An assembly to repair a thermoplastic composite. The assembly includes a heating device positioned on opposing sides of the thermoplastic composite. The heating device includes one or more susceptor with a Curie temperature to heat the thermoplastic composite. A pressure device applies a compressive force to the heating device. A pressure distribution device is positioned between the heating device and the thermoplastic composite. The pressure distribution device distributes the compressive force from the pressure device over areas of the opposing sides of thermoplastic composite.

A manufacturing method is for repairing a damaged three-dimensional (3D) article having a fracture zone which is a site of a broken-off portion of the 3D article. The method includes using a forming tool to form an attachment feature into material at the fracture zone, imaging the 3D article including the fracture zone to provide image data, defining a repair portion 3D body based upon a comparison between the image data and data defining an intact 3D body, printing the repair portion 3D body including a complementary attachment features, and attaching the repair portion to the damaged 3D article through the interengagement of the complementary attachment feature and the attachment feature.

Methods for repairing composite component voids are provided. For example, one method comprises locating a void in a composite component and subjecting the composite component to a process for repair. The process for repair includes creating a flow path through the void, applying a filler material to the composite component at the flow path, and processing the composite component having the filler material. In some embodiments, the flow path has a first opening on a first side of the composite component and a second opening on a second, opposite side of the composite component. In other embodiments, at least one portion of the flow path extends at a first angle with respect to a lateral direction defined by the CMC component, and at least another portion extends at a second angle with respect to the lateral direction.

An acoustic panel (200) for an aircraft nacelle (100) may comprise a perforated first skin (220), a second skin (230), and a core (210) sandwiched between them. A camera system (330) may scan a perforation pattern of a damaged portion (311) of the perforated first skin (220). The damaged portion (311) of the perforated first skin (220) may be removed. A replacement patch (660) may be formed. A CNC machine (450) may drill the replacement patch (660) according to the perforation pattern. The perforations (425) in the replacement patch (660) may be aligned with perforations (325) in the perforated first skin.

An annular bushing includes an annular cylindrical portion with a flange that defines a fastener aperture along an axis. A multiple of spacers extend from an outer surface of the annular cylindrical portion and the flange. The multiple of spacers are operable to control a bond line thickness.

A method of repairing a mat including: cutting an irregular section of the mat to an approximately perpendicular edge; applying a sealant to the perpendicular edge; conjoining a secondary piece to the perpendicular edge; clamping the secondary piece to the perpendicular edge temporarily; and fixing the secondary piece to the perpendicular edge; where the mat being configured to support the weight of people, vehicles and equipment thereupon and undergo movement relative to one or more other mats without disengaging from another, and the mats include at least four sides and an edge extending along each side, the first and second sides of each mat having a lower lip extending horizontally outwardly below the edge thereof and the third and fourth sides of each mat having an upper lip forming the edge thereof, the respective upper and lower lips of different mats being interconnectable with pins.

A method for repairing a target member including a ceramic matrix composite reinforced by ceramic fiber includes: a removal step of removing at least a part of a surface of the target member; an arrangement step of arranging a green body for repair which includes the ceramic fiber on a portion where the surface is removed in the removal step; an impregnation step of impregnating at least the portion of the target member where the green body for repair is disposed with slurry; and a sintering step of sintering the target member on which the green body for repair is disposed, after the impregnation step.

A method of repairing a mat including: cutting an irregular section of the mat to an approximately perpendicular edge; applying a sealant to the perpendicular edge; conjoining a secondary piece to the perpendicular edge; clamping the secondary piece to the perpendicular edge temporarily; and fixing the secondary piece to the perpendicular edge; where the mat being configured to support the weight of people, vehicles and equipment thereupon and undergo movement relative to one or more other mats without disengaging from another, and the mats include at least four sides and an edge extending along each side, the first and second sides of each mat having a lower lip extending horizontally outwardly below the edge thereof and the third and fourth sides of each mat having an upper lip forming the edge thereof, the respective upper and lower lips of different mats being interconnectable with pins.

A method for repairing a composite structure using pre-cured plugs. In accordance with one method, composite material is removed from a first composite laminate to form a cavity bounded by a tapered internal surface that extends from an opening at an outer mold line surface of the first composite laminate. In addition, a second composite laminate is machined to form a plug having a tapered surface. Then the plug is placed so that the tapered surface of the plug opposes the tapered internal surface of the first composite laminate. Thereafter, the tapered surface of the plug is bonded to the tapered internal surface of the first composite laminate. Optionally, a hole is drilled in the plug for receiving a fastener.

A system and method for repairing fatigue cracks in a multi-layer composite body. The method includes repairing fatigue cracks at a first interface between a first layer of the multi-layer composite body and a second layer of the multi-layer composite body. The method also includes repairing fatigue cracks at a second interface between the second layer of the multi-layer composite body and a third layer of the multi-layer composite body. The method further includes anchoring the second interface with the third layer of the multi-layer composite body to prevent failure from fatigue cracks.