Abstract: A method of manufacture of a shaft including positioning a prefabricated wedge member onto a cylindrical mandrel, winding a fibre material onto the mandrel, the fibre material extending over at least a part of the wedge member, allowing a matrix material impregnated into the fibre material to cure, and machining away at least part of the fibre material in the region of the wedge member to expose fibres thereof.

Abstract: A composite material torque disc which comprises a support layer, and a reinforcing fiber secured to the support layer, the support layer being embedded within a polymer matrix material.

Abstract: A method of manufacture of a shaft including positioning a prefabricated wedge member onto a cylindrical mandrel, winding a fibre material onto the mandrel, the fibre material extending over at least a part of the wedge member, allowing a matrix material impregnated into the fibre material to cure, and machining away at least part of the fibre material in the region of the wedge member to expose fibres thereof.

Abstract: A load transmitting connector 13 for composite tube 11 and a method of attachment of said connector 13 to the tube 11, the connector 13 comprising a screw threaded nut 14 having an outer surface 18 shaped to receive the composite, an annular collar 15, a screw threaded end fitting 16 for engaging the screw thread within the nut 14, and a load means 17, wherein the nut 14 is incorporated within said one end of the tube during tube manufacture, the tube 11 being cured with the nut 14 in situ, the annular collar 15 is placed over said one end of the tube, the end fitting 16 is screwed into the nut, and the load means 17 in use axially moving the end-fitting 16 relative to the collar 15 to exert a clamping load on the composite tube.

Abstract: A composite material torque disc is described which comprises a support layer, and a reinforcing fibre secured to the support layer, the support layer being embedded within a polymer matrix material.

Abstract: A method and apparatus for forming at least one external annular flange (48 or 49) adjacent one end of a fiber reinforced thermoplastic tube (10) in which the tube (10) is mounted on a mandrel (12) and a first end portion of the tube is clamped in a collar (13) having at least one internal annular cavity (18 or 19) for forming a flange, a second end portion of the tube in the region (R1, R2) of the cavity is heated to soften the thermoplastic, and an axial load (L) is applied to the end of the tube by a piston (24) causing the softened tube to flow into the cavity (18, 19) in the collar (13) to form a flange on the tube.

Abstract: A load transmitting connector 13 for composite tube 11 and a method of attachment of said connector 13 to the tube 11, the connector 13 comprising a screw threaded nut 14 having an outer surface 18 shaped to receive the composite, an annular collar 15, a screw threaded end fitting 16 for engaging the screw thread within the nut 14 , and a load means 17, wherein the nut 14 is incorporated within said one end of the tube during tube manufacture, the tube 11 being cured with the nut 14 in situ, the annular collar 15 is placed over said one end of the tube, the end fitting 16 is screwed into the nut, and the load means 17 in use axially moving the end-fitting 16 relative to the collar 15 to exert a clamping load on the composite tube.

Abstract: A method and apparatus for forming at least one external annular flange (48 or 49) adjacent one end of a fibre reinforced thermoplastic tube (10) in which the tube (10) is mounted on a mandrel (12) and a first end portion of the tube is clamped in a collar (13) having at least one internal annular cavity (18 or 19) for forming a flange, a second end portion of the tube in the region (R1, R2) of the cavity is heated to soften the thermoplastic, and an axial load (L) is applied to the end of the tube by a piston (24) causing the softened tube to flow into the cavity (18, 19) in the collar (13) to form a flange on the tube.

Abstract: A method of forming a fibre reinforced thermoplastic composite tube (P) in which reinforcing fibres (10) and thermoplastic resin matrix material (12) are placed around a mandrel (M) to provide a composite tubular pre-form (20) on the mandrel (M) which is then passed through a heated die (30) to compact and reduce the diameter of the pre-form (20) and change the state of matrix, the mandrel (M) with the formed tube (P) thereon exiting the die and the now formed tube (P) is removed from the mandrel, the composite tubular pre-form (20) being produced by winding reinforcement fiber (10) and thermoplastic fiber (11) onto the mandrel, the thermoplastic matrix being caused to flow and then solidify on cooling.

Abstract: A fiber reinforced composite shaft bearing a metallic flanged end coupling attached to the outside diameter through a concentric cylindrical torsional joint is provided. The composite shaft is press fitted into a flanged metallic end coupling including a multiplicity of teeth running parallel to the tube axis which cut longitudinal channels into the outside diameter of the composite shaft wall during the press fit process. Pairs of inverted troughs adjacent to and running parallel to the cutting teeth in the serrated region allow space for the redistribution of the composite material and debris formed during the press fitting process. This combined action forms a mechanical interface capable of supporting torsional and axial stresses. A structural adhesive may be applied to the joint region to form a secondary joint. In this case the composite formed between the cutting debris and the adhesive fills the trough channels.

Abstract: A fiber reinforced composite shaft bearing a metallic flanged end coupling (Fl) attached to the outside diameter through a concentric cylindrical torsional joint, comprising: a) a cylindrical end region comprising a wedge shaped inner layer of fiber (Hp) composite; b) a layer of outer helical composite plies (He) forming the shaft and extending over the wedge shaped inner layer, wherein the layer of outer helical plies has a tapered end part overlying wedge shaped inner layer to form the cylindrical end portion, wherein all helical plies of fibre layers are exposed on an outer surface; and c) a metallic flanged end coupling attached to the outer surface of the cylindrical end region through a primary mechanically interface (Sp) which may be splined. The joint may be strengthened by internally reinforcing the main shaft with an interference fit tubular plug (Pg) and protected from environmental degradation by inboard secondary adhesive bond (Ad).