Example mechanical supports or mandrels are described for composite part curing. In one example, a mandrel includes a housing, and components within the housing and positioned to create a central opening. An expander is also positioned in the central opening, and the expander has a width that increases along a length of the expander. A narrow end of the expander is positioned in the central opening. An actuator is provided to move the expander into the central opening causing the components to expand the housing, and to retract the expander from the central opening causing the components to collapse the housing.

A center wing box assembly for an aircraft which includes: a composite lower wing skin, a composite upper wing skin and a composite spar which extends between the composite lower wing skin and the composite upper wing skin. The center wingbox assembly further includes a composite stringer which extends along a web of the composite spar in a wing span direction. The composite spar has a co-cure securement with the composite lower wing skin and with the composite upper wing skin and the composite stringer has a co-cure securement with the web 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.

A composite stringer assembly includes a composite stringer and a radius filler. The composite stringer includes a skin flange, a web, a corner portion extending from the skin flange to the web, an inner surface, and an outer surface. At the corner portion, the outer surface is defined by a first radius of curvature, which is substantially constant between the skin flange and the web. The support structure includes at least one of a skin of a vehicle or a base charge. The radius filler includes a first surface coupled to the inner surface at the corner portion, a second surface configured to couple to the support structure, and a third surface extending between the first surface and the second surface. The first surface of the radius filler is defined by a second radius of curvature, which is substantially constant between the second surface and the third surface.

Aircraft, aircraft wings and associated shear ties are disclosed. An example apparatus includes a first panel coupled to a second panel to define a wing box; a rib disposed chordwise within the wing box; and a stringer disposed spanwise within the wing box immediately adjacent at least one of the first panel or the second panel, the rib including a shear tie including first and second legs extending in opposite directions, the first and second legs to be coupled to at least one of the first panel, the second panel, or the stringer.

An aircraft includes a wing having a first upstream spar and a second downstream spar extending in the direction of the span of said wing, and at least one propulsion unit supported by the wing. The propulsion unit includes a turboprop engine and a propeller. The propeller includes an external annular casing fixed to a suction surface of the wing, and at least to the first upstream spar via at least one first and second fastener.

A vehicle body may have an internal skeleton forming a wing shape, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may curve from a base end near a fore/aft center of the wing shape outward toward leading and trailing edges of the wing shape at a tip end.

In an example, a composite stringer is described. The composite stringer includes a skin flange having a first gage, a top flange having a second gage, and a web having a third gage and extending between the skin flange and the top flange. The skin flange is configured to be coupled to a support structure. The support structure includes at least one of a skin of a vehicle or a base charge. The second gage of the top flange is greater than the first gage of the skin flange and the third gage of the web. The skin flange, the top flange, and the web include a plurality of plies of composite material.

In an example, a composite structure having a variable gage is described. The composite structure includes a first end having a first gage, a second end having a second gage, which is less than the first gage, a plurality of continuous plies, and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. Each drop-off ply extends from the first end to a respective position of the tip of the drop-off ply between the first end and the second end. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern.

A composite stringer assembly includes a composite stringer and a radius filler. The composite stringer includes a skin flange, a web, a corner portion extending from the skin flange to the web, an inner surface, and an outer surface. At the corner portion, the outer surface is defined by a first radius of curvature, which is substantially constant between the skin flange and the web. The support structure includes at least one of a skin of a vehicle or a base charge. The radius filler includes a first surface coupled to the inner surface at the corner portion, a second surface configured to couple to the support structure, and a third surface extending between the first surface and the second surface. The first surface of the radius filler is defined by a second radius of curvature, which is substantially constant between the second surface and the third surface.