Abstract: Method to make a T shaped stiffener form from a stiffener preform (100) having a foot (130) configured to be in contact with an aircraft panel, and a sole (120) with an edge (120a). The manufacturing method includes: obtaining laminates (110a, 110b) formed of layers of composite material, folding the laminates (110a, 110b) to be L shaped in cross section, joining the laminates to form a T shaped preform (100), molding the edge of the sole (120a) so that the edge is semicircular in cross section, applying to the edge (120a) a strip of semi-cured carbon fabric (L1) and a fresh strip of prepreg fiberglass (L2), and curing the preform (100) to obtain the stiffener.

Abstract: A device for forming a composite laminate (10) for obtaining a Z-shaped profile (1) including: a grip module (5) comprising two plates (6) configured to enclose and grip between the two plates (6) a first portion of the composite laminate (10) that will form a first flange (3), and a feed module (7) comprising two plates (8) configured to enclose between the two plates (8) a second portion of the composite laminate (10), wherein the feed module (7) is configured to heat the portion of the composite laminate (10) located between its two plates (8) and to be movable with respect to the grip module (5) parallel to the plane of the web (2) of the composite profile (1) once formed to a second position in which the two plates (8) enclose the portion of the composite laminate (10) that will form a second flange (4).

Abstract: A composite forming station for forming a T-profile composite part from a planar laminate. The composite forming station includes in-line rollers arranged along a forming direction, wherein a thickness and/or edge angle each roller is greater than the preceding roller, wherein the rollers gradually splay apart feet sections of the planar laminate to convert the laminate to the T-profile composite part.

Abstract: A manufacturing system (1) for manufacturing shaped laminates including: forming tools (2.1, 2.2) extending along a longitudinal direction X, located parallel to one another and configured to receive a laminate (4) between the forming tools; a shaping tool (3) extending along the longitudinal direction X and along a transversal direction Z, and configured to receive the laminate (4) on an external surface of the shaping tool, wherein the forming tools (2.1, 2.2) or the shaping tool (3) are movable in the longitudinal direction X and in the transversal direction Z, relative to the at least one of the shaping tool (3) and the two forming tools (2.1, 2.2).

Abstract: A device for forming a composite laminate (10) for obtaining a Z-shaped profile (1) including: a grip module (5) comprising two plates (6) configured to enclose and grip between the two plates (6) a first portion of the composite laminate (10) that will form a first flange (3), and a feed module (7) comprising two plates (8) configured to enclose between the two plates (8) a second portion of the composite laminate (10), wherein the feed module (7) is configured to heat the portion of the composite laminate (10) located between its two plates (8) and to be movable with respect to the grip module (5) parallel to the plane of the web (2) of the composite profile (1) once formed to a second position in which the two plates (8) enclose the portion of the composite laminate (10) that will form a second flange (4).

Abstract: A method for manufacturing a structure by curing together a base laminate and structural components placed thereon. Particularly, the uncured structural component has a peripheral tapered foot edge so that the vacuum bag placed thereon follows all the uncured plies without an abrupt leap from the structural component foot to the base laminate.

Abstract: A composite forming station for forming a T-profile composite part from a planar laminate. The composite forming station includes in-line rollers arranged along a forming direction, wherein a thickness and/or edge angle each roller is greater than the preceding roller, wherein the rollers gradually splay apart feet sections of the planar laminate to convert the laminate to the T-profile composite part.

Abstract: A system for testing bonded joints that comprises a swing tool, an actuator, pressure measuring device and a first fixing arrangement. The actuator of the system is configured to apply a compression force or a traction force on the swing tool in order to separate two elements, and the pressure measuring device is configured to measure the force applied on the swing tool. A method for testing bonded joints using the system is also provided.

Abstract: A manufacturing method of structures formed co-bonding second structural components to a first structural component. The method comprises the following steps: a) preparing for each second structural component an ensemble wherein a preform of the second structural component, surrounded by a band of a suitable material to form a vacuum bag, is disposed between curing tools which are thus in contact with the bag and not with the preform; b) positioning the ensembles on the first structural component and forming the vacuum bag for the complete structure joining the bands and complementary pieces; c) applying to the resulting assembly an autoclave cycle.

Abstract: Inspection methods and systems for detecting leaks in a vacuum bag assembly used in the manufacture of a composite part based on spraying helium over the vacuum bag and detecting the helium drawn by the vacuum inside the vacuum bag through a leak. The inspection methods comprise creating a local helium atmosphere in a chamber over the vacuum bag assembly by zones, following a programmed zonal sequence, for a first leak detection test of each zone and a subsequent second leak detection test if the first test gives a positive result. The inspection systems comprise a helium spraying system and helium detecting equipment arranged to implement the inspection methods.

Abstract: A system for testing bonded joints that comprises a swing tool, an actuator, pressure measuring device and a first fixing arrangement. The actuator of the system is configured to apply a compression force or a traction force on the swing tool in order to separate two elements, and the pressure measuring device is configured to measure the force applied on the swing tool. A method for testing bonded joints using the system is also provided.

Abstract: An apparatus for manufacturing composite stringers from a composite laminate comprising a male mold, a main caul plate, two fixed female mold halves, two secondary movable caul plates and a retention device. The main caul plate is located below the male mold, the female mold halves are located at both sides of the main caul plate and the secondary movable caul plates, each of them located respectively over each one of the two female mold halves. The male mold, the main caul plate, the two female mold halves and the two secondary caul plates are non-developable surfaces. The retention device keeps each secondary movable caul plate at a predetermined distance of its respective female mold half.

Abstract: A method of manufacturing T-shaped stringers made of composite material, including a second shaping step for shaping laminates into L-shaped preforms, which includes providing a set of tools formed by a fixed tool comprising a lower portion and an upper portion, and a moveable tool comprising a lower element and an upper element. It also includes the segment of the laminate intended for the foot of the preform being located between the lower portion and the upper portion of the fixed tool, and the segment of the laminate intended for the web of the preform being located between the lower element and the upper element of the moveable tool. It further includes vertically moving the moveable tool to progressively bend the web of the preform supporting it on a vertical wall of the fixed tool. The end of its web adopts a rounded shape.

Abstract: Inspection methods and systems for detecting leaks in a vacuum bag assembly used in the manufacture of a composite part based on spraying helium over the vacuum bag and detecting the helium drawn by the vacuum inside the vacuum bag through a leak. The inspection methods comprise creating a local helium atmosphere in a chamber over the vacuum bag assembly by zones, following a programmed zonal sequence, for a first leak detection test of each zone and a subsequent second leak detection test if the first test gives a positive result. The inspection systems comprise a helium spraying system and helium detecting equipment arranged to implement the inspection methods.

Abstract: A manufacturing method of structures formed co-bonding second structural components to a first structural component. The method comprises the following steps: a) preparing for each second structural component an ensemble wherein a preform of the second structural component, surrounded by a band of a suitable material to form a vacuum bag, is disposed between curing tools which are thus in contact with the bag and not with the preform; b) positioning the ensembles on the first structural component and forming the vacuum bag for the complete structure joining the bands and complementary pieces; c) applying to the resulting assembly an autoclave cycle.

Abstract: A method of manufacturing T-shaped stringers made of composite material, including a second shaping step for shaping laminates into L-shaped preforms, which includes providing a set of tools formed by a fixed tool comprising a lower portion and an upper portion, and a moveable tool comprising a lower element and an upper element. It also includes the segment of the laminate intended for the foot of the preform being located between the lower portion and the upper portion of the fixed tool, and the segment of the laminate intended for the web of the preform being located between the lower element and the upper element of the moveable tool. It further includes vertically moving the moveable tool to progressively bend the web of the preform supporting it on a vertical wall of the fixed tool. The end of its web adopts a rounded shape.

Abstract: An apparatus for manufacturing composite stringers from a composite laminate comprising a male mould, a main caul plate, two fixed female mould halves, two secondary movable caul plates and a retention device. The main caul plate is located below the male mould, the female mould halves are located at both sides of the main caul plate and the secondary movable caul plates, each of them located respectively over each one of the two female mould halves. The male mould, the main caul plate, the two female mould halves and the two secondary caul plates are non-developable surfaces. The retention device keeps each secondary movable caul plate at a predetermined distance of its respective female mould half.

Abstract: A method of manufacturing “T” shaped stringers for an aircraft whereby the “T” shaped stringers have a stringer web and a stringer foot, the method comprising: a first step of hot-forming a carbon fiber laminate in order to achieve semi-stringers with an “L” shaped cross-section, a second step of placing together two hot-formed “L” shaped semi-stringers in order to form a “T” shaped stringer, a third step of co-bonding the resulting “T” shaped stringer on a cured skin with an adhesive line between them, and a fourth step of curing the obtained “T” shaped stringer inside a vacuum bag using invar alloy angles as curing tools. The invar alloy angles are cut at a radius area eliminating a part of the invar alloy angles covering the stringer foot in order to define an invar alloy piece having no foot.

Abstract: Aircraft component, such as an aircraft wing, that comprises at least one panel (11) of a composite material formed by a skin (13) and at least a stiffening stringer (15) configured by a web (17) and a foot (19) bonded to said skin (13); the stringer (15) having a run-out zone inside said panel (11) subjected to a high load level; the stringer (15) having a web (17) of decreasing height in said run-out zone and a foot (19) having a first section (31) of variable width from an initial value W1 to a final value W2 and a second section (33) with a width W2 in said run-out zone; the foot (19) and the web (17) of said stringer (15) having a decreasing thickness in said run-out zone for improving the load transfer from the stringer (15) to the skin (13).

Abstract: Method of manufacturing “T” shaped stringers for an aircraft whereby the “T” shaped stringers have a stringer web and a stringer foot, the method comprising: a first step of hot-forming a carbon fiber laminate in order to achieve semi-stringers geometry with an “L” shaped cross-section, a second step of placing together two hot-formed “L” shaped semi-stringers in order to form a “T” shaped stringer, a third step of co-bonding the resulting “T” shaped stringer on a cured skin with an adhesive line between them, and a fourth step of curing the obtained “T” shaped stringer inside a vacuum bag using invar alloy angles as curing tools. The method characterised in that the invar alloy angles are cut at a radius area eliminating a part of the invar alloy angles covering the stringer foot in order to define an invar alloy piece having no foot.