Abstract: A system for fusing thermoplastic composite structures includes a skin and a substructure on an inner surface of the skin. The system also includes a shaping surface of a tool, with the skin laid up on the shaping surface. The shaping surface is configured to maintain the shape of an outer mold line. The system further includes at least one insulation layer applied over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and a vacuum bag at least partly enclosing the skin and the substructure. Heat can be applied to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: A cap for a temporary fastener comprises a hollow, cup-shaped body and an inwardly tapered neck. The hollow body fits over a workpiece-engaging portion of the temporary fastener, and the neck extends from the hollow body. The tapered neck terminates in a hollow tip that is sized and configured to fit over aligned holes in the joined workpieces and to contact a minimal surface area of the outermost workpiece to reduce surface damage to the workpieces such that any damage will be removed when the holes are countersunk in the normal course of assembly.

Abstract: A cascade assembly for a thrust reverser of an aircraft engine. The cascade broadly comprises a number of vanes formed of a pliable material and shiftable between a collapsed position when the thrust reverser is in a stowed configuration and a distended position when the thrust reverser is in a deployed configuration to redirect fan duct flow in a reverse thrust flow opening created by the thrust reverser.

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.

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 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 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 an amorphous 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 amorphous thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.

Abstract: A system for peen-forming of thermoplastic composite material is provided. The system includes a tool, a heater, and a peen-forming device. The thermoplastic composite material is positioned on the tool, which supports the thermoplastic composite material as it is being process. The tool has a surface to which a portion of the thermoplastic composite material is intended to conform. The heater is configured to heat the thermoplastic composite material while it is positioned on the tool to make the thermoplastic composite material more malleable. The peen-forming device directs particles against the thermoplastic composite material positioned on the tool so that the portion of the thermoplastic composite material conforms to the surface of the tool.

Abstract: A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.

Abstract: A cap for a temporary fastener comprises a hollow, cup-shaped body and an inwardly tapered neck. The hollow body fits over a workpiece-engaging portion of the temporary fastener, and the neck extends from the hollow body. The tapered neck terminates in a hollow tip that is sized and configured to fit over aligned holes in the joined workpieces and to contact a minimal surface area of the outermost workpiece to reduce surface damage to the workpieces such that any damage will be removed when the holes are countersunk in the normal course of assembly.

Abstract: A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: A cascade assembly for a thrust reverser of an aircraft engine. The cascade broadly comprises a number of vanes formed of a pliable material and shiftable between a collapsed position when the thrust reverser is in a stowed configuration and a distended position when the thrust reverser is in a deployed configuration to redirect fan duct flow in a reverse thrust flow opening created by the thrust reverser.

Abstract: A modular floor system with an integral utility for temporary installation in an unfinished aircraft fuselage to facilitate construction. The system includes multiple floor modules, each including a catch pan defining a pan volume, a grid top surface supported on the catch pan over the pan volume, and a utility manifold carrying a utility across the module and to the next module. The modules may be sized and shaped to conform to different installation locations within the vehicle body. The grid top surface is openable to access the pan volume to remove debris or items. Adjacent modules are coupled together with connectors. The utility may be vacuum, air, electricity, or water, and one manifold may carry air and another manifold may carry vacuum. A fixture may be connected to the vacuum manifold and receive an end of a drill so as to remove debris resulting from operation of the drill.

Abstract: A method for fusing thermoplastic composite structures includes placing a thermoplastic substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one metal layer over the substructure and applying an insulation layer over edge portions of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure and applying a vacuum bag that at least partly encloses the skin, the substructure, and the metal layer. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: A system and method for drilling a hole in a vehicle structure and installing a fastener in the hole. A drill plate having openings and associated machine-readable elements is positioned on the structure. A drill gun is positioned in a particular opening and reads hole information from the associated element, and a computer determines whether the drill gun is properly set-up to drill the hole. A fastener insertion gun is positioned in the particular opening and reads fastener information from the element, and the computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set-up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of every hole, the insertion of every fastener, and the overall operation of the fastener delivery subsystem.

Abstract: A system for peen-forming of thermoplastic composite material is provided. The system includes a tool, a heater, and a peen-forming device. The thermoplastic composite material is positioned on the tool, which supports the thermoplastic composite material as it is being process. The tool has a surface to which a portion of the thermoplastic composite material is intended to conform. The heater is configured to heat the thermoplastic composite material while it is positioned on the tool to make the thermoplastic composite material more malleable. The peen-forming device directs particles against the thermoplastic composite material positioned on the tool so that the portion of the thermoplastic composite material conforms to the surface of the tool.

Abstract: A system for mounting an engine on an aircraft. The system includes a lower forward element, lateral linkages, an upper forward element, and an aft element. The lower forward element couples a forward portion of an engine core with a lower forward portion of a pylon. The linkages extend laterally between the lower forward element and the forward portion of the engine core. The upper forward element couples an outer portion of the fan case with an upper portion of the pylon. The aft element is spaced aftwardly apart from the lower and upper forward elements, and couples an aft portion of the engine core to an aft portion of the pylon. The system reacts all major moments acting on the engine, and the system does not extend beyond an outer periphery of the fan case, which eliminates the need for or minimizes the height of an aerodynamic fairing.

Abstract: A system and method for more consistent joule heating of a material blank to a desired temperature. An electrical terminal delivers a current to an end portion of the blank. The terminal has a heat sink effect which would otherwise prevent the end portion from reaching the desired temperature. An active thermal buffer element is interposed between the terminal and the end portion. The buffer element includes a first surface which abuts the end portion and a second surface which abuts the terminal. The buffer element is joule heated with the blank, and a temperature gradient is created across the buffer element such that the first surface is at the desired temperature and the second surface is at a lower temperature due to the heat sink effect of the terminal. The buffer element thereby compensates for the heat sink effect and allows the end portion to reach the desired temperature.

Abstract: A cascade assembly for a thrust reverser of an aircraft engine. The cascade broadly comprises a number of vanes formed of a pliable material and shiftable between a collapsed position when the thrust reverser is in a stowed configuration and a distended position when the thrust reverser is in a deployed configuration to redirect fan duct flow in a reverse thrust flow opening created by the thrust reverser.

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.