Abstract: Method for eliminating core distortion in diffusion bonded and superplastically formed structures or panels, wherein metal blanks or workpieces of metal, capable of diffusion bonding and superplastic forming such as a titanium alloy, preferably in the form of thin sheets of the order of 0.030 inch thick or less, are placed in contact with each other in a tooling apparatus or die, the sheets are joined at selected areas by diffusion bonding and are then expanded superplastically to form a desired panel or a truss core panel structure. In such method, the metal sheets are diffusion bonded at certain preselected areas under pressure and at elevated temperature, and the unbonded areas of the sheets are then expanded by superplastic forming into contact with the walls of the tool or die cavity, at elevated temperature e.g., 1600-1650.degree. F. and an internal gas pressure e.g., about 300 psi, to form the desired panel.

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: 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 process for heat treating an aluminum-lithium alloy material while preventing formation of lithium oxide and attendant lithium loss and associated strength degradation of the alloy, by application of a copper plating on the aluminum-lithium alloy material by electroplating, prior to heat treatment, and removing the copper plate subsequent to heat treatment by treating the aluminum-lithium alloy material in a suitable acid bath, such as an aqueous nitric acid solution.

Abstract: A seat system for a crewmember of an aircraft is disclosed which provides support and restraint to the crewmember while in a crouched as well as an erect position. The crewmember is secured by means of a strap harness to an insert which is positioned behind and in contact with the crewmember's back. The insert is rotatably connected to the seat providing multi-axis rotation to the insert relative to the seat. The insert's multi-axis rotation allows the crewmember to turn in the seat while secured to the insert. The insert also has a limited degree of translational movement toward as well as away from its connection to the seat; this allows the crewmember to lean forward, backward and laterally in the seat while still secured to the insert. A mechanism locks the insert into a desired forwardly inclined position. Instead of an insert, however, the crewmember's upper torso may be directly connected, at the crewmember's back, to the seat by means of a strap system or a rigid extendable support member.

Abstract: Aircraft thermal management is optimized by integration of normally separate airframe and engine fuel transfer/heat sink systems into a composite heat sink and secondary power source. Fuel temperature is controlled to limits set by coking and varnishing within the engine fuel nozzles. Fuel in excess of engine demand is returned to the aircraft's main fuel tank after being cooled by either aerodynamic surfaces or by a "fuel to ram-air" heat exchanger. Airframe and engine systems are cooled through use of fuel as coolant passing through heat exchangers mounted in the feed line from the "cool" main tank to the engines. The Engine Electronic Control Unit (ECU) is cooled by the airframe Environmental Control System (ECS) increasing its operational reliability. Controlling engine burn fuel to nozzle temperature limits results in lower main tank fuel temperature, less fuel boiloff, smaller sized ECS, greater heat sink capacity and less dependence on supplemental ram air.

Abstract: Elastomer injection dry seal construction produced by placing a tube-like flexible elastic body member having a hollow cross-section between spaced part surfaces, particularly between a curved transparency such as an aircraft windshield, and a curved support. The parts are then connected together as by means of bolts passing through aligned bolt holes in the parts, and a curable liquid resin, such as a catalyzed liquid silicone resin, is injected into the hollow interior of the tubular body member, causing it to stretch laterally in the space between the adjacent part surfaces, and to be compressed into engagement with such surfaces. The liquid resin is then cured to a solid elastomeric state. The energy stored in stretching the tube-like body member laterally and in compressing same into contact with the part surfaces, effects a seal therebetween.

Abstract: A reamer for making a tapered hole is disclosed. The reamer comprises a cylindrical forward portion joined to the front end of a conical rear portion, the rear portion tapering outwardly from its front end. The forward and rear portions have co-incident longitudinal axes and at least three cutting flutes extending continously on the forward and rear portions and which are unequally spaced about the longitudinal axes. In one embodiment the flutes are either aligned with or helical about the longitudinal axes; and furthermore are misindexed about the axes and therefore are unequally spaced apart. In another embodiment the flutes have different helix angles about the longitudinal axis. In other embodiments the cylindrical forward portion is eliminated leaving only the conical rear portion making a reamer suitable for enlarging holes having existing tapers.

Abstract: A method for producing a composite structural beam, particularly a sine wave beam, is disclosed utilizing as an essential feature, the bonding of the junctures of the sine wave web to the opposite flange areas of the beam with a fibrous braided material. The braiding is carried out during assembly of the composite web and composite flange components, prior to curing the components. In one embodiment the braided material extends along the entire height of the web, as well as along the flange areas, and is bonded thereto. In another embodiment the braided material does not extend along the entire height of the web, but only along the opposite edge portions of the web adjacent the junctures thereof with the flanges, the central portion of the web having no braided material applied thereto.

Abstract: A fluidized bed of solid particulate material cools a heated workpiece through a temperature range critical to strength property determination. Upon immersion into the fluidized bed container the bed is allowed to collapse around the workpiece forming a universal fixture which firmly supports the workpiece for the remainder of the cooling, allowing cooling to be completed at a slower rate to prevent or minimize distortion caused from differential thermal contractions.

Abstract: A method is disclosed for scribing chemical milling maskant applied to a metal substrate by impinging a laser beam on the maskant and controlling the beam to penetrate through the maskant substantially without damaging the underlying metal. In carrying out the process, a metal part such as aluminum, titanium or their alloys is coated with an organic polymer maskant having absorption to a laser beam, a predetermined pattern is scribed in the maskant by impinging a laser beam, e.g. a Nd:YAG (neodymium doped yttrium aluminum garnet) laser, under controlled conditions to scribe a predetermined pattern in the maskant and substantially without damaging the underlying metal, removing the maskant portion within the circumscribed area of the pattern to expose the underlying metal and leaving the remaining maskant portion adhered to the substrate, immersing the metal substrate in a chemical milling solution, e.g.

Abstract: A process for generating electrically conductive patterns on a dielectric substrate, such as an insulating sheet, which comprises applying to preselected areas of the substrate a preselected concentration of an ink in the form of an oxidizing agent, such as a solution of a ferric salt, e.g., ferric chloride or ferric ethylbenzenesulfonate, and which can also contain a suitable binder or thickening agent, to form printed images on the substrate surface. The resulting printed surface of the substrate is then exposed to an excess of reactant, e.g., pyrrole monomer in vapor phase, which reacts with the oxidizing agent to develop conductive images, as by forming polypyrrole, in those printed areas of the substrate containing the oxidizing agent.

Abstract: A device adapted to be removably placed over a computer keyboard which converts the keyboard to the format of a muscial instrument. The computer is programmed such that selected computer keys of the keyboard will synthesize different musical sounds. The device includes a housing and a plurality of first keys and second keys which are pivotally mounted to the housing. The first and second keys are arranged in a row and are accessible through a cutout in the housing. The first and second keys are shaped to simulate piano or organ keys (white and black). The first and second keys are positioned to register with the selected computer keys. Depressing the first and second keys respectfully depresses corresponding computer keys such that playing of a piano or organ is simulated. The device can also employ a second row of keys.

Abstract: Production of electrically conductive polypyrrole powder, by treating a liquid pyrrole with a solution of a strong oxidant, capable of oxidizing pyrrole to a pyrrole polymer, and oxidizing the pyrrole by such strong oxidant in the presence of a substantially non-nucleophilic anion and precipitating a conductive polypyrrole powder. The strong oxidant, e.g., Fe.sup.3+ ion, and non-nucleophilic anion, e.g., sulfate or chloride ion, can be derived from a single compound, e.g., FeCl.sub.3 or Fe.sub.2 (SO.sub.4).sub.3. The anion serves as dopant for the polypyrrole. The reaction can be carried out in aqueous solution or in an organic solvent medium, such as acetonitrile.

Abstract: Production of electrically conductive polypyrrole of enhanced stability by treating a liquid pyrrole with a solution of a strong oxidant, capable of oxidizing pyrrole to a pyrrole polymer, and oxidizing the pyrrole by such strong oxidant in the presence of a relatively large organic dopant anion, and precipitating a conductive polypyrrole. The strong oxidant, e.g., Fe.sup.3+ ion, and dopant anion, which can be an alkyl or aryl sulfonate, e.g., methylbenzenesulfonate, or a perfluorinated carboxylate, e.g., trifluoroacetate, anion, can be derived from a single compound, e.g., ##STR1## the anion serving as dopant for the polypyrrole.

Abstract: Production of electrically conductive composite or structural materials comprising a dielectric substrate, e.g. fiberglass fabric, and a layer of a pyrrole polymer on the substrate, by treating the substrate with a solution of a strong oxidant containing a substantially non-nucleophilic anion, e.g. ferric chloride, drying the substrate and exposing the so treated substrate with the vapors of a pyrrole and oxidizing the pyrrole by the strong oxidant and depositing a polypyrrole layer or film on the substrate.

Abstract: A power drill system is disclosed which is hand held and manually operable. The drill system includes a drill and a positive feed unit for the drill connected thereto. A clamping member is connected at a lower portion thereof to a housing for the drill and feed unit. The clamp member is pneumatically powered to move it against a workpiece and clamp it against the housing at the location of the drill. A four way toggle switch controls the air pressure to the clamp member allowing the operator to control the clamping operation with one hand while the other hand holds the housing in the desired position.

Abstract: A programmable crewmember emergency ejection system is disclosed which will eject the crewmember expeditiously from a disabled aircraft, while at the same time assuring that the crewmember will not be subjected to forces that are beyond crewmember tolerance. This is accomplished by a control system involving sensors having signals that are processed and used to vary ejection thrust and acceleration onset rate. The system involves a two phase ejection: A catapult phase followed by a rocket phase, both phases cooperating to provide a substantially constant maximum thrust that is well within human tolerances such that a second jolt to the crewmember is substantially minimized.

Abstract: A head restraint system is disclosed that is designed to protect the pilot's head against severe lateral forces. A circular track surrounds and is affixed to the pilot's helmet. The track is attached by two cables to a seat back. During normal flight conditions, the cables provide a small but constant tension to the helmet, and allow the pilot's head free movement in all directions. A spring loaded inertia reel will lock the cables in place when the lateral forces exceed a predetermined level. The system will also provide afterward head support during the pilot's emergency ejection from the aircraft, and the cables are automatically severed when the pilot is separated from the seat.

Abstract: A reamer for making a tapered hole is disclosed. The reamer comprises a cylindrical forward portion joined to the front end of a conical rear portion, the rear portion tapering outwardly from its front end. The forward and rear portions have co-incident longitudinal axes and at least three cutting flutes extending continuously on the forward and rear portions and which are unequally spaced about the longitudinal axes. In one embodiment the flutes are either aligned with or helical about the longitudinal axes; and furthermore are misindexed about the axes and therefore are unequally spaced apart. In another embodiment the flutes have different helix angles about the longitudinal axis. In other embodiments the cylindrical forward portion is eliminated leaving only the conical rear portion making a reamer suitable for enlarging holes having existing tapers.