Abstract: A method of determining an allowable moisture content of a composite structure includes performing a thermal analysis on the composite structure to determine a surface temperature profile of the composite structure. The surface temperature profile is determined independently of a moisture content of the composite structure. The method also includes performing a moisture analysis on the composite structure to determine an allowable moisture content of the composite structure such that the moisture analysis is based on the determined surface temperature profile.

Abstract: A window system and method of attenuating light in a window system for improving usefulness and reliability of an electronic dimmable window in the window system. An automatically adjusting photochromatic material is integrated into a window pane of the window system such that the electronic dimmable window is positioned between the automatically adjusting photochromatic material in the window pane and a dust cover of the window system. The automatically adjusting photochromatic material is formulated to attenuate incoming light in a local area of the photochromatic material in response to a solar flux intensity of the incoming light in the local area being greater than or equal to a threshold intensity while areas outside the local area of the photochromatic material that are subjected to solar flux intensity less than the threshold intensity do not attenuate incoming light.

Abstract: Method and apparatus for curing a composite laminate. The apparatus comprising an electromagnetic radiation source creating electromagnetic microwave energy in an enclosed volume and a heating source for providing a convective airflow in the enclosed volume. A composite laminate assembly comprising a composite laminate is placed in the enclosed volume, wherein the composite laminate of the composite laminate assembly is cured by both the electromagnetic microwave energy created by the electromagnetic radiation source, and the convective airflow provided by the heating source. A vacuum bag may be placed over the composite laminate assembly. A source may be activated such that a vacuum within the vacuum bag is created according to design specifications.

Abstract: Aspects of the present disclosure generally relate to an SMA actuator that includes a cooling device disposed within a torque tube. In one aspect, the cooling device includes a sliding sleeve, an expandable sleeve, and plurality of cooling fins coupled to the expandable sleeve. Axial movement of the sliding sleeve relative to the expandable sleeve facilitates radial expansion of the expandable sleeve and urges the cooling fins into contact with the torque tube. The cooling fins function as heat sinks when in contact with the torque tube to facilitate the removal of heat from the torque tube to increase the cooling rate of the torque tube. During heating of the torque tube, the cooling fins may be spaced apart from the torque tube to reduce the thermal mass that is heated, thus increasing the heating rate of the torque tube.

Abstract: Method and apparatus for curing a composite laminate. The apparatus comprising an electromagnetic radiation source creating electromagnetic microwave energy in an enclosed volume and a heating source for providing a convective airflow in the enclosed volume. A composite laminate assembly comprising a composite laminate is placed in the enclosed volume, wherein the composite laminate of the composite laminate assembly is cured by both the electromagnetic microwave energy created by the electromagnetic radiation source, and the convective airflow provided by the heating source. A vacuum bag may be placed over the composite laminate assembly. A source may be activated such that a vacuum within the vacuum bag is created according to design specifications.

Abstract: Systems and methods for curing complex fiber-reinforced composite structures utilize two distinct heat sources. A first heat source is utilized for heating a complex fiber-reinforced composite structure from within an internal portion of the complex fiber-reinforced composite structure. A second heat source is utilized for heating the complex fiber-reinforced composite structure from an external surface of the complex fiber-reinforced composite structure.

Abstract: Chopped fiber composite systems and methods are disclosed. Sorting systems include a conveyor, an imager, a plurality of receptacles, a pneumatic device, and controller. Molding systems include a conveyor, an imager, a mold, a pneumatic device, and a controller. The controller directs the pneumatic device to alter the freefall of chopped fiber composite pieces based on characteristics of the chopped fiber composite pieces as they drop from the conveyor and into a receptacle or a mold. Sorting and molding methods include dropping chopped fiber composite pieces, detecting characteristics of the dropping pieces, and directing the pieces based on the detected characteristics.

Abstract: In one or more aspects of the present disclosure, a mandrel is disclosed. The mandrel having a shape memory alloy (SMA) shell having a longitudinal axis, an interior extending along the longitudinal axis and an exterior contour, the SMA shell being configured to interface with a structure to be cured, and at least one SMA actuation member disposed within the interior and connected to the SMA shell, where the at least one SMA actuation member is configured to exert pressure against the SMA shell effecting an interface pressure between the exterior contour of the SMA shell and the structure to be cured where the exterior contour has a predetermined actuated shape that corresponds to a predetermined cured shape of the structure to be cured.

Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.

Abstract: A system for manufacturing a composite tubular structure. The system includes an outer tube configured to remain rigid up to at least a first threshold pressure. The system includes an inner tube internal to the outer tube and substantially coaxial with the outer tube. The inner tube has a first outer surface and a first inner surface. The inner tube is configured to remain rigid up to a second threshold pressure that is less than the threshold first pressure. The system includes a composite tubular layup laid on the first outer surface of the inner tube. The system includes an assembly of a plurality of separate segments disposed inside the inner tube, each segment adjacent to two other segments, to form a segmented inner cylinder having a second outer surface of a cylindrical shape and an inner channel of a first conical shape.

Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.

Abstract: Methods and systems for determining optical properties for light transmitted mediums are provided. One method includes acquiring one or more measured values indicative of a reflectance for a material, acquiring one or more measured values indicative of a transmittance for the material, and determining a set of calculated values for an index of refraction coefficient and an extinction coefficient from the one or more measured values indicative of reflectance and transmittance, respectively. The method includes identifying a calculated value from the set of calculated values for the index of refraction coefficient and a calculated value from the set of calculated values for the extinction coefficient that are within a threshold determined by the difference between the one or more measured values indicative of the reflectance or transmittance and a predicted reflectance or transmittance, respectively. The method includes determining a reflectance and transmittance for the material using the calculated values.

Abstract: A method of bonding materials may comprise defining a bond interface between two materials in a cure zone on a surface of an object, and non-conductively heating the bond interface without directly heating the surface outside of the cure zone. Non-conductively heating the bond interface may involve applying microwave radiation to the bond interface.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A method and apparatus for managing heating of a window system. The apparatus comprises a dimmable window panel and a heating system. The dimmable window panel has an inner portion and an outer portion around the inner portion. The heating system is thermally connected to the outer portion of the dimmable window panel.

Abstract: A system for varying a camber of an airfoil may include an airfoil having an upper surface and a lower surface meeting to form a leading edge and a trailing edge, the lower surface having a first actuator including shape memory alloy sheet, a controller including a plurality of heating elements attached to the shape memory alloy sheet for selectively heating the sheet to a temperature above ambient to deform the upper and lower surfaces to morph a geometry of a camber of the airfoil thereby, a computer control connected to selectively control individual activation of the heating elements to heat the shape memory alloy sheet to a selected temperature to effect a selected deflection, and a cooling device to allow ambient air to enter the wing and exit over the actuator to resume a non-morphed state.

Abstract: Described herein is an apparatus for controlling an actuator made from a shape-memory alloy includes a first layer made from a thermally conductive material and a second layer. The second layer is made from a thermally conductive material. The apparatus also includes at least one thermoelectric heater positioned between the first and second layers. Additionally, the apparatus includes at least one thermoelectric cooler positioned between the first and second layers.

Abstract: A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.

Abstract: A system for heating a shape memory alloy (SMA) actuator may include an SMA actuator, a smart susceptor, a plurality of induction coils, and a control module. The SMA actuator may have at least one layup. The SMA actuator may be selectively heated to a transition temperature. The smart susceptor may be in thermal contact with the at least one layup of the SMA actuator. The induction heating coils may be configured to receive an alternating current and generate a magnetic field based on the alternating current. The magnetic field may create an eddy current in at least one of the SMA actuator and the smart susceptor to heat the SMA actuator to the transition temperature. The control module may be configured to drive the alternating current supplied to the induction heating coils.

Abstract: A heated roller shade system is provided. The heated roller shade system includes a roller located in a cavity defined between an inner wall of a vehicle and an outer wall of the vehicle. The roller shade system also includes a shade coupled to the roller. The roller is configured to selectively move the shade between a deployed position and an open position. The roller shade system also includes a heating mechanism coupled to at least one of the roller and the shade. The heating mechanism facilitates increasing a temperature of at least one of the roller and the shade.