Abstract: Method and apparatus for mechanically-joining components to assemble a composite structure. A first component and a second component may be provided. At least one of the first and second components may comprise a composite component. A hole may be formed in each of the first and second components. A metallic sleeve may be placed in the holes in the first and second components such that the metallic sleeve is in contact with the first and second components, and a composite rivet may be placed in the metallic sleeve. Heat and a deforming force may be applied to the composite rivet to join the first and second components to form an assembled composite structure.

Abstract: A method and apparatus for attaching parts. A composite male fastening component is placed through at least a first part and a second part. The composite male fastener component preferably has a threaded portion. A composite female fastener component is positioned adjacent to and surrounding the threaded portion of the male fastener component. A portion of the composite female fastener component is caused to flow around and form into the threaded portion of the composite male fastener component. The portion of the composite female fastener component that flowed around and formed into the threaded portion of the composite male fastener component is re-solidified and re-consolidated such that the composite female fastener component is securely attached to the composite male fastener component thereby joining the mating parts.

Abstract: A hybrid fastening system comprising a female fastener component, i.e., swage collar, fabricated from a titanium or titanium-alloy material, preferably Ti-3Al-2.5V, and a mating titanium or titanium-alloy material male fastener component, i.e., threaded pin, each preferably pre-coated with an organic coating material comprising an organic, phenolic resin. The threaded pin component is installed through two or more structural components to be joined. The swage collar component is then deformed or swaged onto the threads of the pre-coated threaded pin component to achieve the same, if not improved, fastener/joint performance characteristics of existing lockbolt systems using aluminum-alloy material swage collar components.

Abstract: A hybrid fastening system comprising a female fastener component, i.e., swage collar, fabricated from a titanium or titanium-alloy material, preferably Ti-3A1-2.5V, and a mating titanium or titanium-alloy material male fastener component, i.e., threaded pin, each preferably pre-coated with an organic coating material comprising an organic, phenolic resin. The threaded pin component is installed through two or more structural components to be joined. The swage collar component is then deformed or swaged onto the threads of the pre-coated threaded pin component to achieve the same, if not improved, fastener/joint performance characteristics of existing lockbolt systems using aluminum-alloy material swage collar components.

Abstract: The present invention is directed to a method for applying to a substrate, in the form of a seal, a polysiloxane-containing coating, preferably a polysiloxane(amide-ureide) coating capable of inhibiting corrosion as well as the accumulation of ice. One embodiment of the present invention is directed to a polysiloxane(amide-ureide) that forms a durable, long lasting, anti-corrosive and anti-ice coating when applied to a substrate as a seal.

Abstract: A composite fastener and method for fastening structural members are provided. The fastener is formed at least partially of a composite material. For example, at least one component of the fastener can be formed of a composite material and the remaining components of the fastener can be formed of a metallic material. The fasteners can be compatible with the materials of the structural members to be fastened or joined, such as where all or at least one of the structural members are formed of a composite material. In some cases, the fastener can be installed blindly from one side of the structural members with no or limited access to the opposite side.

Abstract: The present invention relates to the use of a pre-coating process, which utilizes metallic plating as a surface pre-treatment for a ferrous-alloy precursor prior to applying a corrosion-inhibiting coating to improve the overall corrosion protection of the pre-treated and pre-coated component. Preferably the ferrous-alloy precursor is a heat-treatable, precipitation-hardenable stainless-steel material and the pre-treatment is a cadmium or a zinc-nickel alloy plating without a subsequent chromate or phosphate seal finish.

Abstract: An apparatus and method are provided for angularly extruding a workpiece through a die to form blanks and articles having refined grain structure. The die is also used to form the workpiece to a desired shape, such as a cylinder. The angular extrusion method can be used in place of some heat treatments, thereby lowering the cost and time for manufacturing articles. The method is compatible with materials with high strength-to-weight ratios such as aluminum, titanium, and alloys thereof. The blanks can be used to form articles having favorable mechanical properties such as strength, toughness, formability, and resistance to fatigue, corrosion, and thermal stresses.

Abstract: A test method for determining, quantifying, and qualifying the stress-relaxation characteristics of a sealant material compound comprising applying a sealant material layer between a first plate and a second plate, disposing a fastener assembly through the plates, and providing tension preload upon the fastener assembly so as to compress the plates together. The elongation of the fastener assembly is measured and the test assembly is heated and cooled under controlled parameters and the elongation of the fastener assembly is again measured. The stress-relaxation of the sealant material compound is correlated to the corresponding change in fastener assembly elongation for the purposes of measuring, quantifying, and qualifying the sealant material compound.

Abstract: The present invention provides a method for the direct measurement and quantification of the material volume loss on and beneath a first surface of a substrate and thus provides an accurate depiction of the profile of the substrate. The method of the invention comprises inducing multiple eddy currents in a test substrate to determine volume loss.

Abstract: An apparatus and method are provided for angularly extruding a workpiece through a die to form blanks and articles having refined grain structure. The die is also used to form the workpiece to a desired shape, such as a cylinder. The angular extrusion method can be used in place of some heat treatments, thereby lowering the cost and time for manufacturing articles. The method is compatible with materials with high strength-to-weight ratios such as aluminum, titanium, and alloys thereof. The blanks can be used to form articles having favorable mechanical properties such as strength, toughness, formability, and resistance to fatigue, corrosion, and thermal stresses.

Abstract: A test method for determining, quantifying, and qualifying the flow characteristics of a sealant material compound comprising the steps of applying a uniform layer of known initial mass of sealant material between two test surfaces and compressing the sealant material between the surfaces at a specific pressure for a specific length of time, and at a specific temperature, causing an amount of sealant to be extruded from between the test surfaces. The amount of the extruded sealant is measured and compared to the total mass of initial sealant material to determine the ratio of the extruded to initial sealant material. Based upon the mass ratio of extruded sealant material versus the initial sealant material, the flow characteristics of the sealant material may be expressed for any given combination of temperature, pressure, and duration and compared to other sealant materials.

Abstract: The apparatus for operating on a workpiece includes a die defining first and second apertures and an interior therebetween. The first aperture and the interior of the die are structured to receive the workpiece. The interior of the die can be structured to shape the workpiece into a predetermined configuration. The apparatus includes at least one rotatable pin extending at least partially into the interior of the die. The pin is structured to at least partially stir the workpiece as the workpiece moves through the interior of the die to thereby refine the grain structure of the workpiece.

Abstract: A high-strength, corrosion- and heat-resistant aircraft structural component such as a fastener is prepared by providing a corrosion-resistant stainless steel or heat-resistant superalloy metallic component precursor that is not in its final heat-treated state, and coating with an aluminum-containing, curable polyaromatic phenolic coating material having a non-volatile portion that is predominantly organic and is curable at about the high-strength metallic alloy component's stress equalizing tempering temperature. The coated, high-strength metallic-alloy component is then thermally treated to concurrently impart pre-determined metallurgical properties to the finished, metallic substrate, and cure the organic, aluminum-containing coating.

Abstract: The present invention is directed to a method for applying to a substrate having a faying surface, a polysiloxane-containing coating, preferably a polysiloxane(amide-ureide) coating capable of inhibiting corrosion as well as the accumulation of ice. One embodiment of the present invention is directed to a polysiloxane(amide-ureide) that forms a durable, long lasting, anti-corrosive and anti-ice coating when directed to a substrate faying surface.

Abstract: The present invention relates to the use, in a pre-coating process, of a flash plating, without a subsequent chromate seal, as a surface pre-treatment for a ferrous-alloy substrate prior to applying a corrosion-inhibiting coating to improve the overall corrosion protection of the pre-treatment component. Preferably the ferrous alloy is a heat-treatable, precipitation-hardenable stainless steel and the pre-treatement is a cadmium flash plate or a zinc-nickel alloy flash plate.

Abstract: The present invention is directed to a method for applying to a substrate, in the form of a seal, a polysiloxane-containing coating, preferably a polysiloxane(amide-ureide) coating capable of inhibiting corrosion as well as the accumulation of ice. One embodiment of the present invention is directed to a polysiloxane(amide-ureide) that forms a durable, long lasting, anti-corrosive and anti-ice coating when applied to a substrate as a seal.

Abstract: An apparatus and method are provided for angularly extruding a workpiece through a die to form blanks and articles having refined grain structure. The die is also used to form the workpiece to a desired shape, such as a cylinder. The angular extrusion method can be used in place of some heat treatments, thereby lowering the cost and time for manufacturing articles. The method is compatible with materials with high strength-to-weight ratios such as aluminum, titanium, and alloys thereof. The blanks can be used to form articles having favorable mechanical properties such as strength, toughness, formability, and resistance to fatigue, corrosion, and thermal stresses.

Abstract: The apparatus for operating on a workpiece includes a die defining first and second apertures and an interior therebetween. The first aperture and the interior of the die are structured to receive the workpiece. The interior of the die can be structured to shape the workpiece into a predetermined configuration. The apparatus includes at least one rotatable pin extending at least partially into the interior of the die. The pin is structured to at least partially stir the workpiece as the workpiece moves through the interior of the die to thereby refine the grain structure of the workpiece.

Abstract: The present invention is directed to a method for applying to a substrate having a faying surface, a polysiloxane-containing coating, preferably a polysiloxane(amide-ureide) coating capable of inhibiting corrosion as well as the accumulation of ice. One embodiment of the present invention is directed to a polysiloxane(amide-ureide) that forms a durable, long lasting, anti-corrosive and anti-ice coating when directed to a substrate faying surface.