Abstract: A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.

Abstract: A mandrel used to cure a composite part layup has an elastic body and at least one internal open space therein. The internal open space is configured to allow substantially uniform thermal expansion of the body during curing.

Abstract: A composite mandrel includes a generally elongated mandrel body comprising a resilient mandrel core and an elastomeric mandrel outer layer disposed outside the mandrel core. A method for fabricating a contoured stiffened composite panel is also disclosed.

Abstract: A hands-free method and related apparatus are used to shape, place and compact a composite stringer on a composite skin of an aircraft. A composite charge is placed on a tool assembly that used to shape the charge into a preformed stringer. With the stringer held on the tool assembly, the tool assembly is used to move the preformed stringer into proximity with the skin and both place and compact the stringer against the skin. Following compaction of the stringer, the tool assembly is removed and the skin and the stringer are co-cured.

Abstract: A stiffened skin panel of an aircraft that includes an aircraft skin panel of composite material and a composite stringer consolidated with the aircraft skin panel. The stringer has a pair of stringer sides, each extending from a stringer top to a stringer leg. The stringer sides may each extend through a wide radius, smooth continuous curve to a stringer leg. The wide radius, smooth continuous curve may be proximate the base of the stringer side in a region where the stringer side transitions to the stringer leg.

Abstract: In a technique for joining ends of coaxial tubular members, adhesive is applied to their external surfaces at their ends and an expandable insert assembly is positioned longitudinally within them so as to be coextensive with the adjoining ends. Planar side pieces on the assembly are advanced into conforming engagement with the inside surfaces of the tubular members at their adjoining ends, the adhesive is cured to fixedly join the tubular members together, then the side pieces are withdrawn. Simultaneously, the external surfaces of the tubular members are clamped in the region of their adjoining ends until full curing of the adhesive has been achieved. The insert assembly includes a bladder of flexible material with planar side pieces being attached to the inside or outside surfaces and the insert assembly advanced so the bladder engages the internal surfaces of the tubular members at their adjoining ends.