Abstract: The disclosure relates to a method of forming carbon-carbon composites wherein prereaction of the filler ingredients takes place prior to the prepregging operation, thereby ensuring that the sealant phase is both homogeneous and unsegregated on a microscopic scale. Composites prepared from several constituent inhibitor powders often have one inhibitor component segregated within the carbon fabric and fiber bundles during compaction, debulking and press curing. Composites prepared from prereacted powders have inhibitor constituents mixed on an atomic scale. Thus, the oxide sealant which forms from the prereacted particulate filler has an optimized composition with all of the desirable qualities, such as level viscosity, good wetting, low water solubility, low reactivity with the carbon fibers and carbon matrix during graphitization and low reactivity with the chemically vapor deposited coating.

Abstract: A high strength, light weight stabilized skin structure having spaced skin sheets and a plurality of hollow metal spheres filling the space between the skins. The spheres and skins are bonded together, resulting in a unitary structure. The spheres typically have outside diameters of from about 0.005 to 0.5 inch, with tall thicknesses of about 0.0005 to 0.005 inch. Spheres of different sizes may be used, with smaller or heavier wall thickness spheres in high load areas, such as insert attachment points, and larger spheres in lightly loaded areas. The spheres preferably have a surface coating of a brazing material and are bonded together and to the skins by furnace brazing.

Abstract: A method of manufacturing thermal barrier structures comprising at least three inner dimpled cores separated by flat plate material and having outer surfaces of the flat plate material, all elements being joined together by liquid interface diffusion (LID) bonding.

Abstract: An oxygen resistant high temperature composite structure comprises a carbonous matrix and reinforcing high temperature fibers disposed within said matrix, an outer refractory coating covering said matrix, boron, in elemental form and/or as a moiety of a compound dispersed throughout said structure, silicon, in elemental form and/or as a moiety of a compound dispersed throughout said structure, and titanium, in elemental form and/or as a moiety of a compound dispersed throughout said structure, said silicon and said boron oxidizing when exposed to a high temperature, oxidizing environment to form silicon oxide and boron oxide, and said titanium forming titanium oxide which stabilizes the molten phase of the boron oxide. Microcracks which form in the refractory coating are sealed by a molten glass which forms from oxidation of the boron, silicon and titanium, thereby preventing oxidation degradation of the underlying matrix.

Abstract: A method and apparatus for forming and bonding metal assemblies using an internally heated chamber. The parts can be both superplastic formed and diffusion bonded to other parts. A closable chamber contains a heating element near the chamber center. A ceramic die at least partially surrounding the heating element has a forming surface toward the heating element. The inner wall of the chamber is lined with a pressure bladder. A granular material, conical ceramic support, or extensible bladder fills the space between ceramic die and chamber inner wall. With the chamber closed, the heater is activated while an inert gas under pressure is introduced between heater and die and the bladder if used is pressurized. The bladder or packed granules support the outer die surface while the gas pressure presses metal parts on the die forming surface against the die. The metal parts are formed and bonded together by the substantially isostatic forces thereon.

Abstract: A filament winding payoff unit and process for applying strands of adhesive impregnated filament material arranged into a gap-free band to a rotating mandrel. A plurality of side-by-side slightly overlapped impregnated filament strands are passed over bars between tines of combs for positioning when leaving the payoff head. The payoff head is positionable toward and away from the rotating mandrel to allow for mandrel longitudinal dimension changes while maintaining the payoff head roller in contact with the mandrel at a predetermined pressure thereagainst. The payoff head is also freely pivotable horizontally to maintain a proper angle of filament application to any changing mandrel longitudinal configuration.

Abstract: A method of diffusion brazing two or more titanium alloy metal parts, such as sheets, thick sections or a honeycomb core to one or two face sheets, to form a unitary panel. A low melting copper-nickel layer is interposed between the faying surfaces of two parts to be bonded. The layer may be a foil placed between the surfaces or may be a layer plated onto one or both surfaces. The assembly is heated to at least the eutectic melting temperature of the base metal-interlayer eutectic point for a time sufficient to permit effective wetting and diffusion bonding of the surfaces. The assembly is held at the elevated temperature a sufficient additional time so as to allow isothermal solidification to occur. The assembly is then cooled, resulting in a unitary structure. This method is particularly effective with titanium aluminides face sheets and a titanium aluminide or other titanium base honeycomb core and with an interlayer consisting essentially of nickel and copper.

Abstract: An electronic indicator comprising a first portion attached at one end to an object to be controllably stretched or elongated and a second portion slideably connected to the first portion for relative movement therewith and connected at one end remote from the object attachment of the first portion. Electrical connections donating relative movement between the two indicator portions are attached to monitoring equipment to indicate stretch length.

Abstract: Apparatus and method for welding high electrically conductive metal and metal alloys. High thermal and high electrical conductive metals such as, for example copper foil and the like, normally unweldable by resistance welding means due to their physical makeup, can now be welded in a conventional manner by the use of pairs of welding electrodes constructed of molybdenum.

Abstract: The invention is directed to an improved hopper for feeding abrasive material of very small grit size to a cutting head. The device comprises an open hopper vertically disposed with a transverse positioned pick-up tube located in the lower portion of the hopper. The pick-up tube has a tubular center with a necked down diameter intermediate of its's ends. An opening extends from the bottom of the tube into the tubular center at a location centered in the necked down portion thereof. One end of the tube is vented to atmosphere through an adjustable orifice and the other end is connected to a source of low pressure created within the mixing chamber of the nozzle body assembly by high pressure water passing across the open end of the tube. This effect causes abrasive grit to be drawn through the opening in the bottom of the tube out the low pressure end of the tube to the cutting head.

Abstract: A filament winding payoff head unit and process for applying strands of adhesive impregnated filament material arranged into a gap-free band to a rotating mandrel. A plurality of side-by-side slightly overlapped impregnated filament strands are passed over bars between tines of combs for positioning when leaving the payoff head. The payoff head is positionable toward and away from the rotating mandrel to allow for mandrel longitudinal dimension changes while maintaining the payoff head roller in contact with the mandrel at a predetermined pressure thereagainst. The payoff head is also freely pivotable horizontally to maintain a proper angle of filament application to any changing mandrel longitudinal configuration.

Abstract: A method of producing a reinforced duct structure for use with turbo-fan aircraft engines and the like. The duct is first cut from a flat metal sheet in a predetermined pattern. The sheet is rolled to form a tubular or conic structure of the approximate desired configuration and welded along the open seam. The welded tubular structure is then expanded to the exact required shape. The expanded tubular structure is cut out in selected areas to form a tubular grid structure. A tubular liner conforming to the inner surface of the tubular grid structure is installed and bonded to the grid structure forming an integral tubular structure of the desired configuration and strength and; attachment of any required mating flanges and structure bosses to the integral tubular structure.

Abstract: A method of laminating a porous overlay material to a perforated plate with a dry film adhesive which does not block perforations or pores in the two components. A lay-up is preferably prepared by assembling in order on a vacuum platen a porous peel ply sheet, a sheet of dry film adhesive, a perforated plate, a sheet of microporous material to be bonded to the perforated plate and an air permeable sheet. A vacuum is drawn through holes in the vacuum platen contiguous to the bottom surface of the porous peel ply sheet while the assembly is heated to the softening temperature of the adhesive film. The vacuum is directly applied through the perforation, drawing the film down through the perforations and into contact with the peel ply sheet. As heating continues the film softens sufficiently to adhesively bond the microporous material to the perforated sheet.

Abstract: A cascade assembly for directing the gases externally of a jet aircraft engine in a forwardly direction when the engine is in a gas reversing mode. The cascade assembly comprises a plurality of cascade panel sections positioned in a side by side relationship over an opening in the engine nacelle. The panel sections have a plurality of spaced apart curvilinear vanes angled from the centerline of the engine. Longitudinal beams are positioned over the longitudinal edges and adjacent ends of at least one cascade panel section to secure it in place. The beam is "T" configured in the cross-section with feet or pads on each end to overlay the longitudinal outer edge and adjacent end surfaces of the cascade panel section or sections which it is securing in place. The pads or feet on the beam ends include apertures therethrough for securing the beams to aircraft structure. Both the cascade panel sections and beams are constructed of molded plastic or cured composite materials.

Abstract: A boundary layer control device is installed in the acoustically treated inlet duct of a turbofan engine. The device sucks off the turbulent boundary layer of air flowing over the inner or "air wetted" surface of the inlet during aircraft take-off, cruise and approach. The lip of the inlet can thus be made thinner to reduce drag during cruise without degradation of fan performance during take-off. The acoustic liner of the inlet comprises a microporous honeycomb sandwich structure through which air may be sucked at various locations through headers and conduits connected to an onboard pump.

Abstract: A perforated flat ribbon heating element embedded or sandwiched between the porous material and perforated sheet of honeycomb acoustic panel material used for sound suppression and deicing on ice buildup areas of an aircraft engine.

Abstract: The disclosure relates to a method of joining titanium and titanium based alloys to columbium at low pressure and low temperature, wherein a titanium foil is electroplated with layers of copper and nickel with a columbium sheet then being placed in intimate contact with the exposed layer. The materials are then heated in a vacuum to a temperature above the Ti-Cu-Ni eutectic temperature and below the beta-transus of the titanium material to provide a joining of titanium to columbium without materially altering the mechanical properties of the materials involved.

Abstract: A pin assembly for removably attaching a jaw portion of a translatable jaw of a stretch jaw chuck through an elongated slotted opening in the chuck wall. A bushing is threaded into mating threads in a bore in the jaw portion. The bushing has a centrally positioned substantially rectangular shaped opening extending therethrough with a slot formed on the bottom exterior surface of the bushing adjacent to each elongated side of the rectangular opening therethrough. An attachment pin is provided with a first end configured to pass through the opening in the bushing and latch into the aligned slots on the outer surface. The pin has a coil spring confined between a pair of flat washers. The first washer adjacent the second end of the pin rides against a nut adjustable along a threaded portion of the pin.

Abstract: The disclosure relates to a method of joining nickel and nickel based alloys to columbium at low pressure and low temperature, wherein a thin titanium brazing foil is provided, with or without a copper coating electroplated thereon. The layers or foils of the metals to be joined are placed in intimate contact with opposite sides of the brazing foil under pressure and heated in a vacuum to a temperature above the eutectic of the metals being used and below 2000.degree. F. and preferably below 1950.degree. F. to provide the bond.

Abstract: The disclosure relates to a method of bonding columbium to columbium wherein a brazing foil of titanium which has been coated with either a layer of copper or a layer of nickel or layers of copper and then nickel, preferably on both sides of the foil, is disposed between the columbium sheets or the like to be joined. The columbium are placed in intimate contact with opposite sides of the foil and heated to a temperature above the eutectic point of the eutectics of the metals of the foil and no higher than about 1750.degree. F. for about 90 minutes and then cooled to provide the desired bond.