Abstract: A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

Abstract: A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

Abstract: A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

Abstract: Ice protection systems of aircraft and related methods are disclosed. In one embodiment of the present invention, the system includes a gas-discharge lamp and an electric power source. The gas-discharge lamp is configured to emit infrared radiation toward an inner surface of an aircraft skin. The electric power source is operatively connected to the gas-discharge lamp.

Abstract: Precursors, and methods for manufacturing perforated composite parts, an exemplary precursor including structural fibers embedded in a cured matrix material and interposed between two removable plies, where the precursor may also have a sacrificial fiber extending through the removable plies, the matrix material and between the structural fibers.

Abstract: A control rod for incorporation into a composite assembly with at least a first composite preform, a second composite preform, and a cured resin includes a shaft defining an axis, wherein the shaft is disposable within an aperture in the composite assembly, and a plurality of threads disposed on at least a portion of the shaft. The shaft is made from, among other materials, a thermoplastic material. The threads define a thread pitch that encompasses more than one individual fiber layer forming at least one of the first composite layer and the second composite layer.

Abstract: A method for inserting an insert into a hole in a composite material made from a plurality of carbon fiber layers suspended in a resin material includes lowering a temperature of the insert to a reduced temperature at which a coefficient of thermal expansion of a material of the insert causes the insert to contract to a first perimeter, inserting the insert at the reduced temperature into the hole, and permitting the temperature of the insert to increase from the reduced temperature to an operational temperature. At the operational temperature, the insert expands to a second perimeter so that the insert is retained within the composite material due to an interference between the insert and the composite material. The interference transfers a structural load from the insert to the composite material and results in damage to the composite material if the insert is dislodged at the operational temperature.

Abstract: Ice protection systems of aircraft and related methods are disclosed. In one embodiment, the system includes a gas-discharge lamp configured to emit infrared radiation toward an inner surface of an aircraft skin and an electric power source operatively connected to the gas-discharge lamp.

Abstract: Precursors, and methods for manufacturing perforated composite parts, an exemplary precursor including structural fibers embedded in a cured matrix material and interposed between two removable plies, where the precursor may also have a sacrificial fiber extending through the removable plies, the matrix material and between the structural fibers.

Abstract: Precursors and methods for manufacturing perforated composite parts are disclosed. An exemplary precursor (19) comprises structural fibers (24,28) embedded in a cured matrix material (24,26) and interposed between two removable plies (20). The precursor may also comprise a sacrificial fiber (28) extending through the removable plies (20), the matrix material (24,26) and between the structural fibers (24,28). An exemplary method comprises removing the removable plies (20) from the precursor (19) and removing the sacrificial fiber (28) from the precursor after removing the removable plies to form a through hole in the precursor (19) at a location of the sacrificial fiber (28).

Abstract: A method for inserting an insert into a hole in a composite material made from a plurality of carbon fiber layers suspended in a resin material includes lowering a temperature of the insert to a reduced temperature at which a coefficient of thermal expansion of a material of the insert causes the insert to contract to a first perimeter, inserting the insert at the reduced temperature into the hole, and permitting the temperature of the insert to increase from the reduced temperature to an operational temperature. At the operational temperature, the insert expands to a second perimeter so that the insert is retained within the composite material due to an interference between the insert and the composite material. The interference transfers a structural load from the insert to the composite material and results in damage to the composite material if the insert is dislodged at the operational temperature.

Abstract: Precursors and methods for manufacturing perforated composite parts are disclosed. An exemplary precursor (19) comprises structural fibres (24,28) embedded in a cured matrix material (24,26) and interposed between two removable plies (20). The precursor may also comprise a sacrificial fibre (28) extending through the removable plies (20), the matrix material (24,26) and between the structural fibres (24,28). An exemplary method comprises removing the removable plies (20) from the precursor (19) and removing the sacrificial fibre (28) from the precursor after removing the removable plies to form a through hole in the precursor (19) at a location of the sacrificial fibre (28).

Abstract: A control rod for incorporation into a composite assembly with at least a first composite preform, a second composite preform, and a cured resin includes a shaft defining an axis, wherein the shaft is disposable within an aperture in the composite assembly, and a plurality of threads disposed on at least a portion of the shaft. The shaft is made from, among other materials, a thermoplastic material. The threads define a thread pitch that encompasses more than one individual fiber layer forming at least one of the first composite layer and the second composite layer.

Abstract: A control rod for incorporation into a composite assembly comprising at least a first preform, a second preform, and a cured resin includes a shaft defining an axis, wherein the shaft is disposable within an aperture in the composite assembly and a plurality of threads disposed helically on at least a portion of the shaft. Dry fibers from the first preform and second preform are forced into the threads of the control rod.

Abstract: A method and apparatus for forming a fiber reinforced composite structure comprising at least two components, a hard base tool presenting a first tool face, a second tooling element presenting a second tool face to locate the second component against the first component. Components are of a dry fibrous form and are to be injected with a liquid resin. A flexible bagging blanket forms with the tools a sealed enclosure into which the resin is injected to form the structure by resin transfer infusion. To maintain the relative dispositions of the components without the need for elaborate mandrel plates, control rods are inserted at least partially through the two components to act as fasteners and to maintain the relative disposition of the components during resin injection. After injection the assembly is cured and the control rods may remain in situ or be removed from the structure.

Abstract: In the formation of a fiber reinforced composite material component produced by a resin transfer infusion process such as to have an electrically conductive surface layer for lightning strike protection wherein the component is to be drilled and countersunk to receive an electrically conductive fastener, a localized part of the electrically conductive mesh is deformed so as to be relocated in the countersunk recess thus to ensure electrical contact with the fastener when inserted and to eliminate any gap between the mesh and the fastener, thus determining the electrical conductive integrity of the mesh to avoid arcing in the event of lightning strike attachment.

Abstract: A method of forming a nanocomposite material that includes nanoparticles includes disposing in a forming apparatus a fiber material, a carrier material with nanoparticles dispersed therein, the carrier material having a releasing trigger to release the nanoparticles, the releasing trigger being at least one of a releasing temperature and a releasing pressure, and a resin having an infusion temperature, increasing the temperature within the forming apparatus to a temperature at least equal to the infusion temperature of the resin to allow the resin to impregnate the fiber material without triggering the releasing trigger of the carrier material, and triggering the releasing trigger of the carrier material in the forming apparatus by increasing at least one of the temperature and the pressure within the forming apparatus to cause dispersion of the nanoparticles.

Abstract: In the formation of a fiber reinforced composite material component produced by a resin transfer infusion process such as to have an electrically conductive surface layer for lightning strike protection wherein the component is to be drilled and countersunk to receive an electrically conductive fastener, a localized part of the electrically conductive mesh is deformed so as to be relocated in the countersunk recess thus to ensure electrical contact with the fastener when inserted and to eliminate any gap between the mesh and the fastener, thus determining the electrical conductive integrity of the mesh to avoid arcing in the event of lightning strike attachment.

Abstract: A method and apparatus for forming a fibre reinforced composite structure comprising at least two components, a hard base tool presenting a first tool face, a second tooling element presenting a second tool face to locate the second component against the first component. Components are of a dry fibrous form and are to be injected with a liquid resin. A flexible bagging blanket forms with the tools a sealed enclosure into which the resin is injected to form the structure by resin transfer infusion. To maintain the relative dispositions of the components without the need for elaborate mandrel plates, control rods are inserted at least partially through the two components to act as fasteners and to maintain the relative disposition of the components during resin injection. After injection the assembly is cured and the control rods may remain in situ or be removed from the structure.

Abstract: A noise attenuation panel used to attenuate noise in aircraft engines includes a cellular core and a facing sheet formed with an array of holes. The holes are laser drilled to provide: (i) hole size variation over the facing sheet; (ii) non-circular hole cross section; (iii) polygonal hole cross section; (iv) hole locations not contiguous with walls of the cellular core; and (v) inclined holes passing through the facing sheet in a direction inclined to the normal to the facing sheet.