Abstract: Lightning-dissipative A/C assemblies are provided, as are valve frames utilized within lightning-dissipative A/C assemblies. In embodiments, the lightning-dissipative A/C assembly includes a base dielectric component having a mount interface, a strike-susceptible metallic component coupled to the base dielectric component, and mounting hardware configured to engage the mount interface to attach the base dielectric component to an A/C. An electrically-conductive coating overlies or is formed over at least a portion of the base dielectric component to complete a lightning strike dissipation path. The lightning strike dissipation path extends from the strike-susceptible metallic component, through the electrically-conductive coating, through the mounting hardware, and to an A/C electrical ground plane when the lightning-dissipative A/C assembly is installed on the A/C.

Abstract: Outflow valve (OFV) assemblies including non-metallic frames and enhanced attachment features are provided. In embodiments, the OFV assembly includes a non-metallic frame to which at least one valve door is pivotally mounted. The non-metallic frame may, in turn, include a generally rectangular frame body, a central opening through the frame body, an outer peripheral flange extending around at least a portion of the frame body. Frame attachment interfaces are distributed or spaced around the outer peripheral flange of the non-metallic frame. The frame attachment interfaces include fastener openings and elevated platform regions, which project from an inboard side of the outer peripheral flange and through which the fastener openings extend. Base plates seat against the elevated platform regions. Fasteners engage the base plates and extend through the fastener openings to an outboard side of the outer peripheral flange to attach the OFV assembly to an aircraft fuselage.

Abstract: Outflow valve (OFV) assemblies including non-metallic frames and enhanced attachment features are provided. In embodiments, the OFV assembly includes a non-metallic frame to which at least one valve door is pivotally mounted. The non-metallic frame may, in turn, include a generally rectangular frame body, a central opening through the frame body, an outer peripheral flange extending around at least a portion of the frame body. Frame attachment interfaces are distributed or spaced around the outer peripheral flange of the non-metallic frame. The frame attachment interfaces include fastener openings and elevated platform regions, which project from an inboard side of the outer peripheral flange and through which the fastener openings extend. Base plates seat against the elevated platform regions. Fasteners engage the base plates and extend through the fastener openings to an outboard side of the outer peripheral flange to attach the OFV assembly to an aircraft fuselage.

Abstract: Lightning-dissipative A/C assemblies are provided, as are valve frames utilized within lightning-dissipative A/C assemblies. In embodiments, the lightning-dissipative A/C assembly includes a base dielectric component having a mount interface, a strike-susceptible metallic component coupled to the base dielectric component, and mounting hardware configured to engage the mount interface to attach the base dielectric component to an A/C. An electrically-conductive coating overlies or is formed over at least a portion of the base dielectric component to complete a lightning strike dissipation path. The lightning strike dissipation path extends from the strike-susceptible metallic component, through the electrically-conductive coating, through the mounting hardware, and to an A/C electrical ground plane when the lightning-dissipative A/C assembly is installed on the A/C.

Abstract: An actuator includes a housing assembly, a ball nut, a ball screw, and a ball screw stop. The ball nut is rotationally mounted in the housing assembly, is adapted to receive an input torque, and is configured, upon receipt thereof, to rotate and supply a drive force. The ball screw is mounted within the housing assembly and extends through the ball nut. The ball screw has a first end and a second end, and is coupled to receive the drive force from the ball nut. The ball screw is configured, upon receipt of the drive force, to selectively translate between a stow position and a deploy position. The ball screw stop is mounted on the ball screw to translate therewith and is configured to at selectively engage the housing assembly while the ball screw is translating, and engage the ball nut when the ball screw is in the deploy position.

Abstract: An actuator includes a housing assembly, a ball nut, a ball screw, and a ball screw stop. The ball nut is rotationally mounted in the housing assembly, is adapted to receive an input torque, and is configured, upon receipt thereof, to rotate and supply a drive force. The ball screw is mounted within the housing assembly and extends through the ball nut. The ball screw has a first end and a second end, and is coupled to receive the drive force from the ball nut. The ball screw is configured, upon receipt of the drive force, to selectively translate between a stow position and a deploy position. The ball screw stop is mounted on the ball screw to translate therewith and is configured to at selectively engage the housing assembly while the ball screw is translating, and engage the ball nut when the ball screw is in the deploy position.

Abstract: A cured ablative composite assembly comprises a housing enclosing a pair of ablative composite sub-assemblies joined by a film adhesive. The cured ablative composite assembly is made by surface treating both ablative composite sub-assemblies in preparation for joining; coupling one ablative composite sub-assembly to another ablative composite sub-assembly with a film adhesive and enclosing the uncured ablative composite assembly within a housing; and depositing the combination of the housing and uncured ablative composite assembly in a ventilated oven with a load applied to the combination housing and uncured ablative composite assembly. The film adhesive is cured providing a portion of a hot gas valve suitable for use in tactical missiles. The film adhesive does not erode at the high temperatures (5000° F.) encountered in hot gas rocket exhausts, thereby providing a seal that offers high strength, pressure-tight joints.

Abstract: A method is provided for fabricating a missile component, which may be a phenolic component, that includes the steps of covering at least a portion of a core insert with a composite material, compression molding the composite material on to the core insert to form the component, and destructively removing the core insert while the core insert is at least partially disposed within the component. The core insert may be thermally, mechanically, or chemically removed.

Abstract: A cured ablative composite assembly comprises a housing enclosing a pair of ablative composite sub-assemblies joined by a film adhesive. The cured ablative composite assembly is made by surface treating both ablative composite sub-assemblies in preparation for joining; coupling one ablative composite sub-assembly to another ablative composite sub-assembly with a film adhesive and enclosing the uncured ablative composite assembly within a housing; and depositing the combination of the housing and uncured ablative composite assembly in a ventilated oven with a load applied to the combination housing and uncured ablative composite assembly. The film adhesive is cured providing a portion of a hot gas valve suitable for use in tactical missiles. The film adhesive does not erode at the high temperatures (5000° F.) encountered in hot gas rocket exhausts, thereby providing a seal that offers high strength, pressure-tight joints.