A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Stringer stiffened composite panels having improved pull-off strength are disclosed. An example stringer includes a first surface, a second surface, an edge, and a chamfer. The second surface is located opposite the first surface and is to be coupled to a composite structure of an aircraft. The edge extends from the second surface toward the first surface. The chamfer extends from the first surface to the edge at an angle between twelve and eighteen degrees relative to the first surface.

Assemblies and methods for facilitating the assembly of aircraft wings to a fuselage are disclosed. In some embodiments, a wing unit includes features that are configured to define one of more parts of a pressure vessel that is partially defined by the fuselage portion. In some embodiments, the aircraft assemblies disclosed herein comprise one or more first structural interfaces that permit positional adjustment between the wing unit and the fuselage portion so that one or more second structural interfaces may be finished only after such positional adjustment. In some embodiments, the aircraft assemblies disclosed herein comprise one or more structural interfaces that are disposed outside of the wing unit in order to eliminate or reduce the need for assembly personnel to access the interior of the wing unit to carry out the structural assembly of the wing unit to the fuselage portion.

A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

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 also includes a first overwrap layer covering the top segment, the transition segment, and at least a portion of the base segment. The solid laminate stringer also includes a second overwrap layer overlapping at least a portion of the first overwrap layer covering the base segment.

A seal for sealing an aircraft fuel tank, an aircraft wing rib and stringer sealing assembly, an aircraft wing fuel tank, an aircraft structural wing box, an aircraft wing, and a method of sealing an aperture are disclosed. The seal is for sealing a wing rib to a stringer passing through an aperture in the rib at a variable position in the aperture. The seal includes self-adjustment means to absorb any tolerance when forming the seal, upon the stringer being assembled into the aperture in the rib.

An example aircraft wing includes a skin, a composite shear tie, a stringer base charge overlaying the skin, and a stringer overlaying the stringer base charge. The composite shear tie includes a shear-tie web, a first shear-tie flange extending from a first side of the shear-tie web, a second shear-tie flange extending from a second side of the shear-tie web, and a first shear-tie tab extending from an end of the first side of the shear-tie web. The stringer includes a stringer web, a first stringer flange extending from a first side of the stringer web, and a second stringer flange extending from a second side of the stringer web. The first stringer flange is stitched to and integrated with the stringer base charge and the skin. Further, the first shear-tie flange is stitched to and integrated with the first stringer flange.

A method for manufacturing a wing-box for aircraft comprises: arranging, on a curing surface, a first panel of composite material comprising a skin a plurality of longitudinal stringers, and arranging, on each stringer, a caul plate; arranging, on the first panel, pluralities of support inserts so that each support insert rests on a respective caul plate, and on the skin of the first panel, and arranging, on the first panel, a plurality of ribs of non-polymerized composite material, each rib comprising a plate, a first pair of flanges and a second pair of flanges arranged at opposed ends of the plate, and having openings on an edge of the plate, by placing the respective first pair of flanges on the first panel and the respective plurality of openings on the plurality of support inserts, and having the first panel and the plurality of ribs undergo a curing process in autoclave with vacuum bag.

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.

A plugged stringer on a surface of a part, and a method and assembly for production of the plugged stringer. The plug has opposite first and second axial end faces. The plug also has a radially outer margin defined by a radially outer bottom face, radially outer first and second opposite side faces, and a radially outer top face. The plugged stringer also includes a covering overlaying the radially outer top face and the first and second opposite side faces of the plug and extending away from the plug along an axis to form a stringer having first and second segments delineated by the plug. The radially outer margin of the plug is at least partly covered by an adhesive. The radially outer bottom face is adhered to the surface of the part, and the covering is adhered to the radially outer first and second opposite side faces and the radially outer top face. The first and second segments of the stringer respectively define first and second fluid passages separated by the plug. The first fluid passage is fluidly isolated from the second fluid passage by the plug.