Abstract: An acoustic panel assembly includes an acoustic panel including an acoustic core arranged along a transverse direction and a longitudinal direction. The acoustic core extends between and to an inner core side and an outer core side. The acoustic core includes a plurality of cell rows distributed transversely. Each cell row of the plurality of cell rows includes a plurality of cells distributed longitudinally along the respective cell row of the plurality of cell rows. Each cell of the plurality of cells includes a first transverse panel, a second transverse panel, a first longitudinal panel, a second longitudinal panel, and an oblique panel extending between the inner core side and the outer core side. Each cell row of the plurality of cell rows includes a primary folded sheet and a secondary folded sheet. Each of the primary folded sheet and the secondary folded sheet forms the first transverse panel, the first longitudinal panel, and the second longitudinal panel for each cell of the plurality of cells.

Abstract: A formation method is provided during which a honeycomb core, a thermoplastic film and a fiber-reinforced thermoplastic skin are arranged in a stack with the thermoplastic film between the honeycomb core and the fiber-reinforced thermoplastic skin. The thermoplastic film comprises a thermoplastic material. A metal conductor is arranged on the stack with the fiber-reinforced thermoplastic skin between the thermoplastic film and the metal conductor. The metal conductor is induction heated to provide a heated metal conductor. The thermoplastic film is conduction heated through the fiber-reinforced thermoplastic skin using the heated metal conductor to melt the thermoplastic film and bond the fiber-reinforced thermoplastic skin to the honeycomb core with the thermoplastic material.

Abstract: An aircraft propulsion system assembly includes a stationary structure, a nacelle inner structure and a nacelle outer structure. The nacelle inner structure extends circumferentially about an axis and includes a first inner structure section, a second inner structure section and a plurality of inner structure latches. The first inner structure section is disposed to a first side of the stationary structure. The second inner structure section is disposed to a second side of the stationary structure. The second inner structure section is attached to the first inner structure section by the plurality of inner structure latches. The nacelle outer structure extends circumferentially about the nacelle inner structure and includes a first outer structure section and a second outer structure section. The first outer structure section is pivotally coupled to the stationary structure. The second outer structure section is pivotally coupled to the stationary structure.

Abstract: An assembly is provided for an aircraft propulsion system. This assembly includes a fixed structure, a translating structure and a thrust reverser. The translating structure is configured to translate between a stowed position and a deployed position. The thrust reverser includes a blocker door, an actuation linkage and a spring cartridge. The blocker door is pivotally coupled to the translating structure. The actuation linkage operatively couples the blocker door to the fixed structure. The spring cartridge is coupled to the blocker door and the translating structure. The spring cartridge is configured to bias the blocker door closed.

Abstract: A method for applying a sulfonation treatment to a thermoplastic part includes installing a gas sulfonation assembly on one or more surfaces of the thermoplastic part by forming a vacuum bag on the one or more surfaces. The vacuum bag forms a sealed cavity between the vacuum bag and a treatment portion of the one or more surfaces. The method further includes drawing a vacuum in the sealed cavity with the gas sulfonation assembly, directing a sulfonating gas into the sealed cavity with the gas sulfonation assembly to sulfonate the treatment portion, removing the sulfonating gas from the sealed cavity with the gas sulfonation assembly, removing the gas sulfonation assembly from the thermoplastic part, applying a neutralizing agent to the treatment portion, and applying at least one coating to the treatment portion.

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.