Abstract: A method and apparatus for fabricating a composite structure. The method comprises defining a shape for the composite structure with a first face sheet. The method places core sections on the shape defined by the first face sheet. The method places an adhesive in a group of joint cavities. The method places a second face sheet on the core sections placed on the first face sheet, wherein the first face sheet, the core sections, and the second face sheet, define a structural assembly in which the group of joint cavities are present. The method cures the structural assembly with the adhesive in the group of joint cavities to fabricate the composite structure in which the adhesive fills the group of joint cavities when the adhesive is cured.

Abstract: Provided are sandwich panel assemblies. Specifically, a sandwich fuselage panel comprises an outer skin member and an inner skin member coupled to the outer skin member at a first edge and a second edge, forming a cavity comprising a center portion, a first transition portion extending from the center portion to the first edge, and a second transition portion extending from the center portion to the second edge. A cured foam adhesive may occupy each of the first transition portion and the second transition portion of the cavity. A core structure, such as a honeycomb structure may occupy the center portion of the cavity. Alternatively, the cured foam adhesive may occupy the center portion of the cavity. The density of the cured foam adhesive in the transition portions may gradually increase from the center portion to the respective edge. The cured foam adhesive may comprise a polymer foam adhesive.

Abstract: The present invention discloses a tellurium-doped MXene composite material and a preparation method thereof, comprising the following steps: (1) adding MXene and a tellurium source into a dispersant to prepare a dispersion, and then stirring the dispersion; (2) heating the dispersion, reacting, and then cooling; (3) centrifuging the product obtained in the step (2), then washing and drying under vacuum; and (4) placing the dry product obtained in the step (3) into a corundum ark, and then transferring into a tubular furnace, heating under the protection of inert gas, retaining the temperature, and then cooling to obtain the tellurium-doped MXene composite material. The composite material prepared by the present invention can be used as a cathode of a potassium ion battery, which increases the interlamellar spacing, and optimizes an ion diffusion channel, so that the electrochemical performance of the potassium ion battery is improved.

Abstract: Apparatus for forming microscopic features on a film layer are disclosed. An example apparatus includes a tool having an outer surface defining a first microscopic pattern. The outer surface of the tool to engage a thermoplastic film applied to a surface of a structure. The outer surface is structured to frictionally engage the thermoplastic film and rotate relative to the thermoplastic film with a rotational speed that is sufficient to generate heat via friction between the outer surface and the thermoplastic film to heat the thermoplastic film to malleability to form a second microscopic pattern in the thermoplastic film.

Abstract: Systems and methods are provided for fabrication of short-fiber composites. One embodiment is a method for forming a short-fiber composite. The method includes forming a bed of randomly oriented dry fibers on a base, drawing resin into the bed in response to pressure to form a mixture of randomly oriented fibers impregnated with thermoset resin, perturbing the mixture while preserving fiber length at the mixture and degassing the mixture, and extruding the mixture to form a preform.

Abstract: A method and apparatus for fabricating a composite structure. The method comprises defining a shape for the composite structure with a first face sheet. The method places core sections on the shape defined by the first face sheet. The method places an adhesive in a group of joint cavities. The method places a second face sheet on the core sections placed on the first face sheet, wherein the first face sheet, the core sections, and the second face sheet, define a structural assembly in which the group of joint cavities are present. The method cures the structural assembly with the adhesive in the group of joint cavities to fabricate the composite structure in which the adhesive fills the group of joint cavities when the adhesive is cured.

Abstract: The present disclosure relates to systems and methods relating to the application of composite radius filler materials. An example material feed system includes a material container configured to contain a composite material and a material feed actuator. The material feed system also includes a nozzle coupled to the material container and a workpiece sensor configured to provide information about a workpiece. The material feed system also includes a controller. The controller is configured to receive, from the workpiece sensor, workpiece information. The workpiece information is indicative of at least one surface of the workpiece. The controller is also configured to, based on the workpiece information, cause the material feed actuator to apply a force to the composite material contained in the material container so as to extrude at least a portion of the composite material out of the nozzle and onto a surface of the workpiece.

Abstract: Tunable multi-layer thermoplastic polymer sealants and tunable two-layer conductive thermoplastic polymer sealants, and substrates and assemblies comprising the tunable multi-layer sealants; and edge seals and fillet seals produced comprising such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.

Abstract: A composite radius filler material is provided. The composite radius filler includes a resin, a first group of fibers dispersed within the resin, and a second group of fibers dispersed within the resin. The first group of fibers has a first length configured to facilitate orientation in a longitudinal direction. The second group of fibers has a second length that is shorter than the first length, with the second group of fibers configured to facilitate random orientation in a transverse direction.

Abstract: Methods and apparatus for forming microscopic features on a film layer are disclosed. An example method includes using a surface of a tool to contact a thermoplastic film coupled to an outer surface of a structure. The surface of the tool defines a first microscopic pattern. The example method also includes heating the thermoplastic film by moving the surface of the tool on the thermoplastic film to create friction between the tool and the thermoplastic film and urging the heated thermoplastic film into the first microscopic pattern of the surface of the tool to form a second microscopic pattern in the thermoplastic film.

Abstract: A nozzle for extruding a composite material from an extruder barrel. The nozzle includes a body and a tapered nozzle passage extending through the body. The tapered nozzle passage having a nozzle inlet opening configured to interface with the extruder barrel, and a nozzle outlet opening, where the tapered nozzle passage has a contoured nozzle passage surface extending between the extruder barrel and the nozzle outlet opening with smooth transitions, free of angles, so that each nozzle passage surface portion, having a corresponding contour, transitions smoothly to each other nozzle passage surface portion, having a respective different contour, from the nozzle inlet opening to the nozzle outlet opening, and the nozzle outlet opening is defined by at least a first edge and a second edge that intersect each other at an acute angle.

Abstract: The present invention discloses a tellurium-doped MXene composite material and a preparation method thereof, comprising the following steps: (1) adding MXene and a tellurium source into a dispersant to prepare a dispersion, and then stirring the dispersion; (2) heating the dispersion, reacting, and then cooling; (3) centrifuging the product obtained in the step (2), then washing and drying under vacuum; and (4) placing the dry product obtained in the step (3) into a corundum ark, and then transferring into a tubular furnace, heating under the protection of inert gas, retaining the temperature, and then cooling to obtain the tellurium-doped MXene composite material. The composite material prepared by the present invention can be used as a cathode of a potassium ion battery, which increases the interlamellar spacing, and optimizes an ion diffusion channel, so that the electrochemical performance of the potassium ion battery is improved.

Abstract: The present invention discloses a selenium-doped MXene composite nano-material and a preparation method thereof, comprising the following steps: (1) adding MXene and an organic selenium source into a dispersant, and stirring to prepare a dispersion with a concentration of 1 mg/ml to 100 mg/ml; (2) transferring the dispersion into a reaction kettle, then heating, reacting, and then naturally cooling to a room temperature; (3) washing the product obtained in the step (2) with a cleaning agent, then centrifuging to collect a precipitate, and drying the precipitate under vacuum; and (4) placing the sample obtained in the step (3) into a tubular furnace for calcination, introducing protective gas, heating, and then cooling to a room temperature to obtain the selenium-doped MXene composite nano-material. The material prepared by the present invention has high specific surface area, good electrical conductivity, cycle stability performance, rate performance and high theoretical specific capacity.

Abstract: The present invention discloses a selenium-doped MXene material and a preparation method thereof, comprising the following steps: (1) adding MXene and an organic selenium source into a dispersant, and stirring to prepare a dispersion with a concentration of 10 mg/ml to 100 mg/ml, wherein a mass ratio of MXene and an organic selenium source is 0.1 to 1:1; (2) transferring the dispersion into a reaction kettle, heating to 110° C. to 230° C., reacting for 10 h to 30 h, and then naturally cooling to a room temperature; and (3) washing the product obtained in the step (2) with a cleaning agent, centrifuging to collect a precipitate, and drying the precipitate under vacuum to obtain the selenium-doped MXene material. The composite material prepared by the present invention has high specific surface area, good electrical conductivity, cycle stability performance, rate performance and high theoretical specific capacity.

Abstract: The present disclosure provides a heating system for performing thermal spray coating. The heating system includes (a) a thermal spray element configured to be coupled to a robotic arm, (b) a heating unit configured to be coupled to the robotic arm, (c) at least one processor, and (d) data storage comprising program instructions executable by the at least one processor to cause the heating system to perform functions including (i) receiving a first indication of a spray coating material positioned in the thermal spray element, (ii) receiving a second indication of a material of a substrate onto which the spray coating material is to be sprayed, (iii) heating the substrate for a time period until the substrate reaches a desired temperature that is determined based on both the spray coating material and the material of the substrate, and (iv) spraying the spray coating material onto the substrate.

Abstract: Methods, systems, and apparatuses are disclosed for making co-cured coated composite material comprising composite material prepreg stacks and a coating material, with the coating material comprising an outer layer of thermoplastic film, with the coating material co-cured with the composite material, with the co-cured coating material providing a compressive force on the co-cured coated composite material, components comprising the co-cured coated composite material, and larger structures comprising the co-cured coated composite materials.

Abstract: A system and method for preparing a fluid flow surface may include the steps of: (1) producing a laser beam, (2) moving the laser beam across a surface of a work piece, and (3) machining a riblet in the surface by removing material from the surface, wherein the riblet includes a pair of ridges, wherein the pair of ridges is approximately parallel to each other, and each one of the ridges includes opposed sides, and a groove formed between facing ones of the sides and separating the ridges.

Abstract: Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer are presently disclosed, along with tunable coatings made from the disclosed formulations, and methods for delivering such tunable thermoplastic polymer coatings to substrates.

Abstract: Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer, along with tunable coatings made from the disclosed formulations and methods for coating installed fasteners, and fasteners, fastener/substrate interfaces and substrates coated with the tunable thermoplastic polymer coatings.

Abstract: Tunable thermoplastic polymer sealants and tunable conductive thermoplastic polymer sealants, and edge seals and fillet seals produced from such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.