Abstract: A method and a tool for manufacturing a composite structure by integrating and curing together semi-finished components by heat and pressure.

Abstract: A method for manufacturing at least a portion of a box structure obtained from an outer skin and a plurality of sections each having a joining face in contact with the outer skin. The method comprises a step of positioning the sections on a mold, a step of obtaining a flat fiber preform having a thickness substantially equal to the outer skin, a step of placing a central portion of the fiber preform on the sections positioned on a first face of the mold and a step of forming a lateral extension of the fiber preform to press the fiber preform against a forming surface. A central wingbox obtained by the method is provided and a forming tool for carrying out the method.

Abstract: Automated manufacturing of composite laminates for structures, preferably structures of an aircraft, by using laying machines. More particularly, a method for determining the energy of debonding between layers of a laminate of composite material by means of a laying machine, and a laying machine for performing the method.

Abstract: A method for reworking a composite laminate comprising a plurality of tapes, comprising the following steps: detecting the occurrence of a defect on a tape of composite material while the tape is being laid up; continuing the lay-up of the defective tape until a tape length is formed which surpasses a manufacturing length of the tape; catching the part of the defective tape that surpasses the manufacturing length of the tap; cutting the defective tape in the part of the defective tape that surpasses the manufacturing length of the tape; removing from the laminate the caught defective tape by the catching system, and laying-up a replacement tape in the place of the removed defective tape.

Abstract: A method for reworking a composite laminate comprising a plurality of tapes, comprising the following steps: detecting the occurrence of a defect on a tape of composite material while the tape is being laid up; continuing the lay-up of the defective tape until a tape length is formed which surpasses a manufacturing length of the tape; catching the part of the defective tape that surpasses the manufacturing length of the tap; cutting the defective tape in the part of the defective tape that surpasses the manufacturing length of the tape; removing from the laminate the caught defective tape by the catching system, and laying-up a replacement tape in the place of the removed defective tape.

Abstract: The system has special application in the manufacture of aircraft wing covers (10 made of carbon fiber and the stringers (3) cured jointly with the wing cover during the polymerization in autoclave. The tool pieces (4) being used are defined by angular elements (5, 6) copying the geometry of the stringers (3). The shape of these stringers corresponds to the “T” section. The angular elements (5, 6) comprise, in their upper part, a pair of battlements (7) in order to be caught by part of the clamps (9) of a head (10) linked to a robot (11) of the spherical type with articulated arm with six axes. The angular elements (5, 6) are made of INVAR material and they are used to keep in position the stringers during the curing cycle in the autoclave.

Abstract: Procedure for the manufacture of large parts of composite material, controlling the thickness of the edges thereof. It relates to the manufacture of a part (11) possessing edge zone (11) in an aeronautical structure through a join with joining plate (23) and backing plate (25) by means of the following stages: a) Definition of interface surface (15) of edge zone (13) to be in contact with joining plate (23); b) Manufacture of first panel (31) possessing the configuration planned for part (11); c) Obtainment of a map of differences between the thickness of first panel (31) and that which it should possess to be coincident with said interface surface (15); d) Manufacture of supplementary panel (33) having a thickness to be coincident with that of said map of differences; e) joining of supplementary panel (33) to first panel (31).

Abstract: The invention relates to a process for making swaged lighting holes (1) in planar areas of parts (5) made of preimpregnated composite, by means of which the part (5) is arranged between a female tooling (11) with the final shape of the bottom side of the swaged part and a caul plate (19) with the final shape of the top side of the swaged part, except in an area (3) which must be swaged, pressure P1 is applied on the caul plate (19) in the area of the part (5) that must be maintained substantially planar, and pressure P2 is applied by means of a male tooling (17) on the area (3) of the part (5) which must be swaged at a forward speed allowing the flow of the resin during the slippage of the fibers of the material so that it may deform, adapting to the final shape of the female tooling (11).

Abstract: The system has special application in the manufacture of aircraft wing covers (1) made of carbon fiber and the stringers (3) cured jointly with the wing cover during the polymerization in autoclave. The tool pieces (4) being used are defined by angular elements (5, 6) copying the geometry of the stringers (3). The shape of these stringers corresponds to the “T” section. The angular elements (5, 6) comprise, in their upper part, a pair of battlements (7) in order to be caught by part of the clamps (9) of a head (10) linked to a robot (11) of the spherical type with articulated arm with six axes. The angular elements (5, 6) are made of INVAR material and they are used to keep in position the stringers during the curing cycle in the autoclave.

Abstract: The invention relates to a composite structure (11) formed by a plurality of layers (13, 15, 17, 19, 21, 23) including an optical fiber (25) for structural monitoring purposes which is at least partly embedded in said structure (11), incorporating a protective cover (27) in those areas of its embedded part susceptible to needing repair, and to a process for repairing said embedded optical fiber comprising the following steps: identifying the optical fiber area in need of repair, removing material until reaching the cover (27), extracting said area, removing the protective cover (27), repairing the optical fiber (25), relocating the repaired area in the structure and returning the removed material.

Abstract: The invention relates to a device for the manufacture of three-dimensional beam type elements in composite material with reinforcing fibres preimpregnated with polymeric resins, starting with laminates (21, 22) layed and precut without polymerization, said device comprising a head (15) that comprises in its turn a roller train (17), it being possible for said head (15) to move longitudinally along a fixed bedplate, in such a way that, as said head (15) moves, the roller train acts on the laminates (21, 22) without polymerization, compacting and forming them, thus forming the laminates (21, 22) with their final geometry in one go, in such a way that said laminates (21, 22) are ready for their subsequent integration. The invention also relates to a method of manufacture of three-dimensional beam type elements in composite material.

Abstract: The invention relates to a composite structure (11) formed by a plurality of layers (13, 15, 15, 19, 21, 23) including an optical fiber (25) for structural monitoring purposes which is at least partly embedded in a surface layer (13) of said structure (11), and insulation means of the optical fiber (25) areas susceptible to repair with respect to the surface layer (13) in which they are integrated, particularly a protective cover (27) and top and bottom separating films (31, 33), and a process of repairing said areas comprising the following steps: removing the protective cover (27) and the top separating film (31), extracting the area, repairing the optical fiber, relocating the area and providing a new protective cover (27).

Abstract: The invention relates to a quality control process for an adhesive joint of two sub-components of a structure comprising the following steps: a) Providing the structure of composite material to be controlled; b) Providing at least one premanufactured testing device (1) representative of one of the sub-components of the structure; c) Bonding the at least one premanufactured testing device (1) to the other sub-component (7) of the structure in conditions similar to those of the real adhesive joint of the sub-components; d) Carrying out at least one mechanical test on the at least one premanufactured testing device (1) which allows assessing the quality of the adhesive joint.

Abstract: The invention relates to a process for making swaged lighting holes (1) in planar areas of parts (5) made of preimpregnated composite, by means of which the part (5) is arranged between a female tooling (11) with the final shape of the bottom side of the swaged part and a caul plate (19) with the final shape of the top side of the swaged part, except in an area (3) which must be swaged, pressure P1 is applied on the caul plate (19) in the area of the part (5) that must be maintained substantially planar, and pressure P2 is applied by means of a male tooling (17) on the area (3) of the part (5) which must be swaged at a forward speed allowing the flow of the resin during the slippage of the fibers of the material so that it may deform, adapting to the final shape of the female tooling (11).

Abstract: The invention relates to a quality control process for an adhesive joint of two sub-components of a structure comprising the following steps: a) Providing the structure of composite material to be controlled; b) Providing at least one premanufactured testing device (1) representative of one of the sub-components of the structure; c) Bonding said at least one premanufactured testing device (1) to the other sub-component (7) of the structure in conditions similar to those of the real adhesive joint of said sub-components; d) Carrying out at least one mechanical test on said at least one premanufactured testing device (1) which allows assessing the quality of said adhesive joint.

Abstract: A method of monitoring structural damage in a composite structure manufactured by co-curing, co-bonding or secondary bonding of several sub-components (7, 8), using fibre optic Bragg grating sensors attached or embedded to or between (in the bonding line) said sub-components, comprising a first step of measuring the wavelength spectra (31, 33, 40) of said Bragg grating sensors at the end of the manufacturing of the part, and in a known load condition, considered as reference and a second step of identifying the occurrence of a failure of the structure and the progress of said failure detecting the release of the residual stresses/strains stored during the curing process by measuring changes (31 to 32, 33 to 34, 40 to 41) with respect to said reference wavelength spectra.