Abstract: The disclosure discloses apparatus and methods for repairing defects such as porosity and/or edge delamination in composite laminates by infusion of flowable matrix material. In some embodiments, methods disclosed herein comprise infusing the flowable matrix material into a space in the composite laminate through the use of a formed hole extending at least partially through the composite laminate. In some embodiments, methods disclosed herein comprise infusing the flowable matrix material into a space in the composite laminate in a stepwise manner in order to obtain more complete filling of such space.

Abstract: A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

Abstract: Noise attenuating devices and methods, precursors and abrasive blasting masks for manufacturing noise attenuating devices are disclosed. An exemplary method disclosed herein includes bonding a facing sheet of the noise attenuating device to a cellular core and then perforating the facing sheet. Perforating the facing sheet may be performed by abrasive blasting using a mask configured to prevent the abrasive blasting of an underlying structure.

Abstract: A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

Abstract: A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

Abstract: A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

Abstract: A material is formed by dividing a fabric into pieces that are substantially parallelogon in shape, the fabric having multiple parallel fibres. The pieces are placed, for example, with a pick and place machine, adjacent to each other on a carrier veil with fibres of adjacent of the pieces in substantial alignment. The pieces are attached to the carrier veil to form the material, the material including the pieces and the carrier veil.

Abstract: A liquid shim includes a bag (24) defining a closed inner volume and having sealed openings spaced inwardly from a periphery of the bag. The sealed openings are sealed from the closed inner volume and delimit holes extending through the bag. A liquid shim material (22) is flowable through the closed inner volume around the sealed openings and is curable to form a solid. The liquid shim material has a liquid shim material volume being less than the closed inner volume of the bag. A method of creating a liquid shim, and a method of shimming a gap between components, is also disclosed.

Abstract: A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

Abstract: A structural assembly of an aircraft has a fastener extending into first and second structural members. A washer is disposed between the fastener and one of the structural members to electrically insulate the fastener and the structural members. The washer has a core of reinforcement fibers supported in a thermoplastic matrix material. Electrically-insulating outer layers of glass fibers overlay the core.

Abstract: A variable area fan nozzle for a turbofan aircraft engine includes a first structure defining a forward portion of a bypass duct of the turbofan aircraft engine and a second structure defining an aft portion of the bypass duct. The second structure is movable relative to the first structure between a deployed position where a porting flow passage defined between the forward portion of the bypass duct and the aft portion of the bypass duct is open, and a stowed portion where the porting flow passage is closed. The movable second structure comprises a vane and a slat attached to the vane and disposed forward of the vane. The porting flow passage extends between the slat and the vane when the second structure is in the deployed position.

Abstract: Systems and methods for detecting a kiss bond in a composite component are provided. Using reflected ultrasound data representative of reflected ultrasound energy from the composite component, a first threshold amplitude value between 2% and 5% higher than a predetermined baseline noise amplitude value of expected material noise in the reflected ultrasound energy from the composite component, and a second threshold amplitude value higher than the first threshold amplitude value, one or more occurrences of an amplitude of the reflected ultrasound energy exceeding the threshold amplitude value and less than the second threshold amplitude value are identified. The kiss bond is detected in the composite component based on the identified one or more occurrences of the amplitude of the reflected ultrasound energy.

Abstract: A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

Abstract: An isolator fitting for an opening in a metallic rib of an aircraft wing. The isolator fitting has first isolator mountable to the rib to position a first isolator opening in alignment with the opening of the rib. A second isolator is mountable to the rib and has a nut housing segment defining a second isolator opening to be positioned in alignment with the opening of the rib. A conduit extends between a first end and a second end, and a nut is mountable about an outer surface of the conduit to abut against the first isolator and mount the conduit thereto. The conduit is positionable to extend through the opening of the rib and through the first and second isolator openings to position the nut within the nut housing segment of the second isolator such that the nut housing segment is positioned between the nut and the rib.

Abstract: A repair for a structural element made from a composite material includes a bracket defining a first surface and a second surface. The first surface is adapted for facing the structural element. A chamfer is located on a first end of the bracket. An angle is defined between a plane of the chamfer and a plane of the first surface, the first surface of the bracket being adapted to be disposed adjacent to a side of the structural element. The repair also includes a sealant material between the bracket and the structural element, where the sealant material occupies a space established between the chamfer and the structural element.

Abstract: Ice protection systems of aircraft and related methods are disclosed. In one embodiment of the present invention, the system includes a gas-discharge lamp and an electric power source. The gas-discharge lamp is configured to emit infrared radiation toward an inner surface of an aircraft skin. The electric power source is operatively connected to the gas-discharge lamp.

Abstract: An apparatus and methods include infusing the flowable matrix material into a space in the composite laminate through the use of a formed hole extending at least partially through the composite laminate. In addition, the apparatus and methods include infusing the flowable matrix material into a space in the composite laminate in a stepwise manner in order to obtain more complete filling of such space.

Abstract: A nacelle for an aircraft having a thrust reverser including a translating cowl and a blocking panel. The blocking panel is connected by a pivot connection and is connected to the translating cowl by a sliding connection including an engagement member slidingly engaged in a track, the track having a first portion parallel to the longitudinal axis of the outer casing and a second portion non-parallel to the longitudinal axis. Motion of the translating cowl along the longitudinal axis slides the engagement member within the track, and is performed without moving the blocking panel when the engagement member is within the first portion of the track. The motion of the translating cowl causes the blocking panel to pivot about the pivot connection when the engagement member is within the second portion of the track.

Abstract: Noise attenuating devices and methods, precursors and abrasive blasting masks for manufacturing noise attenuating devices are disclosed. An exemplary method disclosed herein includes bonding a facing sheet of the noise attenuating device to a cellular core and then perforating the facing sheet. Perforating the facing sheet may be performed by abrasive blasting using a mask configured to prevent the abrasive blasting of an underlying structure.

Abstract: Apparatus and methods for manufacturing and repairing fibre-reinforced composite materials are disclosed. In various embodiments, the apparatus and methods disclosed herein use a resin retaining/releasing device comprising resin having a viscosity that is temperature dependent for infusion into a region of a part. The resin retaining/releasing device may include a first sheet and an opposite second sheet at least partially enclosing the quantity of resin. The first sheet and the second sheet may be gas-permeable. The second sheet may be substantially resin-impermeable when the viscosity of the resin is above a threshold viscosity and resin-permeable when the viscosity of the resin is below the threshold viscosity.