in confined or space critical areas or volumes.

Abstract: A blind fastener is disclosed comprised of a rivet having an axial internally threaded bore and a threaded pin to be received within the threaded bore of the rivet. The rivet has a head at one end thereof, and preferably a chamfered bore at the other end thereof. The rivet is provided with a plurality of cuts in the outer wall of the rivet, extending axially along the wall of the rivet and forming zones of weakness in the rivet wall. The threaded pin has an outwardly protruding portion, preferably bell-shaped, and a head at the other end of the pin, such as a square head, for threading the pin through the rivet. When the pin is threaded into the rivet, the protruding bell-shaped end portion thereof is received within the chamfered bore of the rivet. The rivet-pin assembly is positioned in a hole of parts to be fastened.

Abstract: A high strength composite piano hinge having an integral structure and of particular utility in aircraft, formed of two similar half portions each comprising a flange and an integrally formed loop, the integral flange and loop comprised of composite tape, fabric or filament, formed of fiber reinforced heat curable resin such as graphite fibers impregnated with epoxy resin. The loop can be formed in one embodiment by wrapping the tape or fabric around a pin, with the flanges of the hinge secured together, as by curing the composite. Stitching can be provided across the flanges adjacent to the loop, to reinforce the loop, and prevent peeling of the composite laminates or plies. The thickness of the flanges can be equal to or smaller than the outer diameter of the loop. Additional composite material or laminates can be co-cured to the flanges.

Abstract: The invention involves a novel method for forming sine wave I-beams, and other sandwich structures having a curved core. The core pieces are flat prior to forming. The sandwich structure consists of two face pieces and two core pieces, wherein the core pieces are similar in shape to each other. The pieces are placed in a stack. Each core piece has two lip portions. The lip portions are extensions of the core pieces, and have a curved shape prior to forming that does not change during forming. The core pieces are joined to each other along one lip portion, and each core piece is joined to one face piece along the other lip portion. The shape of the curved core sheets and the shape of the lip portions determine the curvature of the formed core. The core pieces are unfolded and expanded in forming dies at elevated temperatures and pressures to form the desired structure.

Abstract: The invention concerns novel close-outs for sandwich structures and fabrication methods. The sandwich structures are formed by superplastic forming, accordion expansion, or a combination thereof. The close-out structure is formed from a plurality of flat sheets and members of predesigned shapes and sizes that are positioned in such a manner as to form high strength structures after unfolding and expansion. The corners of the close-out structure are either rounded or angled.

Abstract: A thick metallic sandwich structure having improved strength properties is formed by superplastic forming and selective metallurgical bonding. The structure normally includes at least five sheets (including two face sheets and at least three core sheets), wherein portions of the core sheets are bonded together to form a partially layered core.