Abstract: An inlet assembly for a nacelle includes an inlet cowl and a plenum back wall of a fluid ice protection system (FIPS). The inlet cowl extends a length from a front end of the inlet cowl to a rear end of the inlet cowl. The inlet cowl includes a lipskin that defines a leading edge of the inlet cowl at the front end, and an acoustic panel coupled to the lipskin at an interface along an inner side of the inlet cowl. A seam is defined between the acoustic panel and the lipskin. The plenum back wall is affixed to an interior surface of the lipskin to define a plenum between the interior surface and a front surface of the plenum back wall. The plenum receives an anti-ice liquid. The plenum back wall is disposed in front of the seam along the length of the inlet cowl.

Abstract: A fluid ice protection system for an aircraft includes a plenum back wall and a fluid delivery network. The plenum back wall is affixed to an interior surface of an inlet cowl of a nacelle of the aircraft to define a plenum between the interior surface and a front surface of the plenum back wall. The nacelle surrounds a rotor assembly of an aircraft propulsion system. The inlet cowl defines a plurality of perforations through a thickness of the inlet cowl. The perforations are fluidly connected to the plenum. The fluid delivery network is coupled to the plenum back wall and configured to supply an anti-ice liquid into the plenum for the anti-ice liquid to penetrate through the perforations onto an exterior surface of the inlet cowl along a leading edge section of the inlet cowl.

Abstract: A method for producing a nacelle inlet assembly includes forming a composite panel that has a carbon fiber reinforced polymer (CFRP) material. The composite panel is formed to have a curved contour that represents at least a portion of an annular barrel shape. The method includes applying a metallic coating to the composite panel to form a lipskin. The metallic coating is applied such that the metallic coating defines an exterior surface of the lipskin and the composite panel defines an interior surface of the lipskin. The method includes laser drilling a plurality of perforations through the lipskin. The laser drilling involves emitting a laser beam that impinges upon the interior surface of the lipskin and penetrates the CFRP material of the composite panel before penetrating the metallic coating and exiting the lipskin through the exterior surface.

Abstract: A method for producing a structural material stack includes forming a composite panel that includes a carbon fiber reinforced polymer (CFRP) material, and applying an interface film on an exterior composite surface of the composite panel. The interface film is electrically conductive. The method includes performing an electroplating process to form a metallic coating on the interface film such that the interface film is sandwiched between the composite panel and the metallic coating. The metallic coating has a different material composition than the interface film.

Abstract: An inlet assembly of a nacelle includes an inlet cowl. The inlet cowl includes a lipskin that has a front section which defines the leading edge of the inlet cowl. The front section includes a composite panel and a metallic coating disposed along an exterior surface of the composite panel to protect the composite panel from damage. The lipskin defines perforations that penetrate through the composite panel and the metallic coating at the front section to convey a liquid through a thickness of the lipskin onto an exterior surface of the inlet cowl.

Abstract: An inlet assembly of a nacelle includes an inlet cowl that has a leading edge, an outer side that extends from the leading edge to an outer aft edge, and an inner side that extends from the leading edge to an inner aft edge. An exterior surface of the inlet cowl is seamless along an entire length of the outer side from the leading edge to the outer aft edge. The inlet cowl includes a lipskin that has a metallic coating. The metallic coating defines the exterior surface of the inlet cowl along the leading edge and the entire length of the outer side.

Abstract: Within examples, a method of manufacturing a double-walled titanium conduit is described. Example methods include stitch welding multiple concentric sheets to form a stitch layer, providing the stitch layer between an inner wall and an outer wall of the double-walled titanium conduit, circumferentially seam welding the inner wall and the outer wall to the stitch layer to create a welded assembly, die forming the welded assembly at temperature and pressure to form inner structures between the multiple concentric sheets according to stitch welding lines and to enable a diffusion bond process among the inner wall, the stitch layer, and the outer wall, and removing the double-walled titanium conduit from the die.

Abstract: Within examples, a method of manufacturing a double-walled titanium conduit is described. Example methods include stitch welding multiple concentric sheets to form a stitch layer, providing the stitch layer between an inner wall and an outer wall of the double-walled titanium conduit, circumferentially seam welding the inner wall and the outer wall to the stitch layer to create a welded assembly, die forming the welded assembly at temperature and pressure to form inner structures between the multiple concentric sheets according to stitch welding lines and to enable a diffusion bond process among the inner wall, the stitch layer, and the outer wall, and removing the double-walled titanium conduit from the die.