Abstract: A smart energized tape configured to avoid problems with foreign object damage (FOD) includes: one or more of microdots and radio frequency identification (RFID) nanochips, the one or more of microdots and nanochips configured to facilitate one or more of FOD tracking, cost control, location tracking, and asset tracking. A smart, predominantly red energized tape configured to avoid problems with FOD includes: one or more of microdots and RFID nanochips, the one or more of microdots and nanochips configured to facilitate one or more of FOD tracking, cost control, location tracking, and asset tracking, wherein the smart energized tape is one or more of fluorescent and translucent, wherein the smart energized tape is one or more of internally lit, electrically lit, and chemically detectable.

Abstract: The improved installation tool for installing grommets in a hole in a panel having a countersink end includes an anvil having a convex surface for contacting the head of the grommet after the grommet is installed in the hole. A flaring die having a tapered tubular portion for inserting into the grommet is mounted on the open end there in and chamfered surface for deforming the end of the grommet so that it is deformed into the countersink. This is accomplished by a threaded rod that extends through a hole in the anvil, grommet and threadably engages internal threads in the die. Withdrawing of the rod causes the die to be moved against the grommet and flares the end of the grommet into the countersink and locks it in place.

Abstract: Methods of forming shaped adhesive fillets are disclosed. The adhesive fillets may be made by stacking multiple layers of adhesive sheets, consolidating the stacked layers, cutting strips from the consolidated layers, and forming the strips into adhesive fillets having desired cross sectional shapes. The fillets may be formed by feeding the strips through an apparatus comprising opposing rollers and a catcher, which facilitates release of the adhesive fillets from the rollers. The formed adhesive fillets are useful for applications such as stiffened panels for aircraft.

Abstract: The invention is a non contact laser inspection self centering device to inspect the counter sink portion of a counter sunk fastener hole on a surface. In detail, the self centering and seating device includes a combination laser transmitter and receiver for transmitting a laser bean across a surface and for receiving the return signal from the surface. A self centering device is attached to the combination laser transmitter and receiver for aligning the laser transmitter with the fastener hole such that the transmitted and received laser beam passes across the center of the counter sink portion of the fastener hole. A computer system is connected to the combination laser transmitter and receiver for analyzing the transmitted and returned laser signal from the surface and determining if the counter sink portion of the hole is within tolerance.

Abstract: Methods of forming shaped adhesive fillets are disclosed. The adhesive fillets may be made by stacking multiple layers of adhesive sheets, consolidating the stacked layers, cutting strips from the consolidated layers, and forming the strips into adhesive fillets having desired cross sectional shapes. The fillets may be formed by feeding the strips through an apparatus comprising opposing rollers and a catcher, which facilitates release of the adhesive fillets from the rollers. The formed adhesive fillets are useful for applications such as stiffened panels for aircraft.

Abstract: The invention is a non contact laser inspection self centering device to inspect the counter sink portion of a counter sunk fastener hole on a surface. In detail, the self centering and seating device includes a combination laser transmitter and receiver for transmitting a laser bean across a surface and for receiving the return signal from the surface. A self centering device is attached to the combination laser transmitter and receiver for aligning the laser transmitter with the fastener hole such that the transmitted and received laser beam passes across the center of the counter sink portion of the fastener hole. A computer system is connected to the combination laser transmitter and receiver for analyzing the transmitted and returned laser signal from the surface and determining if the counter sink portion of the hole is within tolerance.

Abstract: The invention is a process for repairing a coating having a precise thickness damaged in a specific area. In detail, the process includes the steps of: 1) removing the damaged coating from the specific area; 2) placing a scrim material having a thickness equal to the required thickness of the coating in the specific; and 3) filling the specific area with coating material to the thickness of the scrim material.

Abstract: A coating applicator assembly is disclosed for coating fasteners ends protruding from a surface of a structure, the fasteners extending a specific distance above the surface. In detail, the applicator assembly includes a handle. A coating member made from open celled compressible foam having a coating transfer surface in a generally W shape is attached to the handle. Preferably, the central V of the W shaped surface has an included angle of between 40 and 50 degrees and a depth of between 65 and 85 percent of the specific distance and the outer surfaces of the W shaped surface extending outward at an angle of between 40 and 50 degrees and the depth of coating member is at least 4 times the depth of the central notch.

Abstract: The invention is an apparatus for de-bulking a composite material preform laid up in a mold. In detail, the apparatus includes a flexible cover adapted to fit over the mold and preform and attach to the sides of the mold. The cover includes an inlet port located in the cover such that when the cover is fit over the mold and preform, the inlet port positioned over the preform. A stretchable cord seals the peripheral portions of the cover to the sides of the mold forming a chamber over the preform. A hot air pump is coupled to the inlet port of the cover for pumping hot air into the chamber.

Abstract: There is provided a variable pressure roller system for installing a preform having contact surfaces onto a configuration of a mold surface by applying pressure thereon. The roller system of the present invention comprises a roller carriage. A grasping handle may be mounted to the roller carriage. Moreover, the roller system may further comprise a plurality of rollers, wherein each respective one of the plurality of rollers is defined by a weight to generate a specific pressure corresponding thereto. Furthermore, each respective one of the plurality of rollers may be removably engageable to the roller carriage. Each respective one of the plurality of rollers may be adapted to uniformly distribute the specific pressure corresponding thereto on the contact surfaces for conforming the preform to the configuration of the mold surface when engaged to the roller carriage.

Abstract: A coating applicator assembly is disclosed for coating fasteners ends protruding from a surface of a structure, the fasteners extending a specific distance above the surface. In detail, the applicator assembly includes a handle. A coating member made from open celled compressible foam having a coating transfer surface in a generally W shape is attached to the handle. Preferably, the central V of the W shaped surface has an included angle of between 40 and 50 degrees and a depth of between 65 and 85 percent of the specific distance and the outer surfaces of the W shaped surface extending outward at an angle of between 40 and 50 degrees and the depth of coating member is at least 4 times the depth of the central notch.

Abstract: Methods of forming shaped adhesive fillets are disclosed. The adhesive fillets may be made by stacking multiple layers of adhesive sheets, consolidating the stacked layers, cutting strips from the consolidated layers, and forming the strips into adhesive fillets having desired cross sectional shapes. The fillets may be formed by feeding the strips through an apparatus comprising opposing rollers and a catcher, which facilitates release of the adhesive fillets from the rollers. The formed adhesive fillets are useful for applications such as stiffened panels for aircraft.

Abstract: The invention is a coating applicator assembly for coating a structure. In detail the invention is a spring-loaded a syringe having an outlet port. A semi-flexible tube having first and second ends is coupled by its first end to the outlet port of the syringe. A coating applicator for applying the coating material to the structure in the form of brush or contoured foam.

Abstract: A method of forming a resin composite part utilizing a mold surface for mitigating post-cure machining of the resin composite part. The method provides for forming a resin preform having a peripheral geometry similarly sized and configured as a configuration of the mold surface. The mold surface is sized and configured to receive the resin preform. The resin preform is then cured to form the resin composite part with the resin composite part being confirmed to the configuration of the mold surface for mitigating post-cure machining of the resin composite part.

Abstract: Variability between composite structures can be reduced by utilizing forming and curing tooling that includes a cure tool and a preform tool. The cure tool has a curing surface. The curing surface defines the shape of a cured composite structure. The preform tool has a preform surface that is divided into at least first and second surface area portions. The first surface area portion is of the same surface shape to the corresponding surface area of the curing surface on the cure tool. The second surface portion is of a surface shape that is different from the surface shape of the corresponding surface area of the curing surface on the cure tool. The differences between the second surface area portion of the preform surface and its complementary surface on the curing surface is such that there is an increase in the surface area of the second surface area portion of the preform surface compared to a corresponding area on the curing surface of the cure tool.

Abstract: Multilayer prepregs containing an engineering thermoplastic film laminated to a cyanate-functional thermosetting resin-impregnated fiber reinforcement are capable of preparing structural composites with extreme damage tolerance.