Abstract: A method for repairing a composite member includes assembling a composite stack on a surface. The composite stack includes a first book nested with a second book. An adhesive is disposed between the first book and the second book. At least one of the first book and the second book includes a first pattern of slots. The method further includes setting the composite stack to yield a composite repair piece. The method further includes attaching the composite repair piece to the composite member. Also disclosed is a composite repair piece. The composite repair piece includes a first book and a second book. The second book is stacked on top of the first book. An adhesive is disposed between the first book and the second book. At least one of the first book and the second book includes a first pattern of slots.

Abstract: Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

Abstract: A method for repairing a composite structure using pre-cured plugs. In accordance with one method, composite material is removed from a first composite laminate to form a cavity bounded by a tapered internal surface that extends from an opening at an outer mold line surface of the first composite laminate. In addition, a second composite laminate is machined to form a plug having a tapered surface. Then the plug is placed so that the tapered surface of the plug opposes the tapered internal surface of the first composite laminate. Thereafter, the tapered surface of the plug is bonded to the tapered internal surface of the first composite laminate. Optionally, a hole is drilled in the plug for receiving a fastener.

Abstract: Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

Abstract: A rework part for a composite structure is described. The rework part comprises an upper composite layer comprising an upper perimeter that extends beyond a damaged area of the composite structure, and a bottom composite layer between the composite structure and the upper composite layer, the bottom composite layer comprising a bottom perimeter that extends beyond the upper perimeter of the upper composite layer. The rework part further comprises a bottom adhesive layer adhering the bottom composite layer to the composite structure, and a rework part adhesive layer bonding the upper composite layer to either the bottom composite layer or to an intermediate composite layer.

Abstract: A method for curing a patch. The method includes generating the patch according to a negative of a scan of a scarf in a composite material. The method also includes pre-curing the patch.

Abstract: A method for curing a patch. The method includes generating the patch according to a negative of a scan of a scarf in a composite material. The method also includes pre-curing the patch.

Abstract: Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

Abstract: Disclosed herein are a repair apparatus, system, and method for structurally reinforcing an abnormal composite structural member. The repair is suited for reinforcing a cured composite structure that defines a strength tolerance and has an abnormality that reduces the structural strength relative to the strength tolerance of the cured composite. The structural reinforcement repairs the abnormality in the cured composite and provides the repair strength so that the repaired composite has a structural strength that meets or exceeds the strength tolerance. The structural reinforcement has a composite patch that is coupled to the cured composite over the abnormality and is covered by pressure-sensitive tape.

Abstract: A method for repairing a composite structure using pre-cured plugs. In accordance with one method, composite material is removed from a first composite laminate to form a cavity bounded by a tapered internal surface that extends from an opening at an outer mold line surface of the first composite laminate. In addition, a second composite laminate is machined to form a plug having a tapered surface. Then the plug is placed so that the tapered surface of the plug opposes the tapered internal surface of the first composite laminate. Thereafter, the tapered surface of the plug is bonded to the tapered internal surface of the first composite laminate. Optionally, a hole is drilled in the plug for receiving a fastener.

Abstract: A method for repairing a composite member includes assembling a composite stack on a surface. The composite stack includes a first book nested with a second book. An adhesive is disposed between the first book and the second book. At least one of the first book and the second book includes a first pattern of slots. The method further includes setting the composite stack to yield a composite repair piece. The method further includes attaching the composite repair piece to the composite member. Also disclosed is a composite repair piece. The composite repair piece includes a first book and a second book. The second book is stacked on top of the first book. An adhesive is disposed between the first book and the second book. At least one of the first book and the second book includes a first pattern of slots.

Abstract: Composite laminates fabricated from one or more respective laminae of composite material (e.g., fiber-reinforced polymers) may be pre-formed and fully cured, yet configured to be selectively conformable to a desired radius of curvature. To repair a damaged composite structure, a plurality of such composite laminates may be bonded together to form a repair part that may be bolted to or otherwise secured to the damaged composite structure, thereby repairing the structure using repair parts that may match the parent material of the damaged composite structure. Methods of forming said repair parts from a plurality of such composite laminates may provide advantages in costs and lead time, over conventional techniques. Kits may include a plurality of such pre-formed and cured composite laminates that may be stacked and combined together in a plurality of different arrangements to create a customizable repair part for a given damaged composite structure.

Abstract: A method for curing a patch. The method includes generating the patch according to a negative of a scan of a scarf in a composite material. The method also includes pre-curing the patch.

Abstract: Composite laminates fabricated from one or more respective laminae of composite material (e.g., fiber-reinforced polymers) may be pre-formed and fully cured, yet configured to be selectively conformable to a desired radius of curvature. To repair a damaged composite structure, a plurality of such composite laminates may be bonded together to form a repair part that may be bolted to or otherwise secured to the damaged composite structure, thereby repairing the structure using repair parts that may match the parent material of the damaged composite structure. Methods of forming said repair parts from a plurality of such composite laminates may provide advantages in costs and lead time, over conventional techniques. Kits may include a plurality of such pre-formed and cured composite laminates that may be stacked and combined together in a plurality of different arrangements to create a customizable repair part for a given damaged composite structure.

Abstract: A method for manufacturing a tool including assembling a stack-up that includes a plurality of precured composite laminates, the stack-up having an engagement surface, wherein each precured composite laminate of the plurality of precured composite laminates is flexible, and wherein an adhesive is positioned between adjacent precured composite laminates of the plurality of precured composite laminates, and placing the engagement surface of the stack-up onto a target surface of a substrate.

Abstract: A rework part for a composite structure is described. The rework part comprises an upper composite layer comprising an upper perimeter that extends beyond a damaged area of the composite structure, and a bottom composite layer between the composite structure and the upper composite layer, the bottom composite layer comprising a bottom perimeter that extends beyond the upper perimeter of the upper composite layer. The rework part further comprises a bottom adhesive layer adhering the bottom composite layer to the composite structure, and a rework part adhesive layer bonding the upper composite layer to either the bottom composite layer or to an intermediate composite layer.

Abstract: Disclosed herein is a method of repairing damage to a fuselage barrel, having a one-piece construction, of an aircraft. The method includes determining at least a first virtual splice line and a second virtual splice line along the fuselage barrel in a direction parallel to a longitudinal axis of the fuselage barrel. The method also includes detecting damage in a first section of the fuselage barrel between the first virtual splice line and the second virtual splice line. The method further includes cutting through the fuselage barrel along the first virtual splice line and the second virtual splice line to physically separate the first section from a main section of the fuselage barrel. The method also includes removing the first section from the main section of the fuselage barrel, and splicing a new section to the main section of the fuselage barrel in place of the first section.

Abstract: A method for manufacturing a tool including assembling a stack-up that includes a plurality of precured composite laminates, the stack-up having an engagement surface, wherein each precured composite laminate of the plurality of precured composite laminates is flexible, and wherein an adhesive is positioned between adjacent precured composite laminates of the plurality of precured composite laminates, and placing the engagement surface of the stack-up onto a target surface of a substrate.

Abstract: Disclosed herein is a method of repairing damage to a fuselage barrel, having a one-piece construction, of an aircraft. The method includes determining at least a first virtual splice line and a second virtual splice line along the fuselage barrel in a direction parallel to a longitudinal axis of the fuselage barrel. The method also includes detecting damage in a first section of the fuselage barrel between the first virtual splice line and the second virtual splice line. The method further includes cutting through the fuselage barrel along the first virtual splice line and the second virtual splice line to physically separate the first section from a main section of the fuselage barrel. The method also includes removing the first section from the main section of the fuselage barrel, and splicing a new section to the main section of the fuselage barrel in place of the first section.

Abstract: Disclosed herein is a method of repairing damage to a fuselage barrel, having a one-piece construction, of an aircraft. The method includes determining at least a first virtual splice line and a second virtual splice line along the fuselage barrel in a direction parallel to a longitudinal axis of the fuselage barrel. The method also includes detecting damage in a first section of the fuselage barrel between the first virtual splice line and the second virtual splice line. The method further includes cutting through the fuselage barrel along the first virtual splice line and the second virtual splice line to physically separate the first section from a main section of the fuselage barrel. The method also includes removing the first section from the main section of the fuselage barrel, and splicing a new section to the main section of the fuselage barrel in place of the first section.