Abstract: The invention is a process for forming a preform for use in a structure having at least one curved portion of a specific length, including the steps of: 1) providing a preform having cable of expanding in length threads in rows parallel to the direction of curvature over a length equal to the length requiring curvature, such that the gaps between each thread row are spaced from the gaps in the adjacent tread rows; and 2) stretching the portions of the preform requiring curvature in a sine-wave pattern.

Abstract: The invention is a process for forming a 3D woven PI shaped cross-section preform having a first and second bottom foot portions and first and second upstanding leg portions for use in a structure having at least one curved portion of a specific length. In detail, the process includes the steps of: 1) cutting the treads parallel to the direction of curvature into over a length equal to the length, such that the cuts in each thread are spaced from the cuts in the adjacent treads; 2) stretching the portions of the preform requiring curvature; and 3) forming the curvature in the preform.

Abstract: A cured composite material formed in accordance with the method of the present invention. The method initially providing for providing a peel-ply sheet which defines opposed planar faces. A multitude of elongate bond fibers are embedded into the peel-ply sheet in a manner wherein a majority of the bond fibers do not extend in co-planar relation to the planar faces of the peel-ply sheet. A resin composite material is provided. The peel-ply sheet is applied to the resin composite material such that the bond fibers are partially embedded therein. The resin composite material is cured. The peel-ply sheet is removed from the cured resin composite material such that the bond fibers remain implanted therein.

Abstract: In accordance with the present invention, there is provided a pressure applicator device for applying pressure to a repair patch of a repair surface. The pressure applicator device is provided with a generally annular suction member for providing suction attachment to the repair composite surface about the repair patch. The pressure applicator device is further provided with a cover member which is disposable above and across the suction member. The cover member is attached to the suction member. The pressure applicator device is further provided with a flexible pressure bladder formed of a generally fluid tight elastic material which is disposed beneath the cover member and interior to the suction member. The pressure bladder defines upper and lower chambers. The upper chamber is disposed between the cover member and the pressure bladder. The lower chamber is disposable between the pressure bladder and the repair surface.

Abstract: A system is provided for filling a gap between adjoining coplanar first and second sheet members mounted on an outer surface of a common substrate and having juxtaposed first and second edge surfaces. A permanent gap filler member of predetermined shape and size intended for eventual permanent reception in the gap is employed for partially filling the gap. A temporary gap filler tool which includes a substitute gap filler element having substantially the same predetermined size and shape of the permanent gap filler member, has an abutting surface for contiguous engagement with the first edge surface of the first sheet member when advanced to an attached position before the permanent gap filler member is mounted in the gap, a minor gap surface facing opposite said abutting surface, and means for releasably attaching the temporary gap filler tool to the first sheet member. A minor gap is thereby defined between the temporary gap filler element and the second edge surface of the second sheet member.

Abstract: A method for repairing a multi-layered damage area in a multi-layered composite structure. The method first includes obtaining depth measurement data, and obtaining topographical measurement data by laser scanning the surface of the damage area. This depth measurement data and topographical measurement data are inputted into a microprocessor along with thickness data of each layer. All inputted information is correlated among itself to thereby internally produce a three-dimensional damage area display-replica and interpolate a two-dimensional pattern of each layer of the damage area and of the surface of the damage area. The damage area is removed by first projecting a two-dimensional laser pattern of the damage area thereat on the surface of the structure, and thereafter manually removing the area to produce a void. Repair is accomplished by projecting onto respective replacement material a two-dimensional laser image pattern of each layer and manually cutting that layer according to the appropriate pattern.

Abstract: A system is provided for filling a gap between adjoining coplanar first and second sheet members mounted on an outer surface of a common substrate and having juxtaposed first and second edge surfaces. A permanent gap filler member of predetermined shape and size intended for eventual permanent reception in the gap is employed for partially filling the gap. A temporary gap filler tool which includes a substitute gap filler element having substantially the same predetermined size and shape of the permanent gap filler member, has an abutting surface for contiguous engagement with the first edge surface of the first sheet member when advanced to an attached position before the permanent gap filler member is mounted in the gap, a minor gap surface facing opposite said abutting surface, and means for releasably attaching the temporary gap filler tool to the first sheet member. A minor gap is thereby defined between the temporary gap filler element and the second edge surface of the second sheet member.

Abstract: The present invention is embodied in an tool and method for structurally applying fiber stiffeners to a material. The tool inserts a plurality of fibers embedded in a transfer material through a hat stiffener and into a substrate and includes a first head, a second head, and a handle. The first head is defined by a roller having first edges and a center cutout. The cutout corresponds to the thickness of the transfer material. The second head is located at a distal end from the first head and is defined by a roller having second edges and a center groove. The groove corresponds to a thickness associated with guiding the tool along the corner of the hat stiffener. The first and second edges conform to the surface of the substrate. The center handle is coupled between the first head and second head for gripping. The first head is adapted to initially drive the fibers embedded in the transfer material through the hat stiffener and into the substrate.

Abstract: In accordance with the present invention, there is provided a method of increasing the surface bond strength characteristics of a resin composite material. The method begins with providing a peel-ply sheet which defines opposed planar faces. A multitude of elongate bond fibers are embedded into the peel-ply sheet in a manner in which a majority of the bond fibers do not extend in co-planar relation to the planar faces of the peel-ply sheet. A resin composite material is provided. The peel-ply sheet is applied to the resin composite material such that the bond fibers are partially embedded therein. The resin composite material is cured. The peel-ply sheet is removed from the cured resin composite material such that the bond fibers remain implanted therein.