Abstract: A system may include a first duct including an air inlet end and an air outlet end, and a valve within the first duct and configured to open to allow or close to prevent fan duct air from the air inlet end to pass through to the air outlet end of the first duct. The system may also include a second duct including a first end and a second end. The first end of the second duct may be coupled to a sidewall of the first duct and configured to allow the fan duct air to flow from the first duct to the second duct. The system may also include a resonance chamber coupled to the second end of the second duct and configured to allow the air in the resonance chamber to act as a spring causing the air in the second duct to oscillate at a predefined frequency.

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: Systems and methods are provided for a thrust reverser system with a straight vane thrust reverser cascade. The thrust reverser system may also include a blocker door and a turning door. The blocker door may divert air flowing within a bypass flow path of the aircraft propulsor to flow through the thrust reverser cascade. The turning door may then deflect air flowing from the thrust reverser cascade to provide reverse thrust. The straight vane thrust reverser cascade may allow for increased reverse thrust and/or a smaller, more efficient, aircraft propulsor.

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: There is provided an inflatable cascade assembly for a cascade thrust reverser system of an engine of an air vehicle. The inflatable cascade assembly has inflatable cascade members for inflation with a pressurized fluid. The inflatable cascade members are movable between a stowed deflated state and a deployed inflated state. Each inflatable cascade member has a forward end, an aft end, and a body. The body has circumferential vanes each having a first non-inflatable rigid side attached adjacent to a second inflatable flexible side. The body further has inflatable support members that are spaced apart and longitudinally extending, and coupled in a perpendicular arrangement to the circumferential vanes. The body further has a plurality of flow openings defined between the circumferential vanes and the inflatable support members. Each inflatable cascade member further has first and second extendable side supports coupled to respective first and second side ends of the body.

Abstract: A cascade assembly for a jet engine thrust reverser comprising an inflow cascade, an outflow cascade, and fasteners. The inflow cascade has a plurality of inflow vanes, a plurality of inflow strongbacks, and a front inflow flange. The outflow cascade has a plurality of outflow vanes, a plurality of outflow strongbacks, and a front outflow flange, wherein each of the plurality of outflow strongbacks are parallel to each other. The fasteners extend through the front inflow flange and the front outflow flange.

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: There is provided an inflatable cascade assembly for a cascade thrust reverser system of an engine of an air vehicle. The inflatable cascade assembly has inflatable cascade members for inflation with a pressurized fluid. The inflatable cascade members are movable between a stowed deflated state and a deployed inflated state. Each inflatable cascade member has a forward end, an aft end, and a body. The body has circumferential vanes each having a first non-inflatable rigid side attached adjacent to a second inflatable flexible side. The body further has inflatable support members that are spaced apart and longitudinally extending, and coupled in a perpendicular arrangement to the circumferential vanes. The body further has a plurality of flow openings defined between the circumferential vanes and the inflatable support members. Each inflatable cascade member further has first and second extendable side supports coupled to respective first and second side ends of the body.

Abstract: Systems and methods are provided for a thrust reverser system with a straight vane thrust reverser cascade. The thrust reverser system may also include a blocker door and a turning door. The blocker door may divert air flowing within a bypass flow path of the aircraft propulsor to flow through the thrust reverser cascade. The turning door may then deflect air flowing from the thrust reverser cascade to provide reverse thrust. The straight vane thrust reverser cascade may allow for increased reverse thrust and/or a smaller, more efficient, aircraft propulsor.

Abstract: Thrust-reverser assemblies that utilize active flow-control and systems and methods including the same are disclosed herein. The thrust-reverser assemblies define a forward-thrust configuration and a reverse-thrust configuration. The thrust-reverser assemblies include a bullnose fairing that defines a portion of a reverser duct and an active flow-control device. The active flow-control device is located to energize a boundary layer fluid flow within a boundary layer that is adjacent to the bullnose fairing to resist separation of the boundary layer from the bullnose fairing when the thrust-reverser assembly is in the reverse-thrust configuration. The methods include flowing a thrust-reverser fluid stream through the reverser duct to generate the boundary layer and energizing a boundary layer fluid flow within the boundary layer with an active flow-control device to resist separation of the boundary layer from the bullnose fairing.

Abstract: Thrust-reverser assemblies that utilize active flow-control and systems and methods including the same are disclosed herein. The thrust-reverser assemblies define a forward-thrust configuration and a reverse-thrust configuration. The thrust-reverser assemblies include a bullnose fairing that defines a portion of a reverser duct and an active flow-control device. The active flow-control device is located to energize a boundary layer fluid flow within a boundary layer that is adjacent to the bullnose fairing to resist separation of the boundary layer from the bullnose fairing when the thrust-reverser assembly is in the reverse-thrust configuration. The methods include flowing a thrust-reverser fluid stream through the reverser duct to generate the boundary layer and energizing a boundary layer fluid flow within the boundary layer with an active flow-control device to resist separation of the boundary layer from the bullnose fairing.