A solid laminate stringer includes a base segment that forms a first generally trapezoidal cross section. The solid laminate stringer also includes a transition segment abutting the base segment, with concave sides that are continuous with the sides of the base segment. The solid laminate stringer also includes a top segment abutting the transition segment, where the top segment forms a second generally trapezoidal cross section with sides that are continuous with the concave sides of the transition segment. The solid laminate stringer may also include a first overwrap layer covering the top segment, the transition segment, and at least a portion of the base segment. The solid laminate stringer may also include a second overwrap layer overlapping at least a portion of the first overwrap layer covering the base segment.

An example aircraft wing includes a first skin, a second skin opposite to the first skin, and a composite spar. The composite spar includes a double-flanged spar cap, a single-flanged spar cap, a spar web connecting the double-flanged spar cap and the single-flanged spar cap, and a tear strap. The double-flanged spar cap includes an inward-facing flange and a first outward-facing flange, and the inward-facing flange and the first outward-facing flange are integrated with the first skin during a co-curing process. The single-flanged spar cap includes a second outward-facing flange that is attached to the second skin. The tear strap is stitched to an inner side of the spar web along at least a portion of a length of the composite spar.

Apparatus and methods for ultrasonic inspection of elongated composite members in a single scan pass using pulse echo phased arrays operating in a bubbler method. The system concept is fully automated by integrating an inspection NDI probe assembly to a robot and using the robot to move the inspection NDI probe assembly along the part (i.e., outside of an inspection tank); and by integrating tooling fixtures that move out of the way as the inspection NDI probe assembly travels along the length of the part during the inspection. In addition, the system allows for generally elongated composite members having lengthwise variation in shape, curvature and dimensions.

Examples include an apparatus configured for attaching a rib of an aircraft wing to a panel of the aircraft wing, the apparatus including: an insert that is configured to be attached, via an interference fit, to a hole in the rib; a shear tie including a socket at a first end of the shear tie, where the shear tie is configured to be attached to the panel at a second end of the shear tie; a ball stud including a shaft and a ball that is opposite the shaft, where the shaft is configured to be attached to the insert and the ball is configured to be positioned within the socket; and a fastener that is configured to secure the ball within the socket, thereby attaching the ball stud to the shear tie.

Examples for low impact hat stringer fluid dams are presented herein. An aircraft structure may include a wing with a vent stringer coupled to the wing. The vent stringer may include a center portion positioned between a first section and a second section. The center portion of the vent stringer includes a slot. A vent dam may be coupled within the vent stringer proximate the slot in the center portion. The vent dam can include a sealant coupled between an integrated pair of baffles such that a combination of the sealant and the integrated pair of baffles prevents fluid communication between the first section and the second section of the vent stringer.

A method of joining an interior wall and a composite channel together is disclosed. The method includes wrapping one or more first composite plies around a first end portion of a first mandrel and wrapping one or more second composite plies around a second end portion of a second mandrel. The method includes positioning the one or more first composite plies located on the first end portion of the first mandrel against the one or more second composite plies located on the second end portion of the second mandrel to create the interior wall, and inserting the first mandrel and the second mandrel into a passageway of a composite channel. The interior wall created by the one or more first composite plies and the one or more second composite plies creates a barrier to block a flow of fluid within the passageway of the composite channel.

A method and apparatus for forming a radius filler. A lattice is formed of connecting elongate members having a three-dimensional shape of the radius filler. A resin is placed within the lattice.

A method for manufacturing a structure by curing together a base laminate and structural components placed thereon. Particularly, the uncured structural component has a peripheral tapered foot edge so that the vacuum bag placed thereon follows all the uncured plies without an abrupt leap from the structural component foot to the base laminate.

A composite assembly includes a composite skin which includes a plurality of composite plies and a composite stringer secured to the composite skin. A first composite plank ply is positioned between a first pair of composite plies of the plurality of composite plies of the composite skin; the first composite plank ply has a width dimension less than a width dimension of the plurality of composite plies of the composite skin; and the first composite plank ply extends along a length of the composite stringer. At least a portion of the composite stringer is positioned in overlying relationship with the first composite plank ply.

There is provided a laminated composite structure having improved impact damage resistance and improved strength. The laminated composite structure has a plurality of stacked layers of a composite material. The plurality of stacked layers have one or more interlaminar corrugations formed within the plurality of stacked layers. Each interlaminar corrugation has a substantially sinusoidal shaped profile, and has a depth and a length dependent on a size of the laminated composite structure formed. The laminated composite structure with the one or more interlaminar corrugations has improved strength and improved impact damage resistance at an exposed edge of the laminated composite structure, when the exposed edge is subjected to an impact force.