An airframe assembly for an aircraft. The airframe assembly includes a first airframe member having a first skin, a second skin, a large cell core joined between the first and second skins and a solid insert having a side surface. The solid insert is joined between the first and second skins such that at least a portion of the side surface is adjacent to the large cell core. The first skin has a first surface disposed opposite the solid insert. The airframe assembly also includes a second airframe member having a second surface. An adhesive joint is disposed between the first and second surfaces structurally bonding the first airframe member to the second airframe member such that the second airframe member is positioned opposite the solid insert.

A core stiffened panel includes first and second skins having a large cell core and a solid insert joined therebetween. The solid insert has a side surface at least a portion of which is adjacent to the large cell core and may be joined to the large cell core. The first skin, the second skin and the solid insert may be formed from composite materials such as carbon composite materials and preferably have generally matching coefficients of thermal expansion.

An airframe assembly for an aircraft includes a first airframe member having first and second skins with a large cell core and a solid insert joined therebetween. The solid insert has a side surface at least a portion of which is adjacent to the large cell core. The first airframe member has a first set of openings extending through the first skin, the solid insert and the second skin. The airframe assembly also includes a second airframe member having a second set of openings operable to be aligned with the first set of openings of the first airframe member. Each of a plurality of fasteners extends through one of the openings of the first set of openings and one of the openings of the second set of openings securably coupling the first airframe member to the second airframe member.

A fan track liner for a fan containment arrangement for a gas turbine includes a cellular impact structure and a supporting sub-laminate integrally formed with each other from fibre-reinforced material. The fan track liner further includes a ballistic barrier comprising a woven reinforcing fibre ply and a layer of reinforcing fibre felt. There is also disclosed an associated fan containment arrangement and a method of manufacturing a fan track liner.

Methods and systems are provided for fabricating a composite structure. In one example, the composite structure may include a honeycomb core sandwiched between face sheets. An edge of the honeycomb core may be abraded and a top face sheet may be perforated. As such, a likelihood of delamination of the composite structure during a curing step may be reduced.

A method for manufacturing a sound attenuating panel uses an alveolar-core structure including a first edge and a second edge separated by alveolar cells, the alveolar cells including walls extending from the first and second edges and defining a primary conduit for the circulation of a sound wave that is to be attenuated. The method includes covering the first edge or the second edge of the alveolar-core structure with a compartmentation wall; deforming the compartmentation wall to define at least one secondary conduit for the circulation of a sound wave that is to be attenuated, the secondary conduit extending at least partially within said primary conduit; and creating an opening in the compartmentation wall to permit communication between the primary and secondary conduits.

The disclosure describes composite liners (such as acoustic panels, fan track liners, and/or ice impact panels or boxes for turbofan engines) and techniques for forming composite liners. In some examples, the composite liner includes at least one region comprising a reinforcement architecture comprising a matrix material, a plurality of relatively tough polymer-based reinforcement elements, and a plurality of second reinforcement elements. The plurality of relatively tough polymer-based reinforcement elements and the plurality of second reinforcement elements are embedded in the matrix material.

A hierarchical sandwich core and a method of making it where a macroscopic honeycomb with a first macroscopic cell with first sandwich cell walls is connected to neighbouring macroscopic cells with neighbouring sandwich cell walls. The first and neighbouring sandwich cell walls are made of a sandwich material having a width, a mesoscopic core, and a first skin layer on a first major surface and a second skin layer on a second major surface of the sandwich material, both skin layers being attached to the mesoscopic core forming each sandwich cell wall of the macroscopic honeycomb. The first and the neighbouring cell walls have a height determined by the width of the sandwich material, both skin layers of the first sandwich cell wall being connected to both skin layers of at least one neighbouring cell wall along the height of the first cell wall.

A stiffened part formed from at least two members of thermoset composite material including at least one body of a first structure and optionally a second structure. A manufacturing method includes: forming a fibre preform and impregnating each body of the first structure with thermosetting resin or forming a pre-impregnated fibre preform to obtain a body formed from uncured thermosetting composite material supported by a mandrel; optionally partially or fully polymerising at least one body supported by a mandrel; optionally, providing the second structure formed from uncured, partially uncured or fully uncured thermosetting composite material; optionally, depositing a layer of uncured thermosetting adhesive on an area where a fully cured member makes contact with another member of the part; joining the members, each member being juxtaposed with; or stacked upon, at least one other member; fully curing the assembly by heat treatment; removing the mandrel from each fully cured body.

Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.