Abstract: An aircraft control structure includes first and second outer surfaced joined to a side wall. Stiffening webs extends between the first and second outer surfaces, each stiffening web at least partially surrounding an associated aperture formed in either the first or second outer surface and defining a stiffening recess. Skin plates are sized to extend over an associated stiffening recess and are shaped to conform to an associated aperture. Each skin plate is joined to an associated stiffening web by a friction stir welded seam.

Abstract: A method of forming a monolithic aircraft structure having multiple aerodynamic surfaces includes forming a body component to have a body skin defining a body skin outer surface, and a body side wall integrally formed with the body skin and defining a body mating surface, the body skin outer surface providing a first aerodynamic surface. A cover component is formed to have a cover mating surface and a cover outer surface opposite the cover mating surface, the cover outer surface defining a second aerodynamic surface. The body component is positioned relative to the cover component so that the body mating surface engages the cover mating surface. At least portions of the cover mating surface are friction stir welded to the body mating surface to form friction stir welded joints between the body component and the cover component.

Abstract: An aircraft control structure includes first and second outer surfaced joined to a side wall. Stiffening webs extends between the first and second outer surfaces, each stiffening web at least partially surrounding an associated aperture formed in either the first or second outer surface and defining a stiffening recess. Skin plates are sized to extend over an associated stiffening recess and are shaped to conform to an associated aperture. Each skin plate is joined to an associated stiffening web by a friction stir welded seam.

Abstract: A method of forming a monolithic aircraft structure having multiple aerodynamic surfaces includes forming a body component to have a body skin defining a body skin outer surface, and a body side wall integrally formed with the body skin and defining a body mating surface, the body skin outer surface providing a first aerodynamic surface. A cover component is formed to have a cover mating surface and a cover outer surface opposite the cover mating surface, the cover outer surface defining a second aerodynamic surface. The body component is positioned relative to the cover component so that the body mating surface engages the cover mating surface. At least portions of the cover mating surface are friction stir welded to the body mating surface to form friction stir welded joints between the body component and the cover component.

Abstract: A load path status detection system comprising a primary fastener, a load sensor, a primary structural link, and a secondary structural link. The primary fastener extends through the primary structural link. The load sensor is associated with the primary structural link. The primary structural link carries a load when a primary load path, formed by the primary fastener and the primary structural link, is functioning. The secondary structural link is parallel to the primary structural link, wherein the secondary structural link does not carry a load when the primary load path is functioning.

Abstract: A fastener status detection system is presented. The fastener status detection system comprises a primary fastener, a secondary fastener, and a sensor. The secondary fastener is configured to be a back-up to the primary fastener. The sensor is positioned to measure at least a portion of a load between the primary fastener and the secondary fastener.

Abstract: A load path status detection system comprising a primary fastener, a load sensor, a primary structural link, and a secondary structural link. The primary fastener extends through the primary structural link. The load sensor is associated with the primary structural link. The primary structural link carries a load when a primary load path, formed by the primary fastener and the primary structural link, is functioning. The secondary structural link is parallel to the primary structural link, wherein the secondary structural link does not carry a load when the primary load path is functioning.

Abstract: A fastener status detection system is presented. The fastener status detection system comprises a primary fastener, a secondary fastener, and a sensor. The secondary fastener is configured to be a back-up to the primary fastener. The sensor is positioned to measure at least a portion of a load between the primary fastener and the secondary fastener.