Abstract: A structural health monitoring system includes a first component and a second component associated at a joint. At least one sensor is embedded within the joint to monitor a health of at least one of the first component, the second component, and the joint.

Abstract: A method of repairing a contoured structure is provided. The method includes forming and curing on the contoured structure an armature formed of materials that are curable at a temperature lower than a service limit temperature of materials of the contoured structure and removing the armature from the contoured structure and placing the armature with prepregs laminated thereon in an oven to heat cure the armature and the prepregs to form a repair patch.

Abstract: A unitary core panel for a composite sandwich structure includes a plurality of cell walls defining a plurality of core cells, the plurality of cell walls extending across a thickness of the core, the plurality of core cells including one or more defined structural nonuniformities resulting in nonuniform properties of the core panel. A method of forming a core panel for a composite sandwich structure includes determining structural requirements of the core panel, designing the core panel to satisfy the structural requirements with one or more local nonuniformities in the core panel, and manufacturing the core panel as a unitary core panel with the one or more local nonuniformities.

Abstract: A fiber-optic sensor system includes a structure having a fiber-optic cable operatively connected thereto. The system includes a network controller with an interrogator operatively connected to the fiber-optic cable to receive optical energy indicative of a characteristic of the structure therefrom and convert optical energy to electrical energy and electrical energy to optical energy for data communication. A sensor and/or a data source are operatively connected to the fiber-optic cable through the network controller to transmit data through the fiber-optic cable and receive data therefrom.

Abstract: An apparatus and method for bonding a member to a substrate is disclosed. A surface of the member is prepared by applying an element to the surface. The element includes a dye agent that changes color when exposed to a level of plasma radiation consistent with preparing the surface for bonding. The surface is exposed to the plasma radiation and is inspected to see whether or not a change in a color of the dye agent occurs. After the dye agent changes color; the surface is bonded to the substrate.

Abstract: A method of repairing a composite structure or forming a component of a part is provided. The method includes releasably laying up of a first member that is curable at a first temperature at or above a constrained temperature limit of the composite structure or part, releasably laying up of a second member on the first member that is curable at a second temperature below the constrained temperature limit, curing the second member into a scaffold at the second temperature at the composite structure or part, transferring the first member and the scaffold remotely from the composite structure or part for first member curing and removing the cured first member from the scaffold for bonding of the cured first member to the composite structure or part.

Abstract: A bond is provided and includes a substrate having a first surface, a bond structure having a second surface and a bonding assembly adhesively disposed between complementary portions of the first and second surfaces. The bonding assembly includes discrete bond elements configured to form first and second adhesive zones with local sections of the complementary portions of the first and second surfaces. The discrete bond elements are displaced such that the respective first and second adhesive zones are correspondingly displaced and define discontinuous bond lines.

Abstract: A joint and a method of bonding a first member to a second member are disclosed. The joint includes a multi-layer adhesive material between the first member and the second member. The multi-layer adhesive material includes at least one adhesive material that is applied to one of the first member and the second member. The multi-layer adhesive material also includes a heating element for heating the at least one adhesive material and at least one permeable layer for allowing air to escape from between the first member and second member during heating of the at least one adhesive material.

Abstract: An apparatus and method for bonding a member to a substrate is disclosed. A surface of the member is prepared by applying an element to the surface. The element includes a dye agent that changes color when exposed to a level of plasma radiation consistent with preparing the surface for bonding. The surface is exposed to the plasma radiation and is inspected to see whether or not a change in a color of the dye agent occurs. After the dye agent changes color; the surface is bonded to the substrate.

Abstract: A composite core structure includes a core having a plurality of elongated fibers and a plurality of spherical members, the elongated fibers and spherical members consolidated into a desired molded shape. The composite core structure also includes a matrix material encapsulating the elongated fibers and spherical members.

Abstract: A method of manufacturing a hollow composite structure is provided. The method includes curing a first portion of the hollow composite structure having at least one open region and at least one wall, the at least one wall partially defining a hollow interior. The method also includes bonding a laminate shell to the first portion of the hollow composite structure proximate to at least one location of the wall to cover the open region and enclose the hollow interior. The method further includes disposing a second portion of the hollow composite structure over the laminate shell, the second portion comprising a plurality of plies. The method yet further includes curing the first portion and the second portion during a final cure.

Abstract: A method of verifying removal of peel ply material from a composite structure is provided. The method includes doping a layer of peel ply fabric with an identifier. The method also includes curing the composite structure with the layer of peel ply fabric disposed on a surface of the composite structure. The method further includes removing the layer of peel ply fabric from the surface. The method yet further includes scanning the surface of the composite structure for the identifier.

Abstract: Embodiments of the disclosure are directed to measuring, via at least one sensor, at least one of a damage and a compromise associated with a vehicle, determining at least one of a region and a location of the at least one of a damage and a compromise and a level of the at least one of a damage and a compromise, and adapting an operational envelope for the vehicle based on the determined at least one of a region and a location of the at least one of a damage and a compromise and the level of the at least one of a damage and a compromise.

Abstract: Embodiments of the disclosure are directed to measuring, via at least one sensor, at least one of a damage and a compromise associated with a vehicle, determining at least one of a region and a location of the at least one of a damage and a compromise and a level of the at least one of a damage and a compromise, and adapting an operational envelope for the vehicle based on the determined at least one of a region and a location of the at least one of a damage and a compromise and the level of the at least one of a damage and a compromise.

Abstract: Embodiments of the disclosure are directed to measuring, via at least one sensor, at least one of a damage and a compromise associated with a vehicle, determining at least one of a region and a location of the at least one of a damage and a compromise and a level of the at least one of a damage and a compromise, and adapting an operational envelope for the vehicle based on the determined at least one of a region and a location of the at least one of a damage and a compromise and the level of the at least one of a damage and a compromise.

Abstract: Embodiments of the disclosure are directed to measuring, via at least one sensor, at least one of a damage and a compromise associated with a vehicle, determining at least one of a region and a location of the at least one of a damage and a compromise and a level of the at least one of a damage and a compromise, and adapting an operational envelope for the vehicle based on the determined at least one of a region and a location of the at least one of a damage and a compromise and the level of the at least one of a damage and a compromise.