Abstract: An integral structure and thermal protection system, particularly designed for hypersonic aerospace vehicles, is comprised of a hard external shell or outer face sheet formed of a ceramic matrix, such as silicon carbide, and a rigid insulator core in the form of foamed ceramic, such as silicon carbide, the outer face sheet being integrally connected to the insulator core. A prime strucutral material, such as an aircraft structural member, is integrally connected as by bonding or brazing to the insulator core, the core being attached to the prime structural material or aircraft structural member by an inner face sheet forming the outer skin of such structural member.

Abstract: A crew protection system designed to isolate an aircraft crew and provide a means for safely evacuating an aircraft, particularly hypersonic vehicles, in emergency situations. The crew compartment is designed within the forebody of the main vehicle. The forebody is designed so as to separate cleanly from the main vehicle as by generation of a circumferential structural break, in the event of a catastrophic failure or explosion of the main vehicle fuel tank. In the event of such an uncommanded failure of the main tank and propellant combustion, resulting in the above noted structural failure, the resultant pressure impulse thrusts the forebody containing the crew compartment clear from the remainder of the vehicle. The provision of a system of baffles in the forebody between the crew compartment and the fuel tank, and the shape of the forebody and the materials used in its construction mitigate the effects of the blast pressure impulse on the crew.

Abstract: A method is disclosed for fabricating rib structures of different sizes for a segment of an airfoil having both a spanwise taper in thickness and at least one aerodynamic surface having a substantially constant radius of curvature in the chordwise direction. In one embodiment a plurality of rib webs are formed at least as large as the largest rib structure. Each of the rib webs is trimmed at their lower edges progressively greater amounts to form rib webs of a proper size for each rib structure. A plurality of upper and lower rib caps as well as front and rear spar attachment brackets are formed and attached to the trimmed rib webs. In another embodiment the rib webs are formed with either or both integral upper rib caps and spar attachment brackets. In still another embodiment a plurality of rib webs are formed and joined together by twos by inverting one rib web to the other and progressively overlapping their lower edges and fastening them together to form properly sized rib structures.

Abstract: A method is disclosed for fabricating rib structures of different sizes for a segment of an airfoil having both a spanwise taper in thickness and at least one aerodynamic surface having a substantially constant radius of curvature in the chordwise direction. In one embodiment a plurality of rib webs are formed at least as large as the largest rib structure. Each of the rib webs is trimmed at their lower edges progressively greater amounts to form rib webs of a proper size for each rib structure. A plurality of upper and lower rib caps as well as front and rear spar attachment brackets are formed and attached to the trimmed rib webs. In another embodiment the rib webs are formed with either or both integral upper rib caps and spar attachment brackets. In still another embodiment a plurality of rib webs are formed and joined together by twos by inverting one rib web to the other and progressively overlapping their lower edges and fastening them together to form properly sized rib structures.