Abstract: A method of friction stir welding joints with shims and an associated structural assembly is provided. The structural assembly includes one or more skin members that are disposed and friction stir welded to a substructure. A shim is disposed in a space defined by the other members of the assembly, e.g., between adjacent skin members or between a skin member and the substructure. The shim can be friction stir welded to the other members. That is, the adjacent skin members can be connected via the shim, and/or the skin members can be connected to the substructure via the shim. In some cases, the skin members and the substructure are relatively stiff, and the shim substantially fills the space to reduce flexing of the members during the friction stir welding operation.

Abstract: The invention provides an apparatus and method for testing the tensile load bearing properties of a sample of uncured prepreg composite material. The apparatus includes a housing comprising an internal cavity for receiving a sample to be tested. It also has a bladder and a block located at least partially within the housing such that inflating the bladder applies pressure to the prepreg sample by urging the block into the sample cavity, against the sample. In addition, the apparatus includes a heater for applying controlled heat to the sample and thermocouples for measuring sample temperature. Ends of the sample prepreg are accessible to jaws of a tensile load testing machine, and load is applied when the desired temperature and pressure are obtained.