Abstract: A composite assembly for an aircraft, the composite assembly including a first carbon fiber material structured for a portion of an outer skin surface of an aircraft, a second carbon fiber material stitched to the first carbon fiber material, wherein the second carbon fiber material is structured for a structural component of the aircraft, and wherein the stitching is configured to bind the first carbon fiber material and the second carbon fiber material, and wherein the aircraft further includes a single deck, wherein a cargo compartment and a passenger compartment are located on or above the single deck.

Abstract: A lightning damage assessment method for the carbon fiber reinforced polymer (CFRP) material considering non-linear impedance characteristic includes steps of: studying various influencing factors of the lightning damage of the CFRP material under the action of the single lightning current component; obtaining the law between the lightning damage of the CFRP material, including the lightning damage area and depth, and various influencing factors, including the peak value, the rising rate, the charge transfer amount, the specific energy of the single lightning current component, and the non-linear impedance characteristic of the CFRP; on the basis of the law, building the multi-factor assessment model of the lightning damage of CFRP material under the action of the single lightning current component; and obtaining mathematical expressions between the lightning damage of the CFRP material and the influencing factors.

Abstract: Aspects described herein generally relate to a sol-gel that is the reaction product of an organosilane, a metal alkoxide, an acid, and a thio-lanthanide salt having a solubility of about 1 gram or greater per gram of sol-gel at 23° C. The thio-lanthanide salt includes a cation and a thio-ligand. The cation can be lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, scandium, yttrium, cobalt, calcium, strontium, barium, and zirconium. In another aspect, a component, such as a vehicle component, includes a metal substrate and a sol-gel disposed on the metal substrate. Methods can include forming a sol-gel by mixing a metal alkoxide and an acid to form a first mixture; mixing with the first mixture an organosilane to form a second mixture; and mixing with the second mixture a lanthanide salt to form a third mixture.

Abstract: Composite assemblies are described that include composite spars that are co-cured with one or more sacrificial members on their flanges, forming an integrated sacrificial surface for the composite spars. In one embodiment, the composite assembly includes a composite spar having a web and flanges that project from sides of the web. The composite assembly further includes a sacrificial member of composite materials co-cured with the composite spar on an outer surface of at least one of the flanges. In addition, the sacrificial member has an outer surface that has been machined into conformance with an inner surface of at least one skin panel for an aircraft structure to form a contact surface with the at least one skin panel.

Abstract: An additively manufactured mandrel is disclosed, including a plurality of separable segments arranged to form a main body having a first end and a second end, each separable segment connected to adjacent segments. A first plug connected to the first end, and a second plug connected to the second end of the main body are configured to support the main body during a composite curing process.

Abstract: A heater mat for heating an airfoil having a chord, a leading edge, and a trailing edge includes a first zone element configured to heat a first chord-wise segment of the airfoil. The system further includes a second zone element configured to heat a second chord-wise segment of the airfoil that is adjacent to the first chord-wise segment of the airfoil. The system further includes a first zone busbar located at the leading edge of the heater mat and electrically coupled to the first zone element.

Abstract: In an example, a composite stringer is described. The composite stringer includes a composite stringer and a base flange. The composite stringer includes a top flange, a first skin flange and a second skin flange configured to be coupled to a support structure, a first web extending between the first skin flange and a first side of the top flange, and a second web extending between the second skin flange and a second side of the top flange. The support structure includes at least one of a skin of a vehicle or a base charge. The base flange includes a bottom surface extending between the first skin flange and the second skin flange. The bottom surface of the base flange is configured to be coupled to the support structure. The base flange also includes a top surface extending between the first web and the second web.

Abstract: A pressure bulkhead for an aircraft fuselage including a sandwich structure defining a central axis and extending between a circumferential border area, the sandwich structure including an inner face sheet and an outer face sheet extending transverse to the central axis, and a core assembly sandwiched between the inner face sheet and the outer face sheet. The pressure bulkhead can receive pressure loads and can be used as a structural bearing element for receiving loads introduced by other structural parts. The inner face sheet and/or the outer face sheet has a corrugated shape. The distance between the outer face sheet and the inner face sheet increases and subsequently decreases from the border area to a central area about the central axis, forming a thickened area where the distance between the outer face sheet and the inner face sheet has a peak.

Abstract: A heated composite structure and a method for forming a heated composite structure. The structure includes carbon fibers embedded within a thermoplastic matrix. The carbon fibers are connected with first and second electrodes that are configured to be connected with an electric source such that applying current to the electrodes causes current to flow through the embedded carbon fibers to provide resistive heating sufficient to heat the composite structure to impede formation of ice on the composite structure.

Abstract: A stringer for having a runout with a raised area configured to reduces stress while improving drainage across the runout when utilized in a close structural component of a vehicle such as an aileron of an aircraft. In one or more configurations, the raised area of the runout of the stringer includes multiple tapered surfaces adjacent to one another oriented and configured as ramps to collectively guide water up, over and down the raised area of the stringer.

Abstract: A method of manufacturing a sheet metal flame includes a step of forming at least one drawn portion in a frame main body formed into a flat plate shape, and a step of engraving groove portions into a linear shape in the frame main body at constant distances from outer edge portions of the at least one drawn portion so as to sandwich the at least one drawn portion between at least opposing sides.

Abstract: A method of impregnating a fiber preform with an impregnation composition, includes applying a liquid on a structure, the structure including a chamber in which a fiber preform for impregnating is present, the chamber being defined between a rigid support on which the fiber preform is placed and a wall, the wall having a face situated facing the fiber preform; and an impregnation composition for impregnating the fiber preform, the impregnation composition being present in the chamber; the liquid being applied against the wall on its side opposite from the chamber, the wall being configured so that its face situated facing the fiber preform conserves its shape during the application of the liquid, the applied liquid enabling sufficient pressure to be created to move the wall towards the rigid support and impregnate the fiber preform with the impregnation composition.

Abstract: A method of making a rub strip includes resin transfer molding an arcuate composite structure. The resin transfer molding step includes inserting a honeycomb core into a mold cavity having an arcuate base so that the honeycomb core assumes an arcuate shape. The resin transfer molding step further includes directing liquid resin into the mold cavity to form the composite structure comprising the liquid resin and the honeycomb core, and curing the liquid resin for a sufficient period of time. The resin transfer molding step further includes removing the composite structure from the mold. The method further includes repeating the resin transfer molding step until a sufficient number of arcuate composite structures are produced. The method further includes coupling a plurality of the arcuate composite structures together to form the rub strip.

Abstract: Aspects of the disclosure relate to fabricating balloon envelopes for high-altitude balloons. One or more segments of reinforcing tape are applied to gore segments of the balloon envelope. The segments are arranged in a ring to circumscribe an upper portion of the balloon envelope, and may be affixed by a pressure sensitive adhesive. Should a catastrophic failure of the balloon envelope occur, the reinforcing tape acts as a ripstop to prevent a tear from extending upward toward the apex of the balloon envelope. Tendons secured to the apex and to a base of the balloon envelope are configured to keep the top film of the envelope in a parachute configuration in the event of a catastrophic failure. The reinforcing tape is positioned above an equator of the balloon envelope, for instance approximately ? of the distance down from the apex to the base of the envelope.

Abstract: A rear fuselage section of an aircraft comprises at least one closed frame constructed as a unitary body, and a horizontal tail plane comprising a box-type central element and two lateral torsion boxes, said horizontal tail plane trimmable with respect to a pivot axis. The horizontal tail plane is mounted at the closed frame and the pivot axis is contained in a horizontal plane below the lowest end of said closed frame.

Abstract: Metal sheets and plates having friction-reducing textured surfaces and methods of manufacturing these metal sheets and plates are disclosed herein. In an embodiment, there is provided a transportation vessel that includes at least one metal product having at least one surface that is substantially grooved, wherein the substantially grooved surface forms a riblet topography, the riblet topography including a multiplicity of adjacent permanently rolled longitudinal riblets running along at least a part of the surface, and wherein the riblet topography is coated with at least one coating sufficiently designed and applied to preserve the riblet topography. In an embodiment, the multiplicity of adjacent permanently rolled longitudinal riblets results in a friction-reducing textured surface. In an embodiment, metal product is used in fabricating at least a portion of an aircraft. In an embodiment, metal product is used in fabricating at least a portion of a rotor blade.

Abstract: A method and apparatus comprising a sol-gel solution. Zirconium n-propoxide is aged in a solvent to form a first part for the sol-gel solution. The first part is combined with deionized water to form a second part for the sol-gel solution. Aminoaryltrialkoxysilane is combined with an alcohol to form a third part for the sol-gel solution. The third part is combined with the second part to form a mixture for the sol-gel solution. The deionized water, or the alcohol, or a combination thereof is combined with the mixture to form a solution. The solution is aged to form the sol-gel solution comprising a mole balance ratio of approximately 1:5 between the zirconium n-propoxide and the aminoaryltrialkoxysilane.

Abstract: The present application relates a core member for a core-stiffened structural assembly. The core member includes a plurality of cell members oriented a direction to provide a tailored stiffness in a certain direction. The core member can further include one or more planar members that can aid in shear transfer between cell members. The cell members can be made from bonding a plurality of corrugated layers together. The core-stiffened structure can be a rotor blade for an aircraft. In such an embodiment, the torsional stiffness of the rotor blade can be tailored in at least one of the chordwise and spanwise directions to provide tailor a torsional stiffness at any give location in the rotor blade.

Abstract: A morphing skin for an air vehicle structure, the skin being formed by a composite material which includes: a multiplicity of fibres, a matrix incorporating the fibres, and a thermo-sensitive material, such as a thermo-plastic. The thermo-sensitive material can be reversibly transitionable in response to a change in temperature, between (i) an ambient temperature mode in which the thermo-sensitive material is capable of transferring loads in the composite material, and (ii) a heated mode in which the ability of the thermo-sensitive material to transfer the loads is reduced. This can allow the stiffness of the skin to be temporarily reduced to enable the skin to be morphed into a different shape.

Abstract: A system and method that allow inspection of hollow structures made of composite material, such as an integrally stiffened wing box of an aircraft. A wing box comprises top and bottom skins connected by a plurality of spaced spars. The system employs a plurality of scanners for inspecting different portions of each spar. The system uses dynamically controlled magnetic coupling to connect an external drive tractor to computer-controlled scanners that carry respective sensors, e.g., linear ultrasonic transducer arrays. A system operator can control the various components by means of a graphical user interface comprising multiple interaction regions that represent the individual scanner motion paths and are associated with respective motion script files.

Abstract: The shape of a laminated composite structure is optimized using finite element analysis. The optimized shape minimizes the weight of the structure while satisfying minimum strength and stiffness requirements.

Abstract: A sealing member for forming a seal in an aircraft, the sealing member comprising: a sealing material; and a stiffening element which provides structural support to the sealing material and comprises a material with a glass transition temperature below +50° C. The stiffening element is relatively flexible when the aircraft is at low altitude (high temperature) but becomes relatively stiff (increasing resistance to seal flutter) when the aircraft is at cruise altitude (low temperature).

Abstract: A fiber-reinforced, organic matrix, composite structural member includes a plurality of layers of fiber-reinforced, organic matrix, composite material in which adjacent layers are bonded to one another, wherein the structural member exhibits a non-linear stress-strain response when mechanically loaded to failure. A helicopter landing gear includes a pair of skids and one or more cross members extending between the pair of skids. The one or more cross members includes a plurality of layers of fiber-reinforced, organic matrix, composite material in which adjacent layers are bonded to one another, wherein the cross members exhibit non-linear stress-strain responses when mechanically loaded to failure.

Abstract: A component for building a fuselage section of an aircraft includes a border area connectable to a corresponding further border area of a further component so as to form an electrically conductive joint, wherein the component includes a composite structure.

Abstract: Disclosed in this application is a novel method and apparatus for reducing electrical resistance of a carbon-reinforced plastic structure to thereby reduce damage due to lightning strikes or precipitation static. This apparatus includes a galvanically compatible conductive interface layer positioned between a nonconductive substrate and a conductive outer surface. The interface layer is electrically conductive to transmit electrical current from the outer surface to the substrate.

Abstract: The disclosed embodiments concern an aircraft fuselage section made of composite material with an internal skeleton having frames that form the radial structure of the fuselage and stringers that form the longitudinal structure of said fuselage, and a skin made of composite material, surrounding the internal skeleton, with said skin having an evolving thickness along a longitudinal axis X, with an approximately constant, regular interior profile. The disclosed embodiments also concern a process for manufacturing the skin of an aircraft fuselage section made of composite material, having a draping operation for strips of fibers precoated with resin around a mold, with the number of strips of fibers varying longitudinally depending on the area of the fuselage being considered so as to create a skin with an evolving thickness.

Abstract: A composite structure has a first section, a second section, and a curved corner joining the first and second sections. The structure has a stack of fiber-reinforced plies including first and second external plies which run from the first section into the second section on an inside and an outside of the corner, respectively. A discontinuous first internal ply is sandwiched between the first and second external plies so that more of the first internal ply is located within the first section than within the second section. A second internal ply is sandwiched between the first and second external plies. The fibers of the first internal ply run at an angle ? to the fibers of the second internal ply. In some embodiments the angle ? is greater than 3° but less than 20°. In one embodiment the angle ? is between 35° and 42°.

Abstract: A structural component includes a fiber composite material structure having an outer surface and an electrically conductive metal profile disposed on the outer surface of the fiber composite material structure. The metal profile provides provide improved electrical conductivity of the structural component and component protection.

Abstract: Techniques and apparatus for providing a fly away caul plate are disclosed. In an embodiment, a method for curing a composite structure includes placing a pre-cured caul plate proximate an uncured composite lay-up, the lay-up may or may not include one or more stiffeners extending substantially perpendicular to the lay-up surface, the caul plate including an aperture for receiving the at least one stiffener. A force may be exerted against the caul plate to engage the composite lay-up. Heat and/or pressure may be applied to the composite lay-up to cure the stiffener panel and co-bond the caul plate to the composite lay-up.

Abstract: In an embodiment of the disclosure, there is provided an apparatus to provide a panel stiffening element. The apparatus has an outer braided thermoplastic tube and an inner braided thermoplastic tube disposed within the outer braided thermoplastic tube. The apparatus further has a separation ply layer co-consolidated between the outer braided thermoplastic tube and the inner braided thermoplastic tube. The separation ply layer provides reinforcement and impact damage resistance to the inner braided thermoplastic tube in order to avoid a loss in structural loading capability.

Abstract: A composite structure has first and second sections, and a curved corner joining the first and second sections. The structure includes a stack of fiber-reinforced plies. First and second external plies run from the first section into the second section round an inside and an outside of the corner, respectively. First and second internal plies are sandwiched between the first and second external plies, and run from the first section into the second section round the corner. The first internal fly is dropped off inside the second section. The second internal ply is dropped off inside the first section. The structure has an increased thickness where the first and second internal plies overlap.

Abstract: A passive non-ablating thermally protective structure body is disclosed. An improved-reliability heat pipe edge comprises a non-porous material formed into a wedge-shaped chamber, and a porous layer. The porous layer extends from interior surfaces of the non-porous material to provide capillary wicking.

Abstract: A lightning strike protection material may include a fiber reinforced composite aircraft component including carbon fibers in a resin matrix. The carbon fibers may have a length greater than at least about 6 mm and include carbon nanotubes grown on the fibers, and the nanotubes may be substantially uniformly distributed on the fibers and have a length between about 1 and 100 microns. The nanotubes may decrease a surface resistance of the resin matrix.

Abstract: A patch for reworking an inconsistent area in a composite structure includes a composite laminate patch adapted to cover the inconsistent area and bonded to the structure by a layer of adhesive. The patch includes a plurality of composite plies having a tapered cross section, and at least first and second regions respectively having differing fracture toughnesses.

Abstract: In accordance with the method, an inside layer of a fuselage section skin made from first fibers is placed on a manufacturing surface, the first fibers being placed in one or more first fiber directions. On the inside layer, a stiffening structure is formed from stiffening fibers, the stiffening fibers being placed in one or more stiffening fiber directions. An outside layer of the fuselage section skin, comprising fourth fibers, is placed on the stiffening structure formed from stiffening fibers, the fourth fibers being placed in one or more fourth fiber directions. The stiffening structure is designed and developed in such a way that the fuselage section does not require an additional stiffening structure, is connected with the fuselage section skin, and comprises the inside layer, the stiffening structure, and the outside layer; in particular, an additional stiffening structure in the form of stringers and frames is not required.

Abstract: A composite laminate, method of forming same, and use for same are disclosed. One example of a composite laminate has multiple layers or plies (305A-305E) composed of generally parallel reinforcing fibers (315A-315E) embedded in a matrix (305M). The reinforcing fibers have orientations in the ranges of 3 to 8 degrees, ?3 to ?8 degrees, 10 to 40 degrees, ?10 to ?40 degrees, and approximately 90 degrees, the orientations being with respect to a predetermined axis (320), such as an axis of tension (T). A method of manufacturing a composite laminate includes laying a resin and fibers having these orientations and then curing the resulting laminate. One example of a use is for the skin on the fuselage or wing of an aircraft.

Abstract: A reduced solar aborptivity appliqué having a surface layer for adhering to an surface and high aspect ratio microstructures extending from the surface layer having pigmentation or spectral tailoring.

Abstract: An aerospace vehicle includes a plurality of composite stiffeners. Each stiffener of the plurality has a stack of plies of reinforcing fibers. At least some of the plies in the stack have reinforcing fibers oriented at ±? with respect to an axis of primary loading, where ? is between 2 and 12 degrees. At least some of the plies in the stack have reinforcing fibers oriented at ±? with respect to the axis of primary loading, where ? is between 50 and 85 degrees.

Abstract: Heat exchange systems, devices and methods are provided. A particular heat exchange device includes a housing defining an inlet and an outlet. The heat exchange device also includes at least one ceramic foam member inside the housing. The at least one ceramic foam member defines a plurality of pores. The heat exchange device also includes a plurality of extended plugs that extend from a first side of the housing through the at least one ceramic foam member to a second side of the housing. The first side of the housing is spaced apart from the at least one ceramic foam member by first ends of the plurality of extended plugs.

Abstract: An aircraft floor system includes a composite panel which generally includes an inboard layer, an inboard interlock layer, a core layer, an outboard interlock layer and an outboard layer. The advanced sandwich core material may include K-Cor™ or X-Cor™ which is pinned through at least one ply of dry composite reinforcement to provide a mechanical lock between the pins and an inboard and outboard interlock layer. Bonding of the locked-in ply with the inboard and outboard results in improved structural performance and damage tolerance.

Abstract: An apparatus having a composite air-based structure with a first carbon nanotube infused material and a second carbon nanotube infused material. The first and second carbon nanotube infused materials each having a range of carbon nanotube loading selected to provide different functionalities.

Abstract: An aircraft fuselage structure which is constructed from a plurality of shells which are joined together is disclosed. Each shell forms part of the aircraft fuselage and comprises a support structure and a skin which is arranged on the latter and outwardly seals the aircraft fuselage in a compression-proof manner. The aircraft fuselage structure comprises an upper and side shell and a lower shell, of which the lower shell has a radius which is essentially significantly larger than the radius of the upper and side shell. The upper and side shell and the lower shell are joined together at transition regions extending in the longitudinal direction of the aircraft. The support structure of the lower shell is designed in terms of its strength in such a manner that it is capable of absorbing the internal pressure loading of the lower shell without the use of a main crossmember.

Abstract: Low weight and non-square carpet tile suitable for use in mass transit vehicles, particularly passenger aircraft. The carpet tile preferably weighs less than about 82 ounces per square yard. The carpet tile of this invention may have a carpet pile and at least one backing layer. The backing layer may use a low weight filler material. The carpet tiles satisfy transportation industry standards for flame, smoke and toxicity. Tiles may be sized during manufacture and installed in configurations that minimize the number of tile sizes needed and minimize the need for cutting tiles during installation. The patterns used for such tiles may be orthogonally ambiguous or otherwise suitable for “random” installation. In other embodiments, a passenger aircraft cabin includes a floor having rectangular carpet tiles installed thereon, and the carpeting can be installed in the aircraft without removing seats from the aircraft.

Abstract: A coating composition and a method for coating metallic substrates, such as aircraft components exposed to elevated temperatures and/or oxidative conditions. The coating composition includes an aqueous mixture having about 2 vol % to about 50 vol % organosilane, about 0.3 to about 25 vol % metal alkoxide, and about 0.1 to about 30 vol % organic complexing agent. The coating composition may be deposited on a metallic substrate and cured to form a sol-gel coating on the surface of the substrate that is adherent to the substrate, and oxidation and discoloration resistant.

Abstract: Optimization of structures subjected to hot gas streams. The invention refers to a fairing (10) for aircraft horizontal stabilizer (3) comprising a front part (11) and a rear part (12), the front part (11) covering a limited extent of the fairing (10) surface, which is the part of the fairing (10) receiving hot air stream (6) coming from the aircraft engines (4), this front part (11) being made of an anti-erosion material, the rear part (12) covering the rest of the surface of the fairing (10), this rear part (12) being made of a material resisting the aerodynamic loads existing on the fairing (10). The invention also refers to an aircraft comprising a horizontal stabilizer (3) with a fairing (10) such as the one described.

Abstract: A patch for reworking an inconsistent area in a composite structure includes a composite laminate patch adapted to cover the inconsistent area and bonded to the structure by a layer of adhesive. The patch includes a plurality of composite plies having a tapered cross section, and at least first and second regions respectively having differing fracture toughnesses.

Abstract: A composite material, the composite material comprising a prepreg, said prepreg comprising at least one polymeric resin and at least one conductive fibrous reinforcement, electrically conducting particles dispersed in the polymeric resin and a top layer of a metal-coated carbon fiber comprising a further resin component, wherein the metal comprises one or more metals selected from nickel, copper, gold, platinum, palladium, indium and silver.

Abstract: Structural panels for use in manufacturing aircraft fuselages and other structures are disclosed herein. In one embodiment, a structural panel configured in accordance with the invention includes a skin and at least first and second stiffeners. The first stiffener can have a first flange portion mated to the skin and a first raised portion projecting away from the skin. The second stiffener can have a second flange portion mated to the skin and a second raised portion projecting away from the skin. At least one of the first flange portion of the first stiffener and the second flange portion of the second stiffener can extend toward the other of the first flange portion and the second flange portion to form an at least approximately continuous support surface to which a frame can be attached.

Abstract: The invention relates to an aircraft side fairing, with a component (9) in the form of individual hollow chambers (12, 13, 14) which are arranged essentially in a preferably curved plane and are arranged between two cover layers (1, 2), wherein a gastight film which completely encases the component (9) with the hollow chambers (12, 13, 14) is provided and, after application of a vacuum to evacuate the hollow chambers (12, 13, 14), surrounds the component (9) with the hollow chambers in a gastight manner.

Abstract: The present invention relates to a method for actively deforming, by feedback control, an aerodynamic profile comprising an elastic material, applied to a part of the surface of the aerodynamic profile, said elastic material being in contact with a fluid flow; said elastic material being able to be deformed by one or more shape memory actuators placed in contact with the elastic material, said actuators being controlled by a computer connected to sensors. This method applies notably to a deformation of an aerofoil of a wing of an aircraft in flight, notably subsonic.