Abstract: A method and system for heating a material includes an induction coil, a susceptor providing a receptacle, where the receptacle is configured to receive the material, and at least one nozzle for ejecting a heated gas onto and/or into the material. During the method, the susceptor is heated by the induction coil, and thermal energy from the susceptor can be transferred to the material. In addition to being heated by heat from the susceptor, the material is also heated by the heated gas, thereby increasing a heating rate of the material to rapidly heat the material to a processing temperature. The system can include other components such as a gas source, at least one conduit that channels gas from the gas source to the at least one nozzle, and a heat source that heats the gas prior to ejecting the gas from the at least one nozzle.

Abstract: Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

Abstract: A method for evaluating a surface of a bore formed in a structure, where the bore defines a bore axis. The method includes moving a probe at least partially through the bore in a first lineal direction about the bore axis while simultaneously rotating the probe about the bore axis. The probe includes a contact element contacting the surface of the bore at a plurality of first contact points as the probe moves in the first lineal direction.

Abstract: A plug gauge including a probe housing defining an internal volume and a longitudinal axis, the probe housing includes a first and second openings, a first contact element having a portion extending through the first opening, a first cam member defining a first axis of rotation, the first cam member being in camming engagement with the first contact element such that movement of the first contact element relative to the probe housing causes corresponding rotation of the first cam member about the first axis of rotation, a second contact element having a portion extending through the second opening, and a second cam member defining a second axis of rotation, the second cam member being in camming engagement with the second contact element such that movement of the second contact element relative to the probe housing causes corresponding rotation of the second cam member about the second axis of rotation.

Abstract: A plug gauge including a probe housing defining an internal volume and a longitudinal axis, the probe housing includes a first and second openings, a first contact element having a portion extending through the first opening, a first cam member defining a first axis of rotation, the first cam member being in camming engagement with the first contact element such that movement of the first contact element relative to the probe housing causes corresponding rotation of the first cam member about the first axis of rotation, a second contact element having a portion extending through the second opening, and a second cam member defining a second axis of rotation, the second cam member being in camming engagement with the second contact element such that movement of the second contact element relative to the probe housing causes corresponding rotation of the second cam member about the second axis of rotation.

Abstract: An induction heating system for molding a thermoplastic article includes a first mold and a second mold defining a mold cavity therebetween for molding the thermoplastic article, a first metallic susceptor as part of or adjacent to the first mold, a first armature-supported induction coil array in proximity to the first metallic susceptor, and a first induction generator electrically coupled with the first armature-supported induction coil array.

Abstract: A plug gauge includes a housing, defining an internal volume, first openings, and second openings. The plug gauge includes first contact elements, each at least partially received in a respective one of the first openings. The plug gauge includes a first plunger in the internal volume and movable relative to the housing. The first plunger is biased to urge the first contact elements radially outward through the first openings. The plug gauge includes a first sensor sensing movement of the first plunger. The plug gauge includes second contact elements, each at least partially received in a respective one of the second openings. The plug gauge includes a second plunger in the internal volume and movable relative to the housing. The second plunger is biased to urge the second contact elements radially outward through the second openings. The plug gauge includes a second sensor sensing movement of the second plunger.

Abstract: Described herein is an apparatus for induction heating. The apparatus includes a plurality of induction heating cells attachably coupled together. Each induction heating cell of the plurality of induction heating cells is movable relative to adjacent induction heating cells of the plurality of induction heating cells to conform the plurality of induction heating cells to a non-planar surface. Each induction heating cell of the plurality of induction heating cells includes a power connector and a coupling feature to couple the respective induction heating cell with one or more other induction heating cells of the plurality of induction heating cells.

Abstract: Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

Abstract: A method and system for heating a material includes an induction coil, a susceptor providing a receptacle, where the receptacle is configured to receive the material, and at least one nozzle for ejecting a heated gas onto and/or into the material. During the method, the susceptor is heated by the induction coil, and thermal energy from the susceptor can be transferred to the material. In addition to being heated by heat from the susceptor, the material is also heated by the heated gas, thereby increasing a heating rate of the material to rapidly heat the material to a processing temperature. The system can include other components such as a gas source, at least one conduit that channels gas from the gas source to the at least one nozzle, and a heat source that heats the gas prior to ejecting the gas from the at least one nozzle.

Abstract: A method for evaluating a surface of a bore formed in a structure, where the bore defines a bore axis. The method includes moving a probe at least partially through the bore in a first lineal direction about the bore axis while simultaneously rotating the probe about the bore axis. The probe includes a contact element contacting the surface of the bore at a plurality of first contact points as the probe moves in the first lineal direction.

Abstract: A plug gauge includes a housing, defining an internal volume, first openings, and second openings. The plug gauge includes first contact elements, each at least partially received in a respective one of the first openings. The plug gauge includes a first plunger in the internal volume and movable relative to the housing. The first plunger is biased to urge the first contact elements radially outward through the first openings. The plug gauge includes a first sensor sensing movement of the first plunger. The plug gauge includes second contact elements, each at least partially received in a respective one of the second openings. The plug gauge includes a second plunger in the internal volume and movable relative to the housing. The second plunger is biased to urge the second contact elements radially outward through the second openings. The plug gauge includes a second sensor sensing movement of the second plunger.

Abstract: Methods of fabricating a component, such as a cascade grid panel for a jet engine thrust reverser, having a plurality of cavities extending through the component, with each cavity having at least one surface with a complex contour, and related devices. A plurality of two or more mold inserts are stacked to form a mold insert stack, with the mold insert stack having a plurality of mold bosses formed by mold boss sets. The mold boss sets are each formed by a mold boss segment from each of the mold inserts. Further, the mold boss segments are affixed to respective baseplates so that the mold boss segments can be handled as a group and remain properly positioned relative to their neighboring mold boss segments.

Abstract: An induction heating system for molding a thermoplastic article includes a first mold and a second mold defining a mold cavity therebetween for molding the thermoplastic article, a first metallic susceptor as part of or adjacent to the first mold, a first armature-supported induction coil array in proximity to the first metallic susceptor, and a first induction generator electrically coupled with the first armature-supported induction coil array.

Abstract: A method and apparatus for forming a part having a cavity with a complex contour is presented. The molding apparatus comprises a mold cavity and a molding insert. The mold cavity is formed by a first mold portion and a second mold portion. The molding insert is within the mold cavity, wherein the molding insert has a forming surface, and wherein the molding insert is configured to move in more than one direction relative to the first mold portion.

Abstract: Methods of fabricating a component, such as a cascade grid panel for a jet engine thrust reverser, having a plurality of cavities extending through the component, with each cavity having at least one surface with a complex contour, and related devices. A plurality of two or more mold inserts are stacked to form a mold insert stack, with the mold insert stack having a plurality of mold bosses formed by mold boss sets. The mold boss sets are each formed by a mold boss segment from each of the mold inserts. Further, the mold boss segments are affixed to respective baseplates so that the mold boss segments can be handled as a group and remain properly positioned relative to their neighboring mold boss segments.

Abstract: Described herein is an apparatus for induction heating. The apparatus includes a plurality of induction heating cells attachably coupled together. Each induction heating cell of the plurality of induction heating cells is movable relative to adjacent induction heating cells of the plurality of induction heating cells to conform the plurality of induction heating cells to a non-planar surface. Each induction heating cell of the plurality of induction heating cells includes a power connector and a coupling feature to couple the respective induction heating cell with one or more other induction heating cells of the plurality of induction heating cells.

Abstract: A method and apparatus for forming a part having a cavity with a complex contour is presented. The molding apparatus comprises a mold cavity and a molding insert. The mold cavity is formed by a first mold portion and a second mold portion.

Abstract: A method of forming an opening in a layered structure includes providing a layered structure including a first layer and a second layer and a near-zero gap interface defined between the first layer and the second layer; providing an opening through the layered structure such that the opening extends through the first layer and the second layer; and working simultaneously the opening in the fay surface of the first layer and the opening in the fay surface of the second layer without separating the first layer and the second layer. An internal chamfering device is also disclosed.

Abstract: A method of forming an opening in a layered structure includes providing a layered structure including a first layer and a second layer and a near-zero gap interface defined between the first layer and the second layer; providing an opening through the layered structure such that the opening extends through the first layer and the second layer; and working simultaneously the opening in the fay surface of the first layer and the opening in the fay surface of the second layer without separating the first layer and the second layer. An internal chamfering device is also disclosed.