A method for inspecting a bonded structure, the bonded structure having a first structural member, a second structural member, and a bondline between the first structural member and the second structural member, includes projecting acoustic waves into the bonded structure at a non-zero angle relative to a normal axis defined by an external surface of the first structural member. The method further includes determining a magnitude of a total refraction of the acoustic waves after the acoustic waves pass through the bonded structure and comparing the magnitude of the total refraction to a predefined value.

A method for forming a fiber-reinforced thermoplastic control surface includes forming first and second skins from a fiber-reinforced thermoplastic resin. The method further includes overmolding fiber-reinforced thermoplastic features onto the first skin and/or second skin, including stiffener structures, sidewalls, and/or hinges. The method further comprises welding or consolidating the first and second skins together, along with the associated internal features overmolded thereon to form a single-piece, stiffened, fiber-reinforced thermoplastic control surface.

A method of manufacturing a lightweight building element assembly is disclosed. The assembly firstly comprises a first object (1) being a lightweight building element that has a first outer building layer (11) and an interlining layer (13). The assembly further comprises a second object (2) secured to the first object. The method comprises firstly providing the first object, wherein the first object has an indentation (19) formed by the first outer building layer. The indentation may form a blind opening or a through opening in the first object. The method further comprises providing the second object (2), wherein the second object comprises an outer surface portion of a thermoplastic material, wherein the outer surface portion is a lateral outer surface portion with respect to an axis. The second object is brought in contact with the first object so that the lateral outer surface is in physical contact with the sidewall (14), and mechanical energy is coupled into the second object so as to cause energy absorption due to friction between the lateral outer surface and the lateral wall, until a flow portion of the thermoplastic material becomes liquefiable and flows relative to the lateral wall. After re-solidification of the thermoplastic material, the flow portion secures the second object to the first object.

A lightning strike protection material for an aircraft includes an electrically-conductive grid with grid-forming members and nodes where grid-forming members overlap or intersect. A plurality of the grid-forming members and/or nodes include an outward-facing surface, and at least a portion of the outward-facing surface is concave.

Systems and methods for mating component parts are described. In some embodiments, a system for mating components may include a first component, a second component, a first adhesive, and a second adhesive. The first adhesive may be configured to set in less than 5 minutes after the first component and the second component are placed in a mating position, and the second adhesive may require greater than 5 minutes to set. The first adhesive, after setting, may have sufficient strength to maintain the first component and the second component in the mating position while the second adhesive sets.

A landing gear system includes a composite tube. The composite tube comprises at least one of (i) a filament wound composite tube, (ii) a filament braided tube, and (iii) a composite tube of laid up filament. The landing gear system further comprises a first lug cluster mounted to the composite tube and a second lug cluster mounted to the composite tube. The first lug cluster and the second lug cluster are oriented at an angle to one another.

Apparatus for forming microscopic features on a film layer are disclosed. An example apparatus includes a tool having an outer surface defining a first microscopic pattern. The outer surface of the tool to engage a thermoplastic film applied to a surface of a structure. The outer surface is structured to frictionally engage the thermoplastic film and rotate relative to the thermoplastic film with a rotational speed that is sufficient to generate heat via friction between the outer surface and the thermoplastic film to heat the thermoplastic film to malleability to form a second microscopic pattern in the thermoplastic film.

A system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

A method of manufacturing a part having an opening for receiving an insert, including forming the opening having an internal surface wherein the internal surface has a polygonal cross-section including a plurality of sides. The polygonal cross-section comprises a polygon having an area larger than a cross-section of the insert, and the sides constrain the insert so as to locate the insert in the opening when the insert is inserted into the opening.