An airfoil system is provided that includes an airfoil. This airfoil includes a first exterior surface, a second exterior surface, a first airfoil segment and a second airfoil segment. The airfoil extends widthwise between the first exterior surface and the second exterior surface. The first airfoil segment includes first composite material and a receptacle. A base of the receptacle is embedded within the first composite material. The second airfoil segment includes second composite material and a key. A base of the key is embedded within the second composite material. The key is mated with the receptacle thereby attaching the second airfoil segment to the first airfoil segment.

A method for forming a fiber-reinforced thermoplastic control surface may comprise: stacking plies of thermoplastic composite sheets to a first desired thickness to form a first skin; stacking plies of thermoplastic composite sheets to a second desired thickness to form a second skin; forming the first skin in a first contour; forming the second skin in a second contour; forming a stiffening member including a thermoplastic resin, the stiffening member including a shape having a plurality of peaks and troughs; assembling the stiffening member between the first skin and the second skin; and joining the stiffening member to the first skin and the second skin.

The present disclosure relates to a structural component of an aircraft wing body and an aircraft including the structural component. According to an aspect of the present disclosure, a structural component of an aircraft wing body is provided. The structural component includes a body part and a profile. The body part includes an edge portion formed by end portions of a first skin and a second skin of the body part superposed together. The profile is attached to the edge portion. The profile has an outer profile conforming to an outer profile of the body part such that the structural component, as a whole, exhibits an aerodynamic outer profile after the profile is attached to the edge portion. The profile is attached to the edge portion via a plurality of separate intermediate members or by contacting the edge portion.

An airfoil system is provided that includes an airfoil. This airfoil includes a first exterior surface, a second exterior surface, a first airfoil segment and a second airfoil segment. The airfoil extends widthwise between the first exterior surface and the second exterior surface. The first airfoil segment includes first composite material and a receptacle. A base of the receptacle is embedded within the first composite material. The second airfoil segment includes second composite material and a key. A base of the key is embedded within the second composite material. The key is mated with the receptacle thereby attaching the second airfoil segment to the first airfoil segment.

An airfoil system is provided that includes an airfoil. This airfoil includes a first exterior surface, a second exterior surface, a first airfoil segment and a second airfoil segment. The airfoil extends widthwise between the first exterior surface and the second exterior surface. The first airfoil segment includes first composite material and a receptacle. A base of the receptacle is embedded within the first composite material. The second airfoil segment includes second composite material and a key. A base of the key is embedded within the second composite material. The key is mated with the receptacle thereby attaching the second airfoil segment to the first airfoil segment.

A hypersonic aircraft includes one or more leading edge assemblies that are designed to manage thermal loads experienced at the leading edges during high speed or hypersonic operation. The leading edge assembly includes a plurality of structural layers and a plurality compliant layers alternately stacked with each other to facilitate thermal expansion and movement between the plurality of structural layers, while also providing a thermal break between the plurality of structural layers.

A hypersonic aircraft includes one or more leading edge assemblies that are designed to manage thermal loads experienced at the leading edges during high speed or hypersonic operation. The leading edge assembly includes a plurality of structural layers and a plurality compliant layers alternately stacked with each other to facilitate thermal expansion and movement between the plurality of structural layers, while also providing a thermal break between the plurality of structural layers.

A no-back device for resisting feedback torque from an actuator. The no-back device comprises: a flange arranged to receive torque via a shaft; a ratchet assembly comprising a ratchet wheel arranged parallel to the flange; and a braking assembly comprising a resistance wheel, which is sandwiched between the flange and the ratchet wheel, and a braking device, which acts on the resistance wheel to generate a resistive angular force reacting against torque exerted on the resistance wheel. The braking device comprises a follower arranged to roll, under bias from a spring in the braking device, on a cam surface extending around a circumferential perimeter of the resistance wheel. Radial displacement of the follower energizes the spring to generate resistive angular force.

A no-back device for resisting feedback torque from an actuator. The no-back device comprises: a flange arranged to receive torque via a shaft; a ratchet assembly comprising a ratchet wheel arranged parallel to the flange; and a braking assembly comprising a resistance wheel, which is sandwiched between the flange and the ratchet wheel, and a braking device, which acts on the resistance wheel to generate a resistive angular force reacting against torque exerted on the resistance wheel. The braking device comprises a follower arranged to roll, under bias from a spring in the braking device, on a cam surface extending around a circumferential perimeter of the resistance wheel. Radial displacement of the follower energizes the spring to generate resistive angular force.

Aspects of the disclosure are directed to a toolset configured to fabricate a component of an aircraft, the toolset comprising: a mold base configured to seat at least one mandrel, a mold lid configured to be coupled to the mold base, and at least one driver block that is integral with the mold lid and projects from an interior surface of the mold lid.