Abstract: A laminate air seal for a gas turbine engine includes at least one fabric layer made of fiberglass, ceramic fiber, basalt and/or carbon, and a polymeric resin that is stable at an operating temperature of the gas turbine engine. The resin may be preimpregnated into the fabric layers, or introduced into the fabric during assembly and formation of the laminate. The resin may be polyimide, bismaelimide (BMI) or cyanate ester. A particular resin selected may depend, in part, on the operating temperatures in that region of the gas turbine engine. In some embodiments, the laminate seal may include a coating to increase lubricity of the seal. In one embodiment, the laminate air seal is used to seal a gap between a pylon fairing and an exhaust nozzle of the turbine engine.

Abstract: A method of repairing a part, which has a first side, a second side opposite of the first side, and an aperture that makes the part susceptible to cracking, includes the steps of forming a slot in the first side of the part near the aperture, inserting a stiffener into the slot, and attaching at least one repair ply onto the first side of the part to cover the stiffener.

Abstract: A method and system of repairing an engine part having a cracked metal skin bonded to a honeycomb core includes removing a portion of the honeycomb that corresponds to a cracked portion of the metal skin. A crack in the metal skin originates from an edge of the engine part. A portion of the honeycomb is removed to form a slot in the honeycomb beginning at the edge of the part. A doubler is inserted into the slot in the honeycomb and is attached to an underside of the metal skin to form a lap joint between the doubler and the metal skin. In one embodiment, the portion of the metal skin that includes the crack remains. In an alternative embodiment, the cracked portion of the metal skin is removed and a metal patch is attached to the doubler such that the patch replaces the removed metal skin.

Abstract: A doubler assembly repairs at least one damaged aperture of a composite flange. The doubler assembly includes an insert, an adhesive, and a support. The insert is positioned in the damaged aperture to provide compressive load transfer through the composite flange. The adhesive is positioned directly on at least a portion of the composite flange proximate the damaged aperture. The support is positioned over the adhesive.

Abstract: A method and system for repairing an insulation blanket having a metallized fabric that becomes disbanded from an underlying layer of the insulation blanket. The method includes cutting a first slit in the metallized fabric near a disbanded portion of the fabric, inserting a repair material through the first slit such that the repair material is between the disbanded portion of the fabric and the underlying layer, and adhering the disbonded fabric and the underlying layer to the repair material to restore the functionality of the metallized fabric.

Abstract: A method and system for repairing a damaged hole includes a deformable rod and a fabric wrapped around a middle portion of the rod. A first portion of the rod is inserted into the damaged hole. The rod is stretched to align the middle portion of the rod and the fabric with an inside circumference of the hole. The rod is then relaxed to compress the fabric against the inside circumference of the hole.

Abstract: An assembly includes a composite flange, an insert, an adhesive and a support. The composite flange has at least one damaged aperture. The insert is positioned in the damaged aperture and extends therefrom to provide compressive load transfer through the composite flange. The adhesive is positioned directly on at least a portion of the composite flange proximate the damaged aperture. The support is positioned over the adhesive and contacts the insert.

Abstract: A method and system of repairing an engine part having a cracked metal skin bonded to a honeycomb core includes removing a portion of the honeycomb that corresponds to a cracked portion of the metal skin. A crack in the metal skin originates from an edge of the engine part. A portion of the honeycomb is removed to form a slot in the honeycomb beginning at the edge of the part. A doubler is inserted into the slot in the honeycomb and is attached to an underside of the metal skin to form a lap joint between the doubler and the metal skin. In one embodiment, the portion of the metal skin that includes the crack remains. In an alternative embodiment, the cracked portion of the metal skin is removed and a metal patch is attached to the doubler such that the patch replaces the removed metal skin.

Abstract: A method and system is described herein for using a polyimide adhesive to bond a first metal layer to a second metal layer used in a gas turbine engine. The polyimide adhesive may be a film or a paste and is able to withstand operating temperatures in excess of 600 degrees Fahrenheit (315 degrees Celsius). In an exemplary embodiment, the second metal layer is an outer face skin of an exhaust nozzle and the first metal layer is a metal doubler configured to cover a damaged portion of the outer face skin. In some embodiments, the first and second metal layers may be formed of titanium.

Abstract: A laminate air seal for a gas turbine engine includes at least one fabric layer made of fiberglass, ceramic fiber, basalt and/or carbon, and a polymeric resin that is stable at an operating temperature of the gas turbine engine. The resin may be preimpregnated into the fabric layers, or introduced into the fabric during assembly and formation of the laminate. The resin may be polyimide, bismaelimide (BMI) or cyanate ester. A particular resin selected may depend, in part, on the operating temperatures in that region of the gas turbine engine. In some embodiments, the laminate seal may include a coating to increase lubricity of the seal. In one embodiment, the laminate air seal is used to seal a gap between a pylon fairing and an exhaust nozzle of the turbine engine.

Abstract: A method and system is described herein for repairing a part used in a gas turbine engine, which has a damaged or worn lubricant layer bonded to a surface of the part. After removing the damaged or worn lubricant layer, a polymeric adhesive may be used to attach a replacement lubricant layer to the metal surface. The polymeric adhesive may be a film or a paste. In some embodiments, the adhesive includes a non-metallic filler. The polymeric adhesive is stable at an operating temperature of the part to which it is attached. In one embodiment, the adhesive is polyimide, which is well-suited for use in a high pressure compressor of the gas turbine engine that operates at high temperatures. In other embodiments, the adhesive is bismaleimide (BMI) or cyanate ester.

Abstract: A method of repairing a part, which has a first side, a second side opposite of the first side, and an aperture that makes the part susceptible to cracking, includes the steps of forming a slot in the first side of the part near the aperture, inserting a stiffener into the slot, and attaching at least one repair ply onto the first side of the part to cover the stiffener.

Abstract: A method of restoring a section of a composite having a honeycomb bonded to a perforated skin includes the steps of separating a first honeycomb from the perforated skin to expose a portion of the perforated skin, inserting pins through perforations in the perforated skin, extending the pins through a repair material, attaching the repair material to the exposed portion of the perforated skin, and attaching a second honeycomb to the repair material. The method may include removing material from the exposed portion of the perforated skin, prior to inserting pins through the perforations, to create a more even bonding surface for attaching the repair material.

Abstract: A method and system for repairing an insulation blanket having a metallized fabric that becomes disbanded from an underlying layer of the insulation blanket. The method includes cutting a first slit in the metallized fabric near a disbanded portion of the fabric, inserting a repair material through the first slit such that the repair material is between the disbanded portion of the fabric and the underlying layer, and adhering the disbonded fabric and the underlying layer to the repair material to restore the functionality of the metallized fabric.