A method for making a composite-metal hybrid shaft for a rotorcraft includes providing a tubular metal member that has an internal surface defining a space therein, preparing a composite member using a curing tool, curing the composite member, creating a cured composite member, expanding the metal member with heat, placing the cured composite member into the space defined by the internal surface of the expanded metal member, and allowing the expanded metal member to cool.

A method for impregnating a fibrous material with a curable resin to form a prepreg is disclosed. The method includes conveying a web material through at least one moving pressure nip formed between a moving pressure roller and a moving supporting surface, wherein the moving pressure roller and the moving supporting surface travel at different velocities relative to each other resulting in a relative velocity between the web material and the pressure nip. The at least one moving pressure nip travels in the same direction as the web material while applying sufficient pressure to compress the web material and to affect impregnation of the fibrous material with the curable resin. Also disclosed is a system for implementing the disclosed impregnation method.

A composite structure is fabricated using a preform comprising a stack of unidirectional prepreg plies that are stitched together. During curing of the prepreg, the stitches melt and dissolve.

A method for manufacturing of a part made of composite material including pre-compacting to a predetermined shape of a mixture of a first thermosetting resin with discontinuous long fibers so as to form a first preform, pre-curing the first preform until an intermediate conversion stage corresponding to a solidification of said first resin, contacting the first preform with a second preform including a fiber structure of continuous fibers impregnated with a second thermosetting resin, polymerizing the first and second preforms so as to form a part made of composite material including a body made of composite material including reinforcement made of continuous fibers consolidated by an organic matrix provided with a portion made of composite material including reinforcement made of discontinuous long fibers consolidated by an organic matrix.

Mechanically attaching articles made from composites has problems due to the difference in properties of the composite in the x, y planar direction and the z perpendicular direction, this results in different properties between the composite and the attachment member such as differences in coefficients of thermal expansion which can weaken the joint further leading to differences in moisture uptake which can further reduce the strength and robustness of the joint. The invention relates to the selection of the position of a joint in order to reduce such problems and to operating the moulding process in a way that improves the provision of mechanical attachments such as bolt holes.

An additional pad 27 is additionally and integrally arranged from an outer surface of a flange 17 opposite to a contacting side of the flange 17 to a small-diameter curved surface of a bend 19 and from there to an end of an outer surface of a part body 13. On an outer surface side of the additional pad 27, a fastening seat 27f is formed by machining. An area end PAe of a processed area PA formed by machining is positioned on the part body 13 beyond the bend 19.

Disclosed are a method for producing a laminate including a step of laminating a resin impregnated fiber reinforced composition layer on a metal member, wherein the method includes a step of forming a resin coating on the metal member and a step of laminating a resin impregnated fiber reinforced composition layer containing a resin impregnated fiber reinforced composition containing (I) 20 to 80% by mass of a polymer having a melting point and/or a glass transition temperature of 50 to 300° C., and (C) 20 to 80% by mass of a reinforcing fiber
(provided that the sum of the component (I) and the component (C) is taken as 100% by mass) via the above resin coating; and a laminate obtained by the method.

A process for manufacturing a hollow body including a thermoplastic wall and a fibrous reinforcement welded on at least one portion of the surface of the wall, or its outer surface, the fibrous reinforcement including a thermoplastic similar to or compatible with that of the wall of the hollow body, having a thickness of at least 1 mm and from 30 to 60% in weight of fibers, the method including heating a portion of the outer surface of the hollow body where the reinforcement will be welded; heating the fibrous reinforcement to soften or melt the thermoplastic of the reinforcement; and moving the reinforcement and applying the reinforcement to the portion of the outer surface of the hollow body. The applying the reinforcement includes: applying an initial pressure on at least one portion of the reinforcement; and applying pressure for a final welding using robotized pressure applying mechanism.

A radome for housing a radar system comprises a plurality of interconnected curved radome thermoplastic composite material panels, each curved radome thermoplastic composite material panel having a plurality of interconnecting edges, a foam core, an inner skin, an outer skin, and a plurality of three-dimensional fiber bundles tying the inner skin and the outer skin to each other through the foam core, inhibiting delamination. The radome includes a hydrophobic exterior surface that is self-cleaning and requires zero maintenance for 25 years.

A method of fabricating a composite assembly may include providing a first laminate and a second laminate respectively formed of first and second composite plies, and having a respective first and second cured section and a respective first and second uncured section. The method may further include interleaving the first composite plies in the first uncured section with the second composite plies in the second uncured section to form an interfacial region. The method may additionally include curing the interfacial region to join the first laminate to the second laminate and form a unitized composite assembly.