Abstract: A method of bonding two or more metallic components into a single piece. The bonding surfaces of the metallic components are protected from reaction with the environment. A force is applied to the metallic components to push the bonding surfaces together. Simultaneous with applying the force, an electric current is passed through the bonding surfaces to joule heat and weld the bonding surfaces together to form the single piece. The bonding surfaces may be protected by plating with a noble metal, applying a coating, shielding with a noble gas, or placing into a vacuum. A press may be used to apply the force. The force and the electric current may be sufficient to push out metal around the joint of the bonding surfaces, and at least one of the bonding surfaces may be drafted to facilitate pushing out the metal. The electric current may be pulsed to induce electroplasticity.

Abstract: Disclosed is a method of resistance welding between composite articles. A conductive element is provided between faying surfaces, having a plurality of lower resistivity electrode portions spaced apart along the length of the contact area between the composite articles. The electrode portions can be used to spot weld across the electrode portions, and along a longitudinal portion of the conductive element between the electrode portions by application of an electrical current. Also disclosed are apparatus for use in the resistance welding methods and composite articles and structures and elements incorporating the conductive element.

Abstract: A method of manufacturing metal matrix composite (MMC) parts, including the steps of applying a metallic sheath around a bundle of MMC laminates, heating the bundle of MMC laminates in the metallic sheath at a curing or fusing temperature to consolidate the bundle of MMC laminates into a single cured or fused part, and then cooling the cured or fused part. The bundle of MMC laminates may be formed by removing surface contamination from the dry reinforcement fibers, creating a plurality of individual MMC laminates by plating dry reinforcement fibers with electroless nickel, and/or electrodeposited nickel or cobalt, and stacking each of the plurality of individual MMC laminates into a bundle. Autocatalytic and/or electroplating may be used as the primary means to incorporate fiber reinforcement into the metal matrix composite by covering and bonding fiber reinforcement into MMC laminates/plies and/or 3-D woven parts.

Abstract: A handheld device for making 3D topography measurements of surface discontinuities in high performance structures, such as aerostructures (e.g., aluminum fuselages). Lights illuminate the discontinuity from multiple angles, and a camera captures images of the discontinuity. A thickness sensor generates thickness data regarding a thickness of the base material and the top protective coating. A position sensor generates position data regarding a location of the discontinuity on the structure. A processor generates geometry data regarding a geometry of the discontinuity based on the images, performs an analysis of the geometry, thickness, and position data, and communicates a result of the analysis on a display. A conforming membrane and/or a gel and an opaque lubricant may be applied over and conform to the discontinuity in order to make more uniform a reflectivity difference and a color difference between the discontinuity and an adjacent portion of the structure.

Abstract: A composite aircraft engine pylon comprising a frame, an aircraft attachment component, and an engine support. The frame includes an outer structural section and an inner structural section configured to at least partially nest with the outer structural section. The outer structural section and the inner structural section sandwich the airframe attachment component and the engine support to form double shear connections between the frame and the aircraft attachment component and between the frame and the engine support.

Abstract: An aircraft propulsion system configured to be supported from an aircraft wing having a leading edge and opposing upper and lower surfaces. The aircraft propulsion system broadly comprises an engine having a core, a fan case, and a nacelle including a plurality of access panels, and an attachment assembly for securing the engine to the aircraft wing. The attachment assembly broadly comprises an upper support section including a number of spars and a number of ribs connected between the spars, a lower support section, and an aft section. The attachment assembly aerodynamically melds the nacelle and the aircraft wing together via the upper support section so that air flowing over the engine flows over the aircraft wing along the upper surface and air flowing laterally alongside the nacelle flows under the aircraft wing along the lower surface.

Abstract: A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.

Abstract: A system and method for thermoplastic composite processing including compressing and heating a thermoplastic composite panel having a plurality of terminal edges. The method further includes heating the thermoplastic composite panel to a melting temperature to create a melt front of the thermoplastic composite panel at a first location and heating the thermoplastic composite panel to the melting temperature in a pre-determined pattern from the first location toward the terminal edges of the thermoplastic composite panel. Extending the melt front toward the terminal edges in this way causes air constrained within the thermoplastic composite panel to escape the thermoplastic composite panel through unmelted portions of the thermoplastic composite panel located between the melt front and the terminal edges. Cooling of the panel may be similarly conducted, cooling a first region and then gradually continuing to cool the panel in a direction toward one or more of the terminal edges.

Abstract: Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.

Abstract: An interspatial blocker for a thrust reverser system of a turbofan engine, and a thrust reverser system and a turbofan engine incorporating the same. The interspatial blocker includes a first and second flap that rotate from a stored position to a blocking position, and a leading-edge structure rotatably coupling the first flap to the second flap. The leading-edge structure is set up to be installed in a fan nacelle of a turbofan engine in a substantially radial orientation such that the first flap rotates in a first direction about a first axis extending in a substantially radial direction from the stored position to the blocking position, and such that the second flap rotates in a second direction about a second axis extending in the substantially radial direction from the stored position to the blocking position, with the first direction being opposite to the second direction.

Abstract: A system for manufacturing a composite part including a conductive flexible facesheet and an automated tape layup (ATL) machine for laying up composite tape onto the facesheet that is laid flat on a flat surface. The system also includes a curved tooling surface for transferring the facesheet with the composite material thereon to the curved tooling surface for attachment of substructures and curing into the composite part. System may also include insulation placed below the facesheet and insulation placed above the composite material, as well as a source of electricity and heat for heating the conductive facesheet to cure, melt, or fuse the composite tape and substructures without heating the tooling surface and other tooling used in the composite curing process. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to conductive wires attached at opposing ends to the facesheet.

Abstract: A system for inspecting features of an airframe, the system including a feature inspection device configured to measure an aspect of a first feature and a tracking subsystem configured to determine a position of the feature inspection device when the feature inspection device measures the aspect of the first feature. The system is configured to determine a position of the first feature on the airframe via the feature inspection device and the tracking subsystem, the determination of the position of the first feature being independent from the measurement of the aspect of the first feature.

Abstract: A method for manufacturing a composite part by laying up courses of composite tape using an automated tape layup (ATL) machine onto a conductive flexible facesheet laid flat on a flat surface, and then transferring the facesheet with the composite material thereon to a curved tooling surface for attachment of substructures and curing into the composite part. The method may also include applying insulation below the facesheet and above the composite material, then heating the conductive facesheet to cure the composite tape and fuse the composite tape to the substructures without heating the tooling surface or any other items used to compress and cure the composite material into the composite part. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to a plurality of conductive wires attached at opposing ends to the facesheet.

Abstract: Tooling, systems, and methods for forming composite parts. The system includes a mold having a first mold portion with a molding surface, a second mold portion with a molding surface, and at least one laminate sheet opening. When the mold is in a closed, molding configuration, the first molding surface and the second molding surface collectively at least partially form an internal cavity defining an outer contour of the composite part. The system also comprises an injection molding nozzle that injects resin into the internal cavity and a laminate sheet supporting frame. The laminate sheet supporting frame supports at least one laminate sheet such that a portion of the at least one laminate sheet is permitted to pass through the at least one laminate sheet opening and conform to at least one of the first molding surface and the second molding surface during the forming of the composite part.

Abstract: A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having a thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.

Abstract: Disclosed is a method of resistance welding between composite articles. A conductive element is provided between faying surfaces, having a plurality of lower resistivity electrode portions spaced apart along the length of the contact area between the composite articles. The electrode portions can be used to spot weld across the electrode portions, and along a longitudinal portion of the conductive element between the electrode portions by application of an electrical current. Also disclosed are apparatus for use in the resistance welding methods and composite articles and structures and elements incorporating the conductive element.

Abstract: An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

Abstract: A system and method for thermoplastic composite welding comprising a cooling means and a heat source. The cooling means cools a heat-side laminate so as to create a thermal gradient in the heat-side laminate. The heat source heats the heat-side laminate after the cooling step is initiated but before the thermal gradient dissipates so that a first side of the heat-side laminate closer to the heat source does not deform as faying surfaces of the heat-side laminate and another laminate farther away from the heat source are welded together.

Abstract: Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.

Abstract: A method for preparing a part using a rigid tool surface having a shape. The method includes applying a breather sheet comprising gas-permeable material over the rigid tool surface. A vacuum bag is applied over the breather sheet, and a vacuum pressure is applied underneath the vacuum bag to conform the breather sheet and the vacuum bag to the shape of the rigid tool surface. A resin pre-impregnated ply is applied over the vacuum bag, and the part is positioned over the ply.