Abstract: An acoustic panel is provided that includes a perforated first skin, a second skin and a core. The core is between and connected to the perforated first skin and the second skin. The core includes a plurality of chambers, a first corrugated structure and a second corrugated structure. The chambers includes a first chamber. The first chamber extends from the perforated first skin, through the first corrugated structure and the second corrugated structure, to the second skin.

Abstract: A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.

Abstract: A manufacturing method is provided. A first end of a set of spars is coupled to a first skin of a flight control surface. A set of ribs is interlocked with the set of spars and a first end of the set of ribs is coupled to the first skin. A second skin is coupled to a second end of the set of spars and a second end of the set of ribs.

Abstract: An end effector for welding composite components includes an end effector housing and a welding member mounted to the end effector housing. The end effector further includes a leading roller mounted to the end effector housing forward of the welding member and at least one follower roller mounted to the end effector housing aft of the welding member. The end effector further includes at least one first cooling air jet positioned to direct a first stream of cooling air toward the at least one follower roller.

Abstract: A latch assembly includes a housing including a first housing portion and a second portion including. The latch assembly further includes a first latch member disposed within the first housing portion and configured for translation along the latch axis. The first latch member includes at least two rotatable arms configured to rotate between an arm retracted position and an arm extended position in which the at least two rotatable arms extend in a first direction away from the latch axis. The latch assembly further includes a second latch member disposed within the second housing portion and configured for translation along the latch axis. The second latch member includes a second latch member body including a base portion and at least one axially extending portion extending from the base portion in a second direction toward the interior surface of the lateral wall.

Abstract: A method for forming a fiber-reinforced thermoplastic control surface includes forming first and second skins from a fiber-reinforced thermoplastic resin. The method further includes overmolding fiber-reinforced thermoplastic features onto the first skin and/or second skin, including stiffener structures, sidewalls, and/or hinges. The method further comprises welding or consolidating the first and second skins together, along with the associated internal features overmolded thereon to form a single-piece, stiffened, fiber-reinforced thermoplastic control surface.

Abstract: A manufacturing method is provided during which a plurality of first apertures are formed in a first plate to provide an apertured first plate. The apertured first plate is configured from or otherwise includes first plate metal. A first sheet is bonded to the apertured first plate to form a first grid structure. The first apertures extend through the apertured first plate to the first sheet. The first sheet is configured from or otherwise includes first sheet metal.

Abstract: A nacelle may comprise a fixed structure and a translating structure configured to translate relative to the fixed structure. A first drive system may be operationally coupled to the translating structure. The drive system may comprise a primary actuator coupled to the fixed structure and including a primary rod and a primary gear rotationally coupled to the primary rod, a torque shaft rotationally coupled to the primary gear, and a secondary actuator operationally coupled to the primary actuator via the torque shaft.

Abstract: A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.

Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).

Abstract: A thrust reverser includes a frame, a track disposed on the frame, a carrier operatively coupled to the track, and a first reverser door operatively coupled to the carrier. The first reverser door is movable relative to the frame. The first reverser door is configured to move to a first position in response to the carrier moving with respect to the track in a first direction, and move to a second position in response to the carrier moving with respect to the track in a second direction.

Abstract: A thrust reverser system is provided that includes a sleeve, a fixed cascade structure and a blocker door. The fixed cascade structure is within a cavity of the sleeve when the sleeve is in a sleeve stowed position. The blocker door is within the cavity of the sleeve when the sleeve is in the sleeve stowed position and the blocker door is in a blocker door stowed position. The blocker door projects in a radial inward direction away from the sleeve towards the centerline when the sleeve is in a sleeve deployed position and when the blocker door is in a blocker door deployed position. The blocker door includes a pivot attachment fixed at an end of the blocker door. The pivot attachment is configured to move in a forward direction from a first location to a second location.

Abstract: A manufacturing method is disclosed herein. The method includes arranging a preform over a surface of an inner mold line; folding the preform over sides of the inner mold line; pressing an end of the preform into a grip strip coupled to a side of the inner mold line; and applying pressure to the preform to force excess material of the preform into a forming bead of the inner mold line.

Abstract: A manufacturing method is disclosed herein. The method includes arranging a preform with a plurality of clamping assemblies, the plurality of clamping assemblies disposed along ends of the preform; and forming the preform into a shaped body, the forming including incrementally tensioning the preform around a surface of an inner mold line using the plurality of clamping assemblies; and drawing the preform into a set of forming beads of the inner mold line.

Abstract: A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is pressed into a grip strip coupled to a side of the inner mold line. The grip strip is translated in a first direction to tension the preform into a shaped body.

Abstract: An induction welding assembly and inductive welding method is disclosed. A tooling block includes a workpiece zone, a conductive heat generation and transfer member, and a heat shield, with the conductive heat generation and transfer member being disposed between the workpiece zone and the heat shield. A first workpiece and a second workpiece may be disposed within the workpiece zone such that the first workpiece is disposed between the conductive heat generation and transfer member and the second workpiece. The heat shield, conductive heat generation and transfer member, first workpiece, and second workpiece may be pressed together. An induction coil may be positioned in spaced relation to the heat shield and may be operated to heat the conductive heat generation and transfer member. Heat is conductively transferred by the conductive heat transfer member to the first workpiece to weld the first workpiece and the second workpiece together.

Abstract: Methods and apparatus' for induction welding a first workpiece to a second workpiece at a welding region may include a metallic strip. The metallic strip may be a mesh. The properties of the metallic strip, such as, for example, pore size, thickness, and density, may be configured to conduct heat uniformly across the welding region and prevent eddy current formation across a workpiece. The metallic strip may be embedded in a workpiece or may be fixed to an induction welding tool that acts on the welding region during induction welding. A removable polymer tape may be disposed between a workpiece and a metallic strip fixed to an induction welding tool. The workpieces may be thermoplastic composite structures and thermoplastic composite stiffeners in aircraft structures.

Abstract: A thrust reverser may include a frame, an actuation arrangement, a reverser door pivotally coupled to the frame, and a deployable fairing pivotally coupled to the frame, wherein the deployable fairing is configured to move away from a central axis of the thrust reverser to provide clearance for one of more thrust reverser pivot doors to rotate into a deployed position.

Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).

Abstract: An assembly is provided for an aircraft propulsion system. This aircraft propulsion system assembly includes a nacelle. The nacelle includes an inlet structure and a cowl. The inlet structure extends axially in a first direction along a centerline to an inlet structure aft end. The inlet structure includes a clip and a hoist bracket integrated with the clip. The clip is at the inlet structure aft end. The clip includes a locator receptacle. The hoist bracket is configured to provide a structural lift point for the inlet structure during assembly and/or disassembly of the nacelle. The cowl extends axially in a second direction along the centerline to a cowl forward end. The cowl includes a locator at the cowl forward end. The locator includes a protrusion received by the locator receptacle.