A method for repairing a part made of composite material includes producing a recessed section by removing the composite material at a damaged area, producing grooves extending on the two faces of the part from edges of the recessed section, producing orifices in the part opening out into the grooves, tree-dimensional weaving of a filling part fiber preforms including a central section having a shape corresponding to the shape of the recessed section and fiber bundles extending from the central section, placing the filling preforms respectively on either face of the part with the fiber bundles in the grooves on the faces of the part and in the orifices such that the fiber bundles open out into the grooves present on the opposite face of the part, impregnating the filling fiber preforms with a precursor resin of a matrix, transforming the resin into a matrix to obtain a filling part.

A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness. The shim may be applied between the part surfaces. The parts may be fitted and assembled together.

Methods and systems for characterizing holes in a combustor liner of a gas turbine engine, and associated repair methods are provided. One method comprises receiving first measured data of the combustor liner in an uncoated state. The method includes determining a first location and a first orientation of a first hole and a first location and a first orientation of a second hole in the combustor liner using the first measured data. The method includes receiving second measured data of the combustor liner in a coated state where the second hole is at least partially obstructed by a coating and the first hole is substantially unobstructed by the coating. The method includes inferring a second location of the second hole of the combustor liner in the coated state using a known spacing between the first location of the first hole and the first location of the second hole. The characterization of the holes may be used to re-drill the obstructed second hole.

Matching pieces for broken structures, kits comprising matching pieces for broken structures, methods for generating 3-D models for matching pieces, methods for fabricating matching pieces, systems for generating 3-D models for matching pieces, and systems for fabricating matching pieces are disclosed.

Matching pieces for broken structures, kits comprising matching pieces for broken structures, methods for generating 3-D models for matching pieces, methods for fabricating matching pieces, systems for generating 3-D models for matching pieces, and systems for fabricating matching pieces are disclosed.

A method of repairing a composite beam having a longitudinal direction including: removing material from a damaged area of the composite beam to form a cut out region; machining a plurality of elongate slots into the composite beam, the elongate slots each having a length in the longitudinal direction of the composite beam and spanning across the damaged area, the elongate slots extending into the composite beam to a depth greater than a depth of the cut out region; introducing a plurality of reinforcing inserts into the respective elongate slots and fixing the reinforcing inserts into the slots with adhesive.

A method of repairing a composite beam having a longitudinal direction including: removing material from a damaged area of the composite beam to form a cut out region; machining a plurality of elongate slots into the composite beam, the elongate slots each having a length in the longitudinal direction of the composite beam and spanning across the damaged area, the elongate slots extending into the composite beam to a depth greater than a depth of the cut out region; introducing a plurality of reinforcing inserts into the respective elongate slots and fixing the reinforcing inserts into the slots with adhesive.

A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.

A hot stapler includes a body, two heat conducting units, an electrical storage unit, a circuit unit, and a switch button. The body includes a head and a handle. The electrical storage unit is disposed in the handle and has a voltage value less than 6 volts. A first wire and a first resistor of the circuit unit are electrically mounted between one of the two heat conducting units and the electrical storage unit. A second wire and a second resistor of the circuit unit are electrically mounted between the other one of the two heat conducting units and the electrical storage unit. The switch button is disposed on the handle and is switchable between a power-on position and a power-off position.

A method of repairing a tip of an airfoil can comprise: removing a coating from the tip of the airfoil; preparing a repair area for bonding, the repair area including the tip and a portion of a concave side of the airfoil; applying an epoxy film and an abrasive component to the repair area; and bonding the epoxy film and the abrasive component to the repair area.