Abstract: A method for preparing a part using a rigid tool surface having a shape. The method includes applying a breather sheet comprising gas-permeable material over the rigid tool surface. A vacuum bag is applied over the breather sheet, and a vacuum pressure is applied underneath the vacuum bag to conform the breather sheet and the vacuum bag to the shape of the rigid tool surface. A resin pre-impregnated ply is applied over the vacuum bag, and the part is positioned over the ply.

Abstract: A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: A cascade segment for a thrust reverser, and a method of manufacturing it. The segment includes individual vane elements, modular units, and a frame. Each element includes a vane and two flanges arranged in a generally “U” shape. Each flange diverges from being perpendicular to the vane by an amount equal to a thickness of the flange over a desired spacing distance, such that when one element is inserted into another the desired spacing distance is established between their respective vanes. The units include first modular units, each of which includes a first column of the elements oriented in a first direction, and second modular units, each of which includes a second column of the elements oriented in a second direction. In the assembled segment, the first units are positioned adjacent to and alternating with the second units. The frame extends at least partly around and secures the units.

Abstract: A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: An acoustic panel for attenuating sound, and a system and method for making the acoustic panel. The acoustic panel employs rounded particles which are introduced into the cells of a core and fixed at a particular depth to form a septum layer providing substantially linear acoustic resistance to sound waves entering the cell. The particles may be between 100 microns and 700 microns in diameter, may be solid or hollow, may have smooth or textured surfaces, and/or may be made of syntactic foam or glass or ceramic. The system includes a positioning mechanism for positioning the particles at the particular depth, metering and gating mechanisms for introducing a metered amount of the particles into each cell, and a vibratory base for vibrating the particles to better pack them. Once the particles are in the cells, the septum layer is fixed, and the positioning mechanism is removed.

Abstract: A system for peen-forming of thermoplastic composite material is provided. The system includes a tool, a heater, and a peen-forming device. The thermoplastic composite material is positioned on the tool, which supports the thermoplastic composite material as it is being process. The tool has a surface to which a portion of the thermoplastic composite material is intended to conform. The heater is configured to heat the thermoplastic composite material while it is positioned on the tool to make the thermoplastic composite material more malleable. The peen-forming device directs particles against the thermoplastic composite material positioned on the tool so that the portion of the thermoplastic composite material conforms to the surface of the tool.

Abstract: A method of manufacturing a composite part having a curved or radiused corner to avoid wrinkling or bridging of outer-most composite plies during consolidation and cure, including laying up composite material on male or female tooling to form two flanges extending at a first angle relative each other and a curved or radiused corner extending between the two flanges. Then the method may include changing an orientation of one or both of the flanges of the composite material, such that the two flanges extend at a second included angle relative each other. The second included angle is smaller than the first angle. The method may also include a step of consolidating the composite material before, after, or during the step of changing the orientation of the composite material to the second angle, as well as a step of curing the composite material oriented at the second angle.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: A tooling assembly and method for bonding composite components together, such as a bonded cascade assembly of a thrust reverser for an aircraft nacelle. The method may include the steps of fixing composite turning vanes between elongated stiffeners, placing them in a cavity formed by a tooling frame, then filling cavities between the turning vanes, the elongated stiffeners, and/or the tooling frame with flowable solid elastomeric material. The method may also include the steps of compressing and/or heating the elastomeric material, the turning vanes, the elongated stiffeners, and the tooling frame. This heat and/or pressure combined with expansion of the elastomeric material may be sufficient to press contacting portions of the turning vanes and the elongated stiffeners toward each other and also causing the turning vanes to bond to the elongated stiffeners under pressure of the elastomeric material expansion.

Abstract: A method of fabricating a thrust reverser cascade assembly including positioning a first frame section on an assembly fixture, positioning a first set of turning vanes on a first elongated stiffener of the first frame section, securing the first set of turning vanes to the elongated stiffener, positioning a second frame section on the assembly fixture adjacent to the first frame section such that the first set of turning vanes are between the elongated stiffeners of the first and second frame section, adding additional sets of turning vanes and frame sections, and fastening the frame sections together.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: An acoustic panel for attenuating sound, and a system and method for making the acoustic panel. The acoustic panel employs rounded particles which are introduced into the cells of a core and fixed at a particular depth to form a septum layer providing substantially linear acoustic resistance to sound waves entering the cell. The particles may be between 100 microns and 700 microns in diameter, may be solid or hollow, may have smooth or textured surfaces, and/or may be made of syntactic foam or glass or ceramic. The system includes a positioning mechanism for positioning the particles at the particular depth, metering and gating mechanisms for introducing a metered amount of the particles into each cell, and a vibratory base for vibrating the particles to better pack them. Once the particles are in the cells, the septum layer is fixed, and the positioning mechanism is removed.

Abstract: An impact triggered dynamic target system includes, a target body with legs that can be ground spikes; a target release assembly, including a target holder including first and second holder pegs; a primary target assembly, including a primary target disc, a secondary target pusher including first and second secondary target pushers, and first and second target sliders slidably mounted on the first and second holder pegs, and a plurality of secondary target discs; a rolling track with a rolling surface and first and second side rails; and a projectile receptacle, such that a practice shooter shoots that the primary target disc, which releases a secondary target disc, which rolls down the rolling track and off the impact triggered dynamic target system, such that the practice shooter can shoot at the rear disc, while the rear disc is rolling on an adjacent ground surface.

Abstract: A cascade segment for a thrust reverser, and a method of manufacturing it. The segment includes individual vane elements, modular units, and a frame. Each element includes a vane and two flanges arranged in a generally “U” shape. Each flange diverges from being perpendicular to the vane by an amount equal to a thickness of the flange over a desired spacing distance, such that when one element is inserted into another the desired spacing distance is established between their respective vanes. The units include first modular units, each of which includes a first column of the elements oriented in a first direction, and second modular units, each of which includes a second column of the elements oriented in a second direction. In the assembled segment, the first units are positioned adjacent to and alternating with the second units. The frame extends at least partly around and secures the units.

Abstract: A method of fabricating a thrust reverser cascade assembly including positioning a first frame section on an assembly fixture, positioning a first set of turning vanes on a first elongated stiffener of the first frame section, securing the first set of turning vanes to the elongated stiffener, positioning a second frame section on the assembly fixture adjacent to the first frame section such that the first set of turning vanes are between the elongated stiffeners of the first and second frame section, adding additional sets of turning vanes and frame sections, and fastening the frame sections together.

Abstract: A method of manufacturing a composite part having a curved or radiused corner to avoid wrinkling or bridging of outer-most composite plies during consolidation and cure, including laying up composite material on male or female tooling to form two flanges extending at a first angle relative each other and a curved or radiused corner extending between the two flanges. Then the method may include changing an orientation of one or both of the flanges of the composite material, such that the two flanges extend at a second included angle relative each other. The second included angle is smaller than the first angle. The method may also include a step of consolidating the composite material before, after, or during the step of changing the orientation of the composite material to the second angle, as well as a step of curing the composite material oriented at the second angle.

Abstract: A method of manufacturing a composite part having a curved or radiused corner to avoid wrinkling or bridging of outer-most composite plies during consolidation and cure, including laying up composite material on male or female tooling to form two flanges extending at a first angle relative each other and a curved or radiused corner extending between the two flanges. Then the method may include changing an orientation of one or both of the flanges of the composite material, such that the two flanges extend at a second included angle relative each other. The second included angle is smaller than the first angle. The method may also include a step of consolidating the composite material before, after, or during the step of changing the orientation of the composite material to the second angle, as well as a step of curing the composite material oriented at the second angle.

Abstract: A tooling assembly and method for bonding composite components together, such as a bonded cascade assembly of a thrust reverser for an aircraft nacelle. The method may include the steps of fixing composite turning vanes between elongated stiffeners, placing them in a cavity formed by a tooling frame, then filling cavities between the turning vanes, the elongated stiffeners, and/or the tooling frame with flowable solid elastomeric material. The method may also include the steps of compressing and/or heating the elastomeric material, the turning vanes, the elongated stiffeners, and the tooling frame. This heat and/or pressure combined with expansion of the elastomeric material may be sufficient to press contacting portions of the turning vanes and the elongated stiffeners toward each other and also causing the turning vanes to bond to the elongated stiffeners under pressure of the elastomeric material expansion.