Abstract: A method and system for heating a material includes an induction coil, a susceptor providing a receptacle, where the receptacle is configured to receive the material, and at least one nozzle for ejecting a heated gas onto and/or into the material. During the method, the susceptor is heated by the induction coil, and thermal energy from the susceptor can be transferred to the material. In addition to being heated by heat from the susceptor, the material is also heated by the heated gas, thereby increasing a heating rate of the material to rapidly heat the material to a processing temperature. The system can include other components such as a gas source, at least one conduit that channels gas from the gas source to the at least one nozzle, and a heat source that heats the gas prior to ejecting the gas from the at least one nozzle.

Abstract: Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

Abstract: Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

Abstract: A smart susceptor assembly including an electromagnetic flux source such as one or more inductors, a geometrically complex-shaped susceptor having one or more contours, and a cladding on or over the susceptor. The cladding can alter both the thermal performance and the electrical operation of the smart susceptor assembly. With regard to thermal performance, the cladding can function as a passive heat exchanger to dissipate thermal energy across the surface of the susceptor. With regard to electrical operation, the cladding can provide a current path after portions of the susceptor heat and become low or non-magnetic.

Abstract: A method and system for heating a material includes an induction coil, a susceptor providing a receptacle, where the receptacle is configured to receive the material, and at least one nozzle for ejecting a heated gas onto and/or into the material. During the method, the susceptor is heated by the induction coil, and thermal energy from the susceptor can be transferred to the material. In addition to being heated by heat from the susceptor, the material is also heated by the heated gas, thereby increasing a heating rate of the material to rapidly heat the material to a processing temperature. The system can include other components such as a gas source, at least one conduit that channels gas from the gas source to the at least one nozzle, and a heat source that heats the gas prior to ejecting the gas from the at least one nozzle.

Abstract: A method for manufacturing a cascade for a thrust reverser for a jet engine includes forming a strip assembly. The strip assembly includes a strong back member which includes a length. The strip assembly includes a plurality of first vane members which extend from a first side of the strong back member in a first direction nonparallel relative to the length of strong back member wherein the plurality of the first vane members are spaced apart from one another along the length of the strong back member.

Abstract: Systems and methods are provided for molding systems that have a low thermal mass. One embodiment is a first tool that includes a first frame. The first frame includes a first set of plates of magnetically permeable material, and a material disposed between plates of the first set. The first tool also includes a first set of induction coils that are disposed within the first frame and that generate a first electromagnetic field, and a first susceptor that extends from the first set of plates. The first susceptor generates heat in response to the first electromagnetic field. The first tool further includes a mold that extends from the first susceptor and receives heat via conductive heat transfer from the first susceptor. Each plate of the first set is thinner than a skin depth at which the first electromagnetic field would generate an electrical induction current.

Abstract: A mold insert assembly includes a base section having a base side removably attachable to a base plate of a mold and a first interface surface having a notched portion thereon. A first section includes a first interface side with a first interconnecting tab sized to engage the notched portion of the base section when the first interface side abuts the first interface surface, the first section further including an adjoining side having an interconnecting notch. A second section includes a second interface side having a second interconnecting tab, where the second interconnecting tab is sized to engage the interconnecting notch of the first section when the second interface side abuts the adjoining side, and where the base section, the first section, and the second section when assembled form a contoured insert configured to create a contoured cavity in a part formed within the mold.

Abstract: Methods of fabricating a component, such as a cascade grid panel for a jet engine thrust reverser, having a plurality of cavities extending through the component, with each cavity having at least one surface with a complex contour, and related devices. A plurality of two or more mold inserts are stacked to form a mold insert stack, with the mold insert stack having a plurality of mold bosses formed by mold boss sets. The mold boss sets are each formed by a mold boss segment from each of the mold inserts. Further, the mold boss segments are affixed to respective baseplates so that the mold boss segments can be handled as a group and remain properly positioned relative to their neighboring mold boss segments.

Abstract: A mold insert assembly includes a base section having a base side removably attachable to a base plate of a mold and a first interface surface having a notched portion thereon. A first section includes a first interface side with a first interconnecting tab sized to engage the notched portion of the base section when the first interface side abuts the first interface surface, the first section further including an adjoining side having an interconnecting notch. A second section includes a second interface side having a second interconnecting tab, where the second interconnecting tab is sized to engage the interconnecting notch of the first section when the second interface side abuts the adjoining side, and where the base section, the first section, and the second section when assembled form a contoured insert configured to create a contoured cavity in a part formed within the mold.

Abstract: A smart susceptor assembly including an electromagnetic flux source such as one or more inductors, a geometrically complex-shaped susceptor having one or more contours, and a cladding on or over the susceptor. The cladding can alter both the thermal performance and the electrical operation of the smart susceptor assembly. With regard to thermal performance, the cladding can function as a passive heat exchanger to dissipate thermal energy across the surface of the susceptor. With regard to electrical operation, the cladding can provide a current path after portions of the susceptor heat and become low or non-magnetic.

Abstract: Methods of fabricating a component, such as a cascade grid panel for a jet engine thrust reverser, having a plurality of cavities extending through the component, with each cavity having at least one surface with a complex contour, and related devices. A plurality of two or more mold inserts are stacked to form a mold insert stack, with the mold insert stack having a plurality of mold bosses formed by mold boss sets. The mold boss sets are each formed by a mold boss segment from each of the mold inserts. Further, the mold boss segments are affixed to respective baseplates so that the mold boss segments can be handled as a group and remain properly positioned relative to their neighboring mold boss segments.

Abstract: Systems and methods are provided for molding systems that have a low thermal mass. One embodiment is a first tool that includes a first frame. The first frame includes a first set of plates of magnetically permeable material, and a material disposed between plates of the first set. The first tool also includes a first set of induction coils that are disposed within the first frame and that generate a first electromagnetic field, and a first susceptor that extends from the first set of plates. The first susceptor generates heat in response to the first electromagnetic field. The first tool further includes a mold that extends from the first susceptor and receives heat via conductive heat transfer from the first susceptor. Each plate of the first set is thinner than a skin depth at which the first electromagnetic field would generate an electrical induction current.

Abstract: A method for manufacturing a cascade for a thrust reverser for a jet engine includes forming a strip assembly. The strip assembly includes a strong back member which includes a length. The strip assembly includes a plurality of first vane members which extend from a first side of the strong back member in a first direction nonparallel relative to the length of strong back member wherein the plurality of the first vane members are spaced apart from one another along the length of the strong back member.