Described herein are thermoplastic composites and methods of making thereof. The thermoplastic composites disclosed herein can include at least one randomly-oriented carbon fiber layer in the laminate to improve induction heating efficiency of the thermoplastic composite.

Described herein are thermoplastic composites and methods of making thereof. The thermoplastic composites disclosed herein can include at least one randomly-oriented carbon fiber layer in the laminate to improve induction heating efficiency of the thermoplastic composite.

Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.

Systems, methods, and apparatus for using aircraft bondline embedded current sensors to determine a lightning damage index are disclosed. A method of predicting lightning strike damage to at least one type of aircraft involves sensing, with at least one current sensor node embedded in at least one type of aircraft, induced current. The method further involves generating, with at least one current sensor node, at least one current signal representative of the induced current. Also, the method involves determining, electromagnetic density data associated with at least one region of at least one type of aircraft by using at least one current signal. Further, the method involves creating an index that provides a numeric representation for predicted lightning strike damage to at least one type of aircraft based on the electromagnetic density data, dimensions of at least one type of aircraft, and design features of at least one type of aircraft.

Systems, methods, and apparatus for using aircraft bondline embedded current sensors to determine a lightning damage index are disclosed. A method of predicting lightning strike damage to at least one type of aircraft involves sensing, with at least one current sensor node embedded in at least one type of aircraft, induced current. The method further involves generating, with at least one current sensor node, at least one current signal representative of the induced current. Also, the method involves determining, electromagnetic density data associated with at least one region of at least one type of aircraft by using at least one current signal. Further, the method involves creating an index that provides a numeric representation for predicted lightning strike damage to at least one type of aircraft based on the electromagnetic density data, dimensions of at least one type of aircraft, and design features of at least one type of aircraft.

A composite article can comprise a composite body including an organic polymer and ceramic particles comprising hexagonal boron nitride (hBN) particles distributed throughout the organic polymer, wherein an amount of the hBN particles ranges from 40 vol % to 90 vol % based on a total volume of the body; and the body comprises an in plane thermal conductivity of at least 15 W/mK. The hBN particles within the composite body can have a March-Dollase Orientation parameter of at least 50%.

The aerospace component joints comprise a first component member comprising a first bonding face, a second component member comprising a second bonding face, one or more bond-enhancing features, and an adhesive layer forming a bond between the first and second bonding faces. The one or more bond-enhancing features comprises a plurality of reinforcing protrusions integral with the first component member, projecting from the first bonding face through the adhesive layer, and into the component member and/or one or more adhesive-receiving recesses defined in the first or second bonding faces and filled by the adhesive layer. The methods of preparing a component member for an aerospace component joint comprise integrating one or more bond-enhancing features into the component member. The methods of forming the aerospace component joint comprise positioning and adhesive-bonding the first bonding face to the second bonding face, and integrating the bond-enhancing feature(s) into the aerospace component joint.

The aerospace component joints comprise a first component member comprising a first bonding face, a second component member comprising a second bonding face, one or more bond-enhancing features, and an adhesive layer forming a bond between the first and second bonding faces. The one or more bond-enhancing features comprises a plurality of reinforcing protrusions integral with the first component member, projecting from the first bonding face through the adhesive layer, and into the component member and/or one or more adhesive-receiving recesses defined in the first or second bonding faces and filled by the adhesive layer. The methods of preparing a component member for an aerospace component joint comprise integrating one or more bond-enhancing features into the component member. The methods of forming the aerospace component joint comprise positioning and adhesive-bonding the first bonding face to the second bonding face, and integrating the bond-enhancing feature(s) into the aerospace component joint.

A composite article can comprise a composite body including an organic polymer and ceramic particles comprising hexagonal boron nitride (hBN) particles distributed throughout the organic polymer, wherein an amount of the hBN particles ranges from 20 vol % to 40 vol % based on a total volume of the body; and the body comprises an in plane thermal conductivity of at least 10 W/mK. The hBN particles within the composite body can have a March-Dollase Orientation parameter of at least 50%.