A system for preparing a bladder for use in manufacturing a composite stringer includes a sock application station, a film application station, and a composite ply application station. The sock application station has a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly. The film application station is located downstream of the sock application station and is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly. The composite ply application station is located downstream of the film application station and has a wrap ply forming bed containing at least one forming bed opening and configured to receive one or more wrap plies of a wrap laminate for urging into the forming bed opening by the film-sock-bladder assembly to produce a ply-film-sock-bladder assembly.

A shear tie connector system for securing a frame component to a composite fuselage skin, which includes a shear tie connector and a fuselage mandrel, which defines a slot within which the shear tie connector is positioned.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

Construction of a sealed connection between an elastomeric or synthetic polymer flexible pipe or hose and a metallic coupling member. The coupling member surrounds an armor layer at a free end of the flexible pipe or hose. A sealing area is defined by a recessed portion of the pipe coupling into which a sealing material is introduced. An inner liner layer of the flexible pipe or hose may extend into the sealing area where it is bonded to the sealing material. The sealing material and the inner liner layer may each be comprised of a semi-crystalline thermoplastic material. Furthermore, a reinforcement material may be provided in the inner liner layer.

In a manufacturing method of an assembly, the assembly including a metal part and a pipe, the pipe including a material containing a resin, an adhesive is first adhered to an outer circumferential surface of the pipe and a metal part covering at least a portion of an outer circumferential surface of the pipe. Here, an area to which the adhesive is adhered on the outer circumferential surface of the pipe is defined as an adhesion area. Next, by a heat source provided inside the pipe, a target area is heated without interposing the metal part. The target area is located radially interior to the adhesion area and located on an inner circumferential surface of the pipe.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

A segmented rotor blade for a wind turbine includes a first rotor blade segment, a second rotor blade segment, at least one thermoplastic material, and an internal pressure source. The first rotor blade segment includes a first joint end. The second rotor blade segment includes a second joint end. The first and second joint ends are arranged together in an end-to-end orientation so as to form at least one scarf joint. The at least one thermoplastic material is arranged at each of the first and second joint ends. The first and second joint ends of the first and second rotor blade segments are bonded together via thermoplastic welding of the at least one thermoplastic material. The internal pressure source provides pressure to the scarf joint during the thermoplastic welding. The internal pressure source remains within the rotor blade after thermoplastic welding is complete.

Embodiments are directed to systems and methods for manufacturing composite assemblies comprising laying up composite plies on molds for two or more uncured components, joining the molds for the two or more uncured components to form a tubular body, and curing the joined components simultaneously to create a single composite assembly. The single composite assembly may form a spar for an aerodynamic component. The method may further comprise forming at least one axial edge having a sloped shape on the uncured components and mating the sloped axial edges together when joining the uncured components. The molds for the two or more uncured components may comprise female tools or both female tools and male tools. The two or more cured composite assemblies may comprise one or more of carbon and fiberglass composite materials.

A shear tie connector system for securing a frame component to a composite fuselage skin, which includes a shear tie connector and a fuselage mandrel, which defines a slot within which the shear tie connector is positioned.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.