Abstract: In accordance with the present invention, there is provided a technique which may be used in conjunction with an automated Z-pin insertion process to automatically monitor the insertion energy applied to the Z-pins during the initial insertion phase of the automated insertion process, and compare it to an empirically derived value for good insertions, thereafter allowing the insertion process to continue to a predetermined additional insertion depth before terminating the process. The insertion energy is calculated by cumulatively summing the insertion force and multiplying it by the insertion time, thus yielding the cumulative energy. At a specified, predetermined insertion depth, the energy accumulation is stopped and the value at the initial insertion depth is stored and compared to an empirically derived value. If the value is less than the empirical value, the insertion energy is too low, thus indicating that either a partial grid insertion is being encountered or defective Z-pins are being inserted.

Abstract: Provided is a composite joint comprising a pair of composite panels each defining a composite panel thickness and having an inner face sheet and an outer face sheet sandwiching a core panel therebetween. The core panel defines a constant thickness portion and a ramp portion along which the core panel tapers to a reduced thickness portion. The outer face sheet is thickened in the area of the reduced thickness portion. The core panel includes a plurality of cells extending between the inner and outer face sheets. The cells within the reduced thickness portions are filled with a filler material. The cells within the ramp portions and constant thickness portions are filled with aerogel. A primary splice plate extends across the reduced thickness portions. Mechanical fasteners extend through the outer face sheet and into the primary and secondary splice plates. A themal barrier compound covers the primary splice plate.

Abstract: Provided is a composite joint comprising a pair of adjoining composite panels disposed in side-by-side arrangement and being generally aligned with one another. Each one of the composite panels has opposing inner and outer face sheets sandwiching a core panel therebetween and includes a ramp portion wherein the composite panel transitions into a reduced thickness solid laminate edge portion. The core panel includes a plurality of cells extending between the inner and outer face sheets. The cells within the ramp portions are substantially filled with a filler material. The cells adjacent to the ramp portions are substantially filled with aerogel. The composite joint further comprises a primary splice plate extending across the solid laminate edge portions of the adjoining composite panels with mechanical fasteners extending through the solid laminate edge portions and passing through the primary splice plate. A layer of thermal barrier compound covers the primary splice plate.