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 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 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 method for heat-treating a titanium alloy, such as Ti-6Al-4V. The method may occur after or include a step of forging the titanium alloy such that localized, highly deformed grains are formed in the titanium alloy. Then the method may include steps of recrystallization annealing the titanium alloy by heating the titanium alloy to a temperature in a range between 30° F. to 200° F. below beta transus of the titanium alloy for 1 hour to 6 hours and then furnace cooling of the titanium alloy to 1200° F. to 1500° F. at a rate of 50° F. to 500° F. per hour. Following the recrystallization annealing, the method may include beta annealing the titanium alloy. These steps may be performed in a single heat treating cycle.

Abstract: A nacelle mounted above a wing of an aircraft. A support structure on the nacelle above the pylon resists forces in different directions, and includes door supports allowing the door to be opened upwardly. A retaining structure on the pylon below the nacelle resists forces in different directions, and includes a fixed support track and multiple keepers. Each keeper includes a first end which slides within the channel, and a second end which engages a latch on the closed door. A pylon below the nacelle supports the nacelle and an engine in the nacelle above the wing, increases aerodynamic efficiency, and may include a side spar for supporting the engine from the side. A fire seal assembly includes a depressor surface and a fire seal, and the latter does not contact the former until the door is almost closed, so that compression is substantially direct and scrubbing is reduced.

Abstract: An aircraft panel assembly including a panel, a number of open-ended composite stringers, and a number of stringer end caps. Each stringer end cap covers an open end of one of the stringers and includes a base, a vertically extending wall, and an overlap section. The base is bonded to the panel near the open end of the stringer. The vertically extending wall is angled upward from the base and includes an upper periphery. The overlap section extends horizontally from the upper periphery and is bonded to the stringer near the open end of the stringer.

Abstract: An acoustic panel for attenuating sound, and a system and method for making the acoustic panel. The acoustic panel employs rounded particles which are introduced into the cells of a core and fixed at a particular depth to form a septum layer providing substantially linear acoustic resistance to sound waves entering the cell. The particles may be between 100 microns and 700 microns in diameter, may be solid or hollow, may have smooth or textured surfaces, and/or may be made of syntactic foam or glass or ceramic. The system includes a positioning mechanism for positioning the particles at the particular depth, metering and gating mechanisms for introducing a metered amount of the particles into each cell, and a vibratory base for vibrating the particles to better pack them. Once the particles are in the cells, the septum layer is fixed, and the positioning mechanism is removed.

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 welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: A system and method for forming a part using a moveable heater to heat a pre-aligned blank and an alignment mechanism to maintain the alignment of the heated blank during the forming process. A frame receives and holds the blank in the pre-aligned position within an open press. The heater advances into the press to heat the pre-aligned blank to a forming temperature, and withdraws to allow the press to close and form the heated blank into the part. The alignment mechanism maintains the blank in the alignment while the blank is heated and the press is closed, and includes a rail extending through the press and the frame and allowing the press to move between open and closed positions, and a collapsible member which pushes the frame as the press closes and collapses to allow the press to fully close and form the heated blank into the part.

Abstract: An automated fiber placement (AFP) and in-situ fiber impregnation system includes a feeder, a resin dispenser, and a compaction roller. The feeder feeds a tow of fiber from a fiber supply toward a forming tool. The resin dispenser deposits resin onto the forming tool in front of the compaction roller. The compaction roller moves over the tow along the forming tool so as to press the tow onto the resin such that the compaction roller impregnates the resin into the tow a direction away from the forming tool via compaction forces immediately after the resin is deposited by the resin dispenser.

Abstract: A system for actuating a blocker door of a thrust reverser, in which a drag link assembly is removed from the airflow through the engine during flight. The assembly couples the door to a sleeve so that translation of the sleeve between deployed and stowed positions moves the door to open and closed positions, respectively. The assembly includes a telescoping drag link having one end rotatably coupled with a drag link anchor and another end coupled with the door. During deployment and stowage, translation of the sleeve causes the door to move and the link to extend or collapse and rotate until it contacts a stop element of the anchor, and then rotate in the opposite direction as the door opens or closes, respectively. A channel may be provided in the door to accommodate the link. The anchor may include a spring which exerts a rotational force on the link.

Abstract: A multi-function support assembly supports, grounds, and shields numerous different types of aircraft systems and simultaneously stabilizes aircraft structures to which the support assembly is mounted. The support assembly includes a support tray and a number of support brackets attached to and spaced along the length of the support tray. The support tray attaches to aircraft floor beams or other aircraft structures to stabilize the structures while providing a mounting location for the support brackets. The support tray also provides electromagnetic and structural shielding for aircraft systems and a ground path for electrical and electronic components in the aircraft. The support brackets are formed of electrically insulative materials and attach to the support tray to support various aircraft systems below the support tray and to electrically isolate the support tray from the aircraft structures and the aircraft systems from the support tray.

Abstract: An acoustic perforation method and assembly for forming holes or perforations into a face sheet of a sandwich panel without damaging a honeycomb core thereof. The method may include photographing or otherwise scanning the face sheet bonded to the honeycomb core after cure, then detecting locations of cell walls of the honeycomb core via image processing or analysis of scan data obtained. For example, discolorations on the face sheet or coatings applied thereto may indicate locations of the cell walls of the honeycomb core. A perforation pattern may then be generated or altered based on the detected locations of the cell walls, and a perforation device may be commanded to perforate the face sheet in accordance with the perforation pattern at locations where the cell walls are not located.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: A structure and a method of creating the structure in which relatively thin pieces of non-weldable aluminum alloy or other non-weldable material are welded together. First layers of a weldable material, such as a weldable aluminum alloy or other weldable material, having a total thickness of between 0.01 and 0.30 inches, are built up on a surface of the first piece using an ultrasonic or other solid state joining technique, and second layers of the weldable material having a similar total thickness are built up on a surface of the second piece using the same technique. The first piece is then welded to the second piece at the first and second layers of weldable material using a fusion welding technique. The resulting structure may be part of an aircraft, landcraft, watercraft, or spacecraft type of vehicle or may be used in other high-performance applications.

Abstract: A part assembly including a curing shield and a method for secondarily bonding two parts of the part assembly utilizing the curing shield. The method for secondary bonding includes fixing a base of a clip of a curing shield to a first surface of a first part. The curing shield includes a pad fixed to the clip. The clip has the base and a spine fixed to and extending away from the base and terminating at a distal end. The pad extends along at least a portion of a length of the spine between the base and the distal end. The method also includes applying adhesive along a faying surface of one of the first part and a second part. The second part is assembled to the first part along the faying surface so that the distal end of the clip extends toward the second surface and the curing shield defines a pocket adjacent the faying surface at least partly enclosed by the pad.

Abstract: A part assembly including a curing shield and a method for secondarily bonding two parts of the part assembly utilizing the curing shield. The method for secondary bonding includes fixing a base of a clip of a curing shield to a first surface of a first part. The curing shield includes a pad fixed to the clip. The clip has the base and a spine fixed to and extending away from the base and terminating at a distal end. The pad extends along at least a portion of a length of the spine between the base and the distal end. The method also includes applying adhesive along a faying surface of one of the first part and a second part. The second part is assembled to the first part along the faying surface so that the distal end of the clip extends toward the second surface and the curing shield defines a pocket adjacent the faying surface at least partly enclosed by the pad.

Abstract: A plugged stringer on a surface of a part, and a method and assembly for production of the plugged stringer. The plug has opposite first and second axial end faces. The plug also has a radially outer margin defined by a radially outer bottom face, radially outer first and second opposite side faces, and a radially outer top face. The plugged stringer also includes a covering overlaying the radially outer top face and the first and second opposite side faces of the plug and extending away from the plug along an axis to form a stringer having first and second segments delineated by the plug. The radially outer margin of the plug is at least partly covered by an adhesive. The radially outer bottom face is adhered to the surface of the part, and the covering is adhered to the radially outer first and second opposite side faces and the radially outer top face. The first and second segments of the stringer respectively define first and second fluid passages separated by the plug.

Abstract: An inlet for a nacelle and an AM system and method for manufacturing the inlet having fewer discontinuities on the exterior surface to achieve a smoother flow over the inlet. The inlet includes an annular lip-cowl and a supporting framework. The AM system includes a support structure providing a form, and AM heads for depositing materials onto the form, with the materials subsequently hardening to become the lip-cowl. The support structure may have an upright or inverted orientation, is rotatable, and may be tiltable. Components may protrude from the form to be incorporated into the lip-cowl. The AM heads are mounted on moveable arms and are computer-controlled to deposit the material onto the form, and may be moveable along a radial axis to accommodate an asymmetrical portion of the form. The AM system may further include one or more machining heads for subtractively machining the deposited material.