Abstract: A method for joining thermoplastic composite includes: providing a first part having a first joining surface disposed in a first plane and a second joining surface disposed in a second plane that is non-parallel to the first plane; providing a second part having a third joining surface disposed in the first plane and a fourth joining surface disposed in the second plane; disposing the parts so that the first and third joining surfaces are in contact with one another, and the second and fourth joining surfaces are in contact with one another; forcing the second and fourth joining surfaces against one another; and welding the first and third joining surfaces together using a vibration welding process, wherein the welding process and the forcing of the second and fourth joining surfaces against one another causes the second and fourth joining surfaces to be welded.

Abstract: A method is provided during which a first thermoplastic composite body is arranged on a rigid support structure. The first thermoplastic composite body contacts the rigid support structure. A second thermoplastic composite body is arranged on the first thermoplastic composite body. The second thermoplastic composite body contacts the first thermoplastic composite body. Energy transmission material is arranged on the second thermoplastic composite body. The first thermoplastic composite body and the second thermoplastic composite body are disposed between the rigid support structure and the energy transmission material. The second thermoplastic composite body is ultrasonic welded to the first thermoplastic composite body using an ultrasonic horn. The energy transmission material is arranged between the second thermoplastic composite body and the ultrasonic horn.

Abstract: A displacement reduction mechanism for coupling to a linear sensor, including a pinion, a first rack having a first plurality of teeth and a second rack having a second plurality of teeth is provided. The first and second racks are parallel to each other. The first plurality of teeth protrude from the first rack in the same direction in which the second plurality of teeth protrude from the second rack. The pinion is configured to be rotated over the first and second racks and to engage simultaneously with the first plurality of teeth and the second plurality of teeth. A number of teeth per unit length of the first rack is different from a number of teeth per unit length of the second rack. Rotation of the pinion over the first rack and the second rack causes the second rack to be displaced relative to the first rack.

Abstract: A compliant consolidation block is provided. The compliant consolidation block includes a non-articulating component, a first articulating self-aligning component coupled to the non-articulating component, and two second articulating self-aligning components coupled to the first articulating self-aligning component. The first articulating self-aligning component is configured to articulate with respect to the non-articulating component. Each of the two second articulating self-aligning components are individually configured to articulate with respect to the first articulating self-aligning component.

Abstract: An assembly is provided for an aircraft propulsion system. This assembly includes a stationary structure, a nacelle inner barrel, a nacelle outer structure, a bifurcation and a mounting yoke. The stationary structure extends axially along an axis. The bifurcation includes a first bifurcation section and a second bifurcation section. The first bifurcation section is disposed to a first side of the stationary structure. The second bifurcation section is disposed to a second side of the stationary structure. The first and the second bifurcation sections each project radially out from the nacelle inner barrel to the nacelle outer structure. The mounting yoke is pivotally attached to the stationary structure at a radial outer end of the mounting yoke. The first bifurcation section is fixedly attached to a first side of the mounting yoke. The second bifurcation section is fixedly attached to a second side of the mounting yoke.

Abstract: A latch assembly includes a first latch assembly portion. The first latch assembly portion includes a hook. The hook includes a hook body and a retention assembly. The hook body forms a hook engagement surface. The hook engagement surface extends about a pin axis. The hook body forms a groove at the hook engagement surface. The groove extends about the pin axis. The hook body forms a slot at the outer body side. The retention assembly includes a stopper, a rack, and a pinion gear. The stopper is disposed within the groove. The stopper extends about the pin axis between and to a first end and a second end. The stopper includes an outer radial surface and an inner radial surface. The stopper includes a stopper gear surface at the outer radial surface. The inner radial surface is disposed at the hook engagement surface. The stopper is pivotable in the groove about the pin axis. The rack is disposed within the slot. The rack extends between and to an outer rack side and an inner rack side.

Abstract: A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. An ultrasonic horn is arranged on the thermoplastic patch. The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn. The thermoplastic patch contacts the ultrasonic horn. The thermoplastic patch is continuous ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn.

Abstract: A tooling element includes a flexible sleeve defining an interior cavity. The flexible sleeve includes a sealable access port extending through the flexible sleeve from the interior cavity to an exterior of the flexible sleeve. The tooling element further includes vacuum-packed tooling particulate disposed within and filling the interior cavity of the flexible sleeve.

Abstract: An apparatus for non-destructive testing of a component is disclosed herein. The apparatus comprises a robotic arm, a probe holder, a probe connected to the robotic arm via the probe holder, and a controller configured to move the robotic arm to move the probe over a surface of a component to be tested. The probe holder comprises a spring assembly for biasing the probe towards the surface of the component to be tested to keep the probe in contact therewith. The spring assembly comprises at least one pair of spring portions that are spaced apart along a first axis.

Abstract: An apparatus is provided for an aircraft which includes an aircraft component. The aircraft component includes a first plate section, a second plate section and an elastic expansion section laterally between the first plate section and the second plate section. The elastic expansion section is configured to elastically deform to increase a lateral width between the first plate section and the second plate section. The aircraft component is formed from at least an elastomeric matrix and a fiber layer at least partially embedded within the elastomeric matrix. A bead is formed in the fiber layer laterally between a first portion of the fiber layer and a second portion of the fiber layer. The first portion of the fiber layer is disposed in the first plate section. The second portion of the fiber layer is disposed in the second plate section. The bead is disposed in the elastic expansion section.

Abstract: An assembly is provided for induction welding. This assembly utilizes a plurality of heat shields (e.g., mica heat shields) that are aligned/disposed in end-to-end relation, with each such heat shield having a recess. An induction welding coil may be disposed within a heat shield recess during induction welding operations and is movable along a welding path while proceeding along the recesses of the various heat shields. This welding path may be axially extending or may be curved. The induction welding assembly may be used to induction weld a stiffener to a curved skin or shell, for instance where a base of the recess for each heat shield is curved such that the induction welding coil may be moved along a curved welding path and while maintaining a constant spacing between the induction welding coil and the recess base of the various heat shields.

Abstract: A door assembly for an aircraft includes a door, a door handle, a door hinge, a support assembly, and a lifting assembly. The door handle is rotatable between an unlatched position and a latched position. The support assembly rotatably mounts the door hinge to the door. The lifting assembly includes a latch cam, a lift track, and a latch idler. The latch cam is mounted to the door handle. The latch cam is rotatable with the door handle about the door handle rotational axis. The latch cam forms an eccentric roller path extending about the door handle rotational axis. The latch idler includes a first roller and a second roller. The first roller is disposed on a lift track of the support assembly and configured to roll along the lift track. The second roller is disposed within the eccentric roller path. The latch idler is mounted to the door. The latch idler is configured to lift the door as the door handle rotates from the latched position to the unlatched position.

Abstract: A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. The thermoplastic patch contacts the thermoplastic aerospace component. The thermoplastic patch is horizontal ultrasonic welded to the thermoplastic aerospace component using an ultrasonic horn.

Abstract: A fiber-reinforced thermoplastic hollow structure is provided that includes a shell and a mating component. The shell includes a first flange, a second flange, and sidewalls. The shell includes a fiber-reinforced thermoplastic material. The mating component is coupled to the first flange and the second flange and includes a first internal surface. The first internal surface and internal surfaces of the sidewalls defining a cavity. The first flange and the mating component defining a first weld seam, the first weld seam being between 20% and 80% of a lateral length of the first flange.

Abstract: A preform is provided. The preform includes first fabric layers that include a first set of commingled fibers and a second set of commingled fibers. The preform includes a second fabric layer positioned between the first fabric layers. The second fabric layer includes a third set of commingled fibers and a fourth set of commingled fibers. The first set of commingled fibers includes a lower percentage of the at least one of first carbon fibers or first fusible fibers than the third set of commingled fibers, The first set of commingled fibers include a higher percentage of first fugitive fibers than the third set of commingled fibers. The first fugitive fibers and the third fugitive fibers are pyrolyzed from the first fabric layers and the second fabric layer.

Abstract: A variable area nozzle assembly includes a fixed nozzle structure, a translating sleeve, a plurality of nozzle segments, and a plurality of segment hoop locking assemblies. The translating sleeve is movably mounted to the fixed nozzle structure. The translating sleeve is translatable along the nozzle axis within the fixed nozzle structure between and to a first axial position and a second axial position. The plurality of nozzle segments form a variable area nozzle extending circumferentially about the nozzle axis. Each nozzle segment of the plurality of nozzle segments is pivotably mounted to the translating sleeve. The plurality of nozzle segments includes a first nozzle segment and a second nozzle segment. The plurality of segment hoop locking assemblies include a first segment hoop locking assembly. The first segment hoop locking assembly includes a hoop crank.

Abstract: A door assembly for an aircraft includes a door, a door hinge, and a support assembly rotatably mounting the door hinge to the door. The support assembly includes a forearm and at least one link. The forearm is rotatably mounted to the door hinge along a first rotational axis. The forearm extends along the first rotational axis between and to an upper end and a lower end. The at least one link extends between and to an inner end and an outer end. The at least one link is rotatably mounted to the forearm at the inner end. The at least one link is rotatable relative to the forearm about a second rotational axis. The at least one link is rotatably mounted to the door at the outer end. The at least one link is rotatable about the second rotational axis between and to a lowered position of the door and a raised position of the door.

Abstract: A method is provided for forming a thermoplastic structure. During this method, a substrate is provided. The substrate includes a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic. The substrate fibers are arranged in a substrate pattern. A first layer is deposited on the substrate using an automated fiber placement device. The first layer includes a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic. The first layer fibers are arranged in a first layer pattern that is different than the substrate pattern. A blank is stamped into the thermoplastic structure. The blank includes the substrate and the first layer where the first layer thermoplastic is consolidated with the substrate thermoplastic.

Abstract: A method of repairing a thermoplastic composite material is disclosed herein. The method includes placing the thermoplastic composite material on a supporting anvil, placing an energy transmission material on top of the thermoplastic composite material, and applying an ultrasonic welder to the thermoplastic composite material to consolidate and repair the thermoplastic composite material. Another method of repairing a thermoplastic composite material is disclosed herein. The method includes placing an energy transmission material on a supporting anvil, placing the thermoplastic composite material on top of the energy transmission material, and applying an ultrasonic welder to the energy transmission material to consolidate and repair the thermoplastic composite material.

Abstract: A method is provided for accessing an engine core for an aircraft propulsion system. During this method, a first outer structure section of a nacelle is uncoupled from a second outer structure section of the nacelle. The second outer structure section is pivoted to an open position. A first inner structure section of the nacelle is uncoupled from a second inner structure section of the nacelle. The second inner structure section is pivoted to an open position. The first outer structure section and the first inner structure section are pivoted to an open position while the first inner structure section is structurally linked to the first outer structure section.