Abstract: A structural armor component includes opposing face sheets and a multi-cell core having abrasive materials disposed within the cells of the core. The face sheets and the core are fabricated from a tough titanium alloy. The core is preferably of honeycomb or truss-core configuration, and the abrasive materials are provided as a loose, particulate material, a sintered powder, or a particulate or powder embedded in polymer matrix. The "outer" face sheet slows travel of a projectile, while the abrasive materials within the core act to erode and ultimately cause disintegration of the projectile(s) before the latter can penetrate the opposite "inner" face sheet.

Abstract: A method for forming a structurally reinforced panel member, and the panel itself, is disclosed. The method requires disposing a first set of sheets of curable composite material atop a tool forming surface, wrapping a plurality of mandrels with a second set of sheets of curable composite material, arranging the wrapped mandrels in side by side relation atop the first set of sheets, curing the structural assembly, and then removing the mandrels from the cured structural assembly. In this way, the structural assembly includes interior channels obtained when the mandrels are removed from the cured structural panel member. The material portions defining the channels provide increased strength for the structural assembly.

Abstract: A process for manufacturing stiffened composite skin panel structures possessing novel hollow crown-shaped stiffener elements, and further including any combination of forward spars, aft spars, and transversely extending shear ties. The novel process embraces fabrication and curing of these structures without the use of mandrels. In practicing the method, the crown-shaped stiffeners, spars and shear ties are integrally bonded to a planar or curved skin structure to provide axial stiffness in semimonocoque components such as aircraft wings, stabilizers, fuselages, etc. The method of fabrication yields highly producible, structurally efficient composite aircraft components.

Abstract: Apparatus and a method are disclosed for eliminating fiber distortions ("fiber swimming") and separations ("fiber fish eyes") via a premliminary step taken prior to consolidation of "green", fiber-reinforced metal matrix materials. The apparatus includes a first member for supporting the "green" metal matrix material pack, a second member to cover the "green" pack, the thermal coefficient of expansion of the first member being smaller than the thermal coefficient of expansion of the second member, the second member being secured to the first member atop the "green" pack to form a retort, and the entire retort being heated to an off-gassing temperature, where the second member bows outwardly away from the pack to relieve pressure from the pack.

Abstract: A method of precision cutting fabric material while obtaining cleanly cut edges involves placing the material on a flat support surface, identifying one or more regions of material to be cut, placing adhesive tape on both sides of the material, and then using an appropriate tool to first squeeze the tape into the fabric at the cutting region, and effecting the cutting of the taped material. A reinforcing woven fabric constituent for incorporation into a metal matrix composite, produced by the method, is also disclosed.

Abstract: A structural armor assembly including a superplastically formed sandwich member having on one side one face sheet of high toughness, high-strength titanium alloy material, and on the other side a second face sheet made of non-superplastically formable metal matrix composite abrasive material. Abrasive materials in the form of "KEVLAR".RTM. or "SPECTRA".RTM. are provided inside cells in the sandwich member to serve as a "catcher's mitt" to absorb part or all of the energy of the ballistic fragments after they have been abraded by the material of the second face sheet.

Abstract: A method for making a cooling system for reducing the temperature of an exhaust-impinged structural panel includes an upper, primary cooling panel having boundary layer film-forming openings therein, a middle, secondary cooling panel having openings for directing a flow of cooling fluid into impingement with the primary cooling panel, and a lower cooling panel. The lower and upper panels together delimit a truss structure which structurally reinforces the cooling system, and the lower panel forms with the upper panel channels for conducting pressurized fluid first to the openings of the secondary cooling panel and then to the openings of the primary cooling panel.

Abstract: A method and apparatus for forming cleanly defined holes through reinforced metal matrix material includes a drill bit with a shank portion and flutes on said shank portion, the drill bit capable of withstanding a chip load of at least about 0.008 inch/rev/flute, and preferably in the range of from about 0.008 inch/rev/flute to about 0.012 inch/rev/flute, achieved through turning the bit at a speed within the range of about 18 surface feet per minute ("sfpm") to about 20 sfpm, and advancing the bit at an aggressive rate through the metal matrix material at a rate of from about 3 inches per minute to about 6 inches per minute.

Abstract: A novel composition comprising a metal or ceramic matrix material includes a reinforcing system of hollow, similarly aligned carbon-coated ceramic fibers which provide high strength, increased creep resistance and a significant reduction in weight. Also disclosed is a novel structural component incorporating the reinforcing system of hollow fibers to provide a mechanism enabling fluids or gases to pass or be injected through the element fibers for cooling or other functions. A method for fabricating the hollow fiber-reinforced component is also disclosed. Various applications for the fiber-reinforced structural component are also disclosed.

Abstract: A high rate, continuous production, slush hydrogen generator includes a tank, apparatus for creating a vacuum in the tank, apparatus for delivering triple point (T.P.) liquid hydrogen (LH2) to the tank, apparatus for interacting with the vacuum in the tank to produce slush hydrogen from the T.P. LH2, where the T.P. LH2 has a substantially constant solid fraction, and apparatus for delivering cold vapors from the slush in the tank to the vacuum creating apparatus. The apparatus for producing slush hydrogen in the generator includes a perforated spray ring for evaporating the T.P. LH2 and apparatus for delivering the LH2 under pressure to the spray ring.

Abstract: A stack of metallic sheets is constructed for selective diffusion bonding followed by superplastic forming to yield a metallic sandwich structure. The invention resides in the provision of gas distribution channels in the stack for assuring balanced and complete distribution of gas throughout the unbonded areas of the stack. The gas is used for expansion of the stack into a sandwich structure during the step of superplastic forming. The novel construction of each channel comprises superimposed grooves in opposed face sheets of the stack and slots in the core sheet(s) of the stack.

Abstract: Aerodynamic boundary layer control apparatus comprising a panel assembly having one surface for immersion in an ambient fluid flow and provided with perforations, a first array of fluid transporting channels fluidly coupled with various ones of the perforations, a second array of fluid transporting channels overlapping the first array of channels, and a suction-generating apparatus fluidly coupled with the second array of channels. An opposing surface of the panel assembly has a contour congruent with that of the aircraft wing or body structure to which it is to be removably attached. The suction-generating apparatus applies a suction force to the second array of channels to draw the ambient fluid into the first array of channels to enable conformace of the fluid with the one surface.

Abstract: An apparatus and a method for measuring the temperature of a reactive metallic workpiece sealed within a retort prior to and during diffusion bonding of the workpiece. The apparatus includes temperature measuring instruments disposed adjacent preselected portions of the workpiece within the retort, thermal conducting means connecting the instruments with display devices located outside the retort, conduits coupled with the interior of the retort and with the display devices, each of the conduits including a first end portion communicating the interior of the retort with vacuum generating means and a second end portion including at least one tubular region through which the thermal conducting means pass to connect with the display devices, and means for sealing the first and second end portions to maintain an evacuated state within the retort after a vacuum is applied thereto.

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: A method and composition facilitating the inspection of structural surfaces, such as fuel tank walls, to identify or locate cracks, flaws and other defects. The composition is a system of materials including a dye-containing penetrant material and a chemiluminescent material which reacts with the dye in the penetrant material. The method involves application of the two materials sequentially such that they react chemically to produce light which is visible to the naked, unaided eye, thereby eliminating the need for electrically-powered or "hot" light.

Abstract: A method and apparatus for establishing discrete zones of pressure at the surface of a perforated panel of the type typically used for laminar fluid flow control includes a first array of channel members fluidly communicating with perforations in the panel, all of the channel members in the first array extending in a first direction and being substantially parallel to one another, and a second array of channel members fluidly communicating with the fluid in the first array of channel members, all of the channel members in the second array extending in a second direction and being substantially parallel to one another, where the first and second arrays of channel members being disposed in crossing relationship with a source of pressure being applied to the second array of channel members. By this arrangement, control of fluid flow in at least one of the first and second arrays results in discrete zones of pressure at the surface of the panel.

Abstract: Circulation of temperature controlled fluid through cavities in structure stiffening members of hypersonic aerospace vehicles precludes destructive temperature gradients in such members and preserves stress residuals for functional requirements.

Abstract: A novel method for sealing the end of tubing connected to and extending from a container housing workpieces to be thermally processed using mechanical as well as thermal means. The invention also contemplates a novel tubing member for connection to such a container, where the sealing material is disposed within the tubing member prior to insertion of the tubing into the container. After fixing the tubing in the container, a plurality of locations along the length of the tubing are identified where mechanical closure of the tubing is effected. Then, the tubing is heated to a temperature sufficiently high to melt the contained sealing material at the crushed locations, such that a metallurgical seal is formed inside the tubing at the crushed locations.

Abstract: A self-powered, mobile maintenance apparatus for continuously supplying slush hydrogen as a powering fuel to an aerospace vehicle prior to take-off including a first apparatus for obtaining liquid hydrogen from the vehicle, a second apparatus for generating slush hydrogen, a third apparatus for delivering the liquid hydrogen obtained from the vehicle to the second apparatus for generating slush hydrogen so that the liquid hydrogen can be converted to slush hydrogen, pump apparatus communicating with the second apparatus generating slush hydrogen for developing a vacuum in a region of the second apparatus for generating slush hydrogen so that a solid hydrogen fraction is produced, and apparatus for delivering the slush hydrogen mixture to the aerospace vehicle to be used as the powering fuel.

Abstract: A test coupon for metal matrix composites is provided with means for structurally isolating the reinforcing fibers in the gage section from the reinforcing fibers in the clamped end regions of the coupon, when the latter is subjected to creep testing, so that the results of creep testing can be more accurately indicative of the creep properties associated with the fiber-reinforced metal matrix composite material in the coupon gage section. More particularly, the test coupon of the invention is provided with a plurality of slots or cut-out regions disposed in a section located between the clamped end regions and the centrally located gage section. The plurality of slots, which can be provided in longitudinally and/or laterally staggered arrays, effectively causes structural isolation of the reinforcing fibers in the gage section from the clamped reinforcing fibers located in the end regions of the coupon.