Abstract: Cap wrinkling in a contoured composite hat stringer is reduced by constraining the cap as the hat stringer is being formed from a flat composite charge. The cap is constrained by an inflatable bladder placed in a tool set used to form the composite charge.

Abstract: During an assembly process for an aircraft, segments of the fuselage are fabricated separately prior to joining the segments together to form the complete fuselage. In order to ensure that abutting ends of the segments mate together correctly, a machining process is performed along the edges of the segments at their ends. A trim-tool assembly includes an indexing cart mounted to a track secured to a surface of the workpiece, where a setting on the indexing cart varies a distance between a centerline of the track and an edge of a workpiece. The trim-tool assembly further includes a tool cart mounted to the track and translatable along the track. The tool cart includes a process tool that performs a machining process on the workpiece at a fixed distance from the centerline of the track.

Abstract: A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.

Abstract: A tool is configured to form a composite charge into a stringer having a net shape with at least one out-of-place feature. The out-of-plane feature is formed by a shim removably attached to the tool. A family of the shims may be used to form a range of out-of-plane features having varying characteristics.

Abstract: Cap wrinkling in a contoured composite hat stringer is reduced by constraining the cap as the hat stringer is being formed from a flat composite charge. The cap is constrained by an inflatable bladder placed in a tool set used to form the composite charge.

Abstract: During an assembly process for an aircraft, segments of the fuselage are fabricated separately prior to joining the segments together to form the complete fuselage. In order to ensure that abutting ends of the segments mate together correctly, a machining process is performed along the edges of the segments at their ends. One embodiment comprises a trim-tool assembly for machining proximate to an edge of a workpiece. The trim-tool assembly includes an indexing cart configured to mount to a track secured to a surface of the workpiece, where a setting on the indexing cart varies a distance between a centerline of the track and the edge of the workpiece. The trim-tool assembly further includes a tool cart configured to mount to and translate along the track, where the tool cart includes a process tool that performs a machining process on the workpiece at a fixed distance from the centerline of the track.

Abstract: A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.

Abstract: Provided are splices, comprising honeycomb cores and adhesive layers with tie clips supporting the honeycomb cores. Also provided are methods of forming such splices. Each tie clip includes two legs and a bridging portion joining the legs. When forming a splice, an adhesive layer is positioned between two honeycomb cores. One leg of the tie clip is inserted into the full cell of one honeycomb core, while the other leg is inserted into the full cell of the other honeycomb core. The bridging portion extends across the adhesive layer. While curing the adhesive layer, the tie clip supports the honeycomb cores with respect to each other and maintains their orientation. The tie clip becomes a part of the splice. The tie clip may be buried in the honeycomb cores without extending above the first face of the splice.

Abstract: Provided are splices, comprising honeycomb cores and adhesive layers with tie clips supporting the honeycomb cores. Also provided are methods of forming such splices. Each tie clip includes two legs and a bridging portion joining the legs. When forming a splice, an adhesive layer is positioned between two honeycomb cores. One leg of the tie clip is inserted into the full cell of one honeycomb core, while the other leg is inserted into the full cell of the other honeycomb core. The bridging portion extends across the adhesive layer. While curing the adhesive layer, the tie clip supports the honeycomb cores with respect to each other and maintains their orientation. The tie clip becomes a part of the splice. The tie clip may be buried in the honeycomb cores without extending above the first face of the splice.

Abstract: A mandrel bladder end fitting includes a compression housing defining a circumferential interior wall; the interior wall constitutes a first clamping surface. An expansion assembly, axially received within the interior wall, includes a plurality of wedges that collectively define a second clamping surface. The expansion assembly also includes a central core and a threaded member received within a threaded aperture of the central core. A radially extending flat washer, seated within the interior wall, prevents axial movement of the expansion wedges in one direction. Thus, upon rotation of the threaded member, the central core will move axially toward the washer, forcing the second clamping surface to move only radially outwardly toward the first clamping surface. As such, because the flat washer restricts axial movement of the expansion wedges, relative motion between first and second clamping surfaces; i.e., between the collective wedges and interior wall, is limited to radial movement, only.

Abstract: Provided are splices comprising honeycomb cores and adhesive layers with tie clips supporting the honeycomb cores. Also provided are methods of forming such splices. Each tie clip includes two legs and a bridging portion joining the legs. When forming a splice, an adhesive layer is positioned between two honeycomb cores. One leg of the tie clip is inserted into the full cell of one honeycomb core, while the other leg is inserted into the full cell of the other honeycomb core. The bridging portion extends across the adhesive layer. While curing the adhesive layer, the tie clip supports the honeycomb cores with respect to each other and maintains their orientation. The tie clip becomes a part of the splice. The tie clip may be buried in the honeycomb cores without extending above the first face of the splice.

Abstract: Provided are splices comprising honeycomb cores and adhesive layers with tie clips supporting the honeycomb cores. Also provided are methods of forming such splices. Each tie clip includes two legs and a bridging portion joining the legs. When forming a splice, an adhesive layer is positioned between two honeycomb cores. One leg of the tie clip is inserted into the full cell of one honeycomb core, while the other leg is inserted into the full cell of the other honeycomb core. The bridging portion extends across the adhesive layer. While curing the adhesive layer, the tie clip supports the honeycomb cores with respect to each other and maintains their orientation. The tie clip becomes a part of the splice. The tie clip may be buried in the honeycomb cores without extending above the first face of the splice.

Abstract: A mandrel bladder end fitting includes a compression housing defining a circumferential interior wall; the interior wall constitutes a first clamping surface. An expansion assembly, axially received within the interior wall, includes a plurality of wedges that collectively define a second clamping surface. The expansion assembly also includes a central core and a threaded member received within a threaded aperture of the central core. A radially extending flat washer, seated within the interior wall, prevents axial movement of the expansion wedges in one direction. Thus, upon rotation of the threaded member, the central core will move axially toward the washer, forcing the second clamping surface to move only radially outwardly toward the first clamping surface. As such, because the flat washer restricts axial movement of the expansion wedges, relative motion between first and second clamping surfaces; i.e., between the collective wedges and interior wall, is limited to radial movement, only.

Abstract: A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.