Abstract: A method and apparatus for forming a tool is provided. A number of members comprised of a thermoplastic material is positioned within a hollow portion of a structure. The tool is formed within the hollow portion of the structure with the number of members positioned within the hollow portion of the structure. Heat is applied within a selected range to the number of members to reduce a size of each of the number of members. The number of members is removed from the tool such that the tool is left with a number of voids.

Abstract: Apparatuses and methods for forming a joggle and a longitudinal ridge in a multi-ply composite charge are disclosed. Charges may be formed in a forming press that comprises a joggled die, with a longitudinal ridge and a joggle that crosses the longitudinal ridge, and a conforming die, with a series of longitudinally-spaced die fingers. The die fingers include pairs of die members configured to move laterally between a closed position and an open position, with each die member configured to tilt longitudinally.

Abstract: A method and apparatus for forming a tool is provided. A number of members comprised of a thermoplastic material is positioned within a hollow portion of a structure. The tool is formed within the hollow portion of the structure with the number of members positioned within the hollow portion of the structure. Heat is applied within a selected range to the number of members to reduce a size of each of the number of members. The number of members is removed from the tool such that the tool is left with a number of voids.

Abstract: Systems and methods for compacting a charge of composite material. These systems and methods may utilize a vacuum compaction device to compact the charge of composite material on a supporting surface. The vacuum compaction device may be reusable and may be configured to define an enclosed volume when positioned on the supporting surface and may include a barrier structure and a sealing structure that is configured to form a fluid seal when compressed between the supporting surface and the barrier structure. The vacuum compaction device also may include a vacuum distribution manifold that is in fluid communication with and configured to selectively apply a vacuum to the enclosed volume. Application of the vacuum to the enclosed volume may decrease a pressure within the enclosed volume and transition the vacuum compaction device from an undeformed configuration to a deformed configuration, thereby compacting the charge of composite material on the supporting surface.

Abstract: Apparatuses and methods for forming a joggle and a longitudinal ridge in a multi-ply composite charge are disclosed. Charges may be formed in a forming press that comprises a joggled die, with a longitudinal ridge and a joggle that crosses the longitudinal ridge, and a conforming die, with a series of longitudinally-spaced die fingers. The die fingers include pairs of die members configured to move laterally between a closed position and an open position, with each die member configured to tilt longitudinally.

Abstract: A multiplexer is constructed, which has a stable volume over its thermal operating range. A composite material is used that utilizes a fabric having fibers of opposing coefficients of thermal expansion. Such fibers are assembled at an angle to each other so that resulting expansion and contractions counter act and cancel. One of the fibers is selected for its high thermal conductivity and extends over the length of the multiplexer to form a heat dissipating path.

Abstract: The invention resides in a method and apparatus for conditioning an inner surface of a tube. A pressurized mixture of air and grit and is supplied to a nozzle having an opening with a given diameter through which diameter the pressurized grit and air pass. An elongated nozzle adapter is connected to said nozzle. The nozzle adapter has a passage having a diameter substantially equal to the diameter of said nozzle and said nozzle adapter is connected to said nozzle such that the opening in said nozzle and said passage are aligned with one another. The nozzle adapter is inserted into a tube and is axially moved and rotated in order to condition the inner surface thereof with a pressurized mixture of air and grit.