A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

A stator vane may comprise an airfoil extending between a first platform and a second platform, a first shear tube may extend through the airfoil and relatively orthogonal to the first platform and the second platform, wherein the first shear tube extends through the first platform and the second platform. In various embodiments, a second shear tube may extend through the airfoil into the first platform and the second platform parallel the first shear tube.

An intentionally activated frangible bonding system comprises a frangible adhesive, adhesive primer, composite material matrix, and/or the like, having a polydispersion of at least one additive spread throughout the frangible bonding material. The additive degrades a bond provided by the frangible bonding material, upon application of a specific energy to the frangible bonding material. An energy emitter is configured to selectively direct the specific energy toward a structure or assembly comprising components bonded by the frangible bonding material to degrade the frangible bonding material bonding the components for disassembly.

An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

A system (100), for manufacturing a rotor blade (112), comprises a first tooling (170), positioned at a factory location (114) and configured to assemble a first blade module (116), comprising a first-module skin (118) and a first-module spar (120), each comprising a first thermoplastic polymer (122) and a first reinforcement material (124). The system (100) comprises a second tooling (172), configured to assemble a second blade module (126), comprising a second-module skin (128) and a second-module spar (130), each comprising a second thermoplastic polymer (132) and a second reinforcement material (134). The system (100) comprises a first support (160), positioned at a field location (140) and configured to receive the first blade module (116), and a second support (162), positioned at the field location (140) and configured to receive the second blade module (126). The system (100) comprises a spar welding assembly (174), positioned at the field location (140) and configured to join the first-module spar (120) with the second-module spar (130), and a skin welding assembly (176), positioned at the field location (140) and configured to join the first-module skin (118) with the second-module skin (128).

A system and method for attaching a damper to a tail rotor blade includes a cuff that is integral with the rotor blade. The cuff has upper and lower lugs formed by extending a skin over a blade core of the rotor blade. The skin extends past the blade core to the root end of the rotor blade. The rod end of the damper is inserted into an opening between the lugs. The rod end of the damper is coupled to the blade with a bolt through aligned holes in the lugs. The cuff also couples the rotor blade to the grip inside the cuff. The cuff includes a same material as that forming the skin. Sacrificial buffer pads are applied to interior faces of the lugs. The buffer pads permit a distance between the lugs to be machined within a tolerance without removing skin from the cuff.

The invention relates to a vane (7) comprising: a structure made of composite material, a vane (7) root (16) attachment (9) comprising a base having a radial outer face (20) and in which a slot (24) configured to receive the vane (7) root (16) is formed and two platforms (26), extending on either side of the blade (18) opposite the radial outer face (20), and two stiffening parts (30), added and fixed on the radial outer face (20) on either side of the stilt (17) so as to tightly abut against the stilt (17).

An airfoil member can have a root end, a tip end, a leading edge, and a trailing edge. The airfoil member can include an upper skin, a lower skin, and a composite core member having a plurality of cells, an upper surface network of the cells can be bonded to the upper skin, a lower surface network of the cells can be bonded to the lower skin. The composite core can have a septum layer embedded in the cells that form the composite core, the septum layer being configured to provide tailored characteristics of the airfoil member.

A method for disposing blocking material within an interior of a component for blocking a beam of radiation from a laser during a laser drilling operation, the method including forming one of a multiple of apertures formed via a first process and forming the remainder of the multiple of apertures formed via a laser drilling process. A component for a gas turbine engine includes a surface with at least one of a multiple of apertures formed via a first process, the at least one of the multiple of apertures formed via the first process in communication with a cavity, a remainder of the multiple of apertures formed via a laser drilling process, the remainder of the multiple of apertures in communication with the cavity.

One aspect of a process of forming an aircraft component includes bonding a first end of a honeycomb structure to a surface of an aircraft skin member, the honeycomb structure including multiple connected cells. Foam is sprayed on a second end of the honeycomb structure opposite the first end. The process also includes curing the foam on the second end of the honeycomb structure.