Abstract: A radar jamming signal generated by equipment carried by a target aircraft, is launched onto the leading end of a towed single wire transmission line so as to travel the length of the line as a nonradiating surface wave. A drogue radiator is attached to the trailing end of the line for radiating the jamming signal transversely of the towed line so as to be received by and cause jamming of tracking and/or fire control radar. The length of the single wire transmission line is selected so that the trailing radiator causes the jamming signal to emanate from a position sufficiently behind the aircraft so as to be outside the destructive radius of weapon fire directed at the apparent source of the jamming signal by fire control radar. A ventriloqual-like deception of the radar is thus achieved.

Abstract: A surface treatment 10 for application to an aircraft wing surface 12 is provided, including at least one reflective metallic film 22 bonded at least one hollow cell structure 24 to provide a thermal barrier that inhibits non-environmental frost formation.

Abstract: Rib and spar webs are joined in a composite wingbox to eliminate fasteners by welding the webs along bondlines defined by overlapping sections of the webs. Heat to produce the weld is generally achieved resistively by connecting a multistrip susceptor positioned along the bond line to a current source, since the geometry makes it difficult to heat these web joints inductively. The wingbox is completed without fasteners by welding skins to the rib-spar wingbox.

Abstract: We make particulates, especially magnetic Fe—Co alloys having high magnetic permeability, of controlled dimensions, especially those having a narrow thickness size distribution centered around a median or target thickness in the range of about 0.1–1.0 ?m, using electrodeposition typically on a smooth (polished) titanium cathode. Our preferred continuous process uses a rotating drum cathode inside a fixed anode to grow flakes and to produce them automatically by inherent instability in the deposited film. The drum preferably rotates about a substantially vertical axis. The particulates shed (slough off) into the electrolyte (because of mismatch between the cathode surface and the plated metal or alloy at the molecular level) where they are separated in a magnetic separator or other suitable device. If the flakes are soft iron or iron-cobalt alloys, the drum generally is titanium or titanium alloy.

Abstract: A preferred rotary actuator includes an actuator assembly having a torque tube formed of a shape memory alloy (SMA), a superelastic NiTinol return spring associated with the torque tube and adapted to bias the torque tube toward an initial position, and a torque tube heating element, especially a thermoelectric device, for switching the SMA to cause rotation to an object connected to the actuator or to generate a torque upon that object. The torque tube (24) includes a proximal end (32) and a distal end (34). The return spring and torque tube are connected at their ends, with the torque tube being pretwisted while in a martensitic state relative to the spring. Activation of the heating element causes the torque tube to enter an austenitic state in which it returns to its previous untwisted configuration. Removal of heat allows the torque tube to return to a martensitic state, when the return spring retwists the torque tube. A unique locking assembly 22 is used with the preferred actuator assembly.

Abstract: A surface treatment, especially for titanium and aluminum alloys, forms a pigmented sol-gel film covalently bonded on the metal surface to produce desired color, gloss, reflectivity, electrical conductivity, emissivity, or a combination thereof usable over a wide temperature range. The coating retains its characteristics and impact resistance following exposures to temperatures at least in the range from ?321° F. to 750° F. An aqueous sol containing an alkoxyzirconium and an organosilane with an organic acid catalyst and zirconium stabilizer is applied to etched or grit blasted substrates by dipping, spraying, or drenching, to produce bonds in a single application comparable in strength and performance to standard anodize controls. Parameters affecting performance include the sol composition, the Si/Zr ratio, the ratio of sol ingredients, the concentration of the sol, the carrier solvent, solution age, catalysts, surface pretreatment, application method, curing process, and primer used.

Abstract: The present invention is a directional reflectometer that measures, for example, the optical bidirectional reflectance distribution function [BRDF] of a surface in situ on a finished article, e.g. a vehicle, to provide information on its surface reflectivity and emissivity. The light wavelength may be IR, near-IR, visible, UV, or longer wavelengths. Light, preferably focused to a small spot on the surface, is projected onto the surface at an angle adjustable in azimuth and elevation. A wide angle mirror, lens system, or both transfers light scattered from the surface onto an imaging sensor, preserving scattering angle information and thereby permitting the BRDFs for a given incidence angle and all scattering angles to be measured simultaneously. A computer reads the sensor outputs and analyzes the quality of the surface in a factory or field environment.

Abstract: Large machines, especially those having working envelopes in excess of fifteen feet, exhibit unacceptable errors because of thermal expansion and mechanical misalignments between the axes. The errors have traditionally been minimized by enclosing the machine in a thermal enclosure, by careful calibration, or by mounting a laser interferometer on each axis. These solutions are costly, may require frequent recalibration, and do not correct for small rotations of one axis relative to another axis due to wear etc. The present invention uses an interferometric laser tracker or a comparable 3D position sensor to measure the position of a retroreflector attached to the end effector, e.g. a machine head when the machine comes to rest. A computer compares the measured position to the desired position according to the machine media, and adds the appropriate correction with trickle feed media statements to move the machine to the correct position prior to further machining.

Abstract: Boeing achieves satellite diversity by having a large discrimination angle for a MEO constellation of communications satellites to limit interference in the Ku-band with GSO communications systems. Each satellite entering an exclusion zone over a GSO ground station terminates all transmissions to provide EPFD within acceptable limits. The Boeing MEO constellation preferably comprises 20 satellites, 5 in each orbit. The four orbits are inclined at about 57° with respect to the equator. Services include an Integrated Digital Service (IDS) and Backhaul Data Service (BDS) to accommodate the needs of different users.

Abstract: A method and apparatus for curing composite materials that emit large volumes of volatiles during processing. The apparatus includes tooling having a rigid forming surface contoured to the shape of the formed composite part. A plurality of passages extend from the forming surface through the tooling. The passages are in fluid contact with an exhaust port. A composite workpiece is laid up and placed adjacent the forming surface. The apparatus includes a heater that heats the composite workpiece to temperatures at which volatiles are emitted. An evacuation system draws the volatiles away from the composite workpiece through the passages in the tooling and out of the exhaust port. One embodiment of tooling according to the invention is used to form a sine wave spar. The tooling includes upper and lower tool inserts upon which U-shaped composite channels are formed. The upper and lower tools are placed adjacent to each other to form the web of the spar.

Abstract: A tubular part having a tubular main body and an integral tubular pullout projecting laterally from the side of the main body and in fluid-tight communication therewith is superplastically formed by inserting the tube in a cavity of a die base and heating the die to a temperature at which the material of which the tube is made exhibits superplastic properties. The distal end of a pull-rod is extended through an opening in the die base and through a hole in the side wall aligned with the opening. A pull-die is selected having a cross section larger than the hole and about equal to the desired internal cross section of the tubular protrusion. The pull die is attached to the distal end of the rod and (before or after attachment) is heated to about the superplastic temperature of the tubing material.

Abstract: An edge wrap machine for applying decorative laminate to an aircraft interior panel, particularly a stowbin door, lifts the edge to be wrapped with an actuator, wraps the edge automatically by drawing a vacuum between two silicone blankets sandwiching the panel, and lowers the actuator to achieve bonding pressure on the wrapped edge. The machine automates a hand operation that is relatively slow and potentially dangerous to the workers.

Abstract: Cure and consolidation of a viscous thermoplastic resin, especially one that softens and melts at a high temperature, is improved by assisting autoclave pressurized momentum transport for compaction of the composite using high frequency, low amplitude acoustic vibration within the resin. The vibration induces shear thinning in the resin which promotes resin flow, achieves filling or collapse of voids, and assists consolidation of the composite preform.

Abstract: A multisheet structure is made using compression diffusion bonding according to the present invention using a CRES template to apply increased pressure in the areas designated for diffusion bonds (DB) to improve the bond quality and to reduce the processing time. The CRES template is patterned to correspond with the DB arrangement in the superplastically formed part. The forming press forces the template against the pack of SPF sheets to provide 300-1200 psi or more pressure along the bond lines to speed their formation.

Abstract: We combine superplastic forming (SPF) with adhesive bonding (AB) to produce quality multisheet sandwich panel structures, especially those using a superplastic aluminum alloy, such as Al 2004, Al 8090, or Al 1570. We produce the parts with improved energy efficiency and at lower cost. We heat the multisheet pack having an adhesive, preferably a polyimide, between the core sheets and the face sheets to its superplastic forming range. Then, we superplastically form the pack to define adhesive bonds between the sheets in the core and between the core and the face sheets with the flowing adhesive. Finally, we cool the formed pack below the superplastic range to set the adhesive.

Abstract: A method of manufacturing a composite uses a hybrid tool which serves both as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration, and as a fixture for holding the bonded or cured materials in the originally applied position during subsequent machining of a peripheral edge of the part. The method includes fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The materials for the part are applied on the face sheet, debulked, bonded or cured, and edge trimmed thereon, all while on the face sheet in the originally applied position.

Abstract: A damage detection device is used to detect damage in bonded and laminated composite structures. A tap hammer or tap coin containing an acceleration sensor is connected to a circuit that can measure the width of an impact signal and then display the result. The result correlates to local stiffness of a structure. A method of determining the desired signal width and the method of using the damage detection device, includes tapping a known good region and then tapping a suspect region. Readings from the two areas are used to determine whether the suspect region is within an acceptable range. The circuit determines the desired signal width by measuring from the time the impact signal exceeds a threshold to the time it falls below the threshold.

Abstract: Boeing achieves satellite diversity by having a large discrimination angle for a MEO constellation of communications satellites to limit interference in the Ku-band with GSO communications systems. Each satellite entering an exclusion zone over a GSO ground station terminates all transmissions to provide EPFD within acceptable limits. The Boeing MEO constellation preferably comprises 20 satellites, 5 in each orbit. The four orbits are inclined at about 57° with respect to the equator. Services include an Integrated Digital Service (IDS) and Backhaul Data Service (BDS) to accommodate the needs of different users.

Abstract: A laminated composite (multi-ply) radius filler includes a plurality of woven fabric reinforced plies cut to fill a radius gap (including, if appropriate, intentional overfill) to increase absolute strength, to increase specific strength, or to reduce cost by reducing cracking and distortion in the radius of a composite assembly. The present invention also describes the method of manufacture and method of use for such laminated composite radius filler.

Abstract: We reduce core crush in honeycomb sandwich structure by using a peripheral tiedown ply, generally in combination with a scrim-reinforced barrier film, between the composite laminate and the core along the panel chamfer to prevent slipping of the barrier film and outer laminates relative to the core during curing. We produce superior panels with lighter weights, improved mechanical properties, and more predictable structural performance.