Systems and methods are provided for hardening wing panel preforms. One embodiment is a method for fabricating a wing panel for an aircraft. The method includes loading a wing skin preform onto a contour of an Outer Mold Line (OML) tool, applying stringer preforms to troughs of an Inner Mold Line (IML) tool, aligning the OML tool with the IML tool, and assembling the IML, tool and the OML tool into a cartridge that molds a wing panel preform comprising the wing skin preform and the stringer preforms. The method further includes inserting the cartridge into a press, and hardening the wing panel preform into a composite part while the cartridge resides in the press.

Advanced single vacuum bag (ASVB) fabrication methods and assemblies are provided to manufacture and repair polymer composites whereby a rigid check plate is mounted over an uncured laminate by a thermally collapsible check plate stand. The check plate stand thereby maintains a gap between the check plate and the uncured laminate during first stage processing conditions, yet is capable of thermally collapsing during subsequent second stage processing conditions to thereby allow the check plate to fall into compressive contact with the uncured laminate After the check plate collapses onto the uncured laminate, the compressive force of the check plate will be transferred to the laminate to consolidate the laminate as desired and thereby form an at least partially cured polymer composite structure of high quality.

An assembly for forming a gas turbine engine according to an example of the present disclosure includes, among other things, a layup tool including a main body extending along a longitudinal axis and a flange extending radially from the main body, the flange defining an edge face slopes towards the main body to an axial face. At least one compression tool has a tool body having a first tool section and a second tool section extending transversely from the first tool section. The first tool section is translatable along a retention member in a first direction substantially perpendicular to the edge face such that relative movement causes the second tool section to apply a first compressive force on a composite article trapped between the axial face of the flange and the second tool section. A method of forming a gas turbine engine component is also disclosed.

Systems and methods are provided for fabricating a wing panel. Methods include aligning a strongback over a wing panel, vacuum attaching a wing panel surface and pogos extending beneath the strongback, and adjusting the length of pogos to enforce a contour to the wing panel. Systems include a strongback to extend over a wing panel, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Other systems include a track, work stations along the track, a strongback to extend over the wing panel and move along the track, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Apparatus includes a shuttle having adapters that mate the shuttle with a track, adjustable-length carriers with vacuum couplers to couple with a wing panel surface, and indexing units that interact with indexing features in a manufacturing excess of the wing panel.

A rotating manifold includes an axle, a hub rotatable relative to the axle about an axis of rotation, and a compressed air line in fluid communication housed in the axle. The rotating manifold further includes a vacuum line in fluid communication with the hub. The rotating manifold further includes a plurality of conduits connected to the hub. Each conduit of the plurality of conduits is in fluid communication with the vacuum line and houses a compressed air line arm in fluid communication with the compressed air line.

A method for manufacturing a wind turbine blade includes the steps of: a) arranging a first pre-casted blade segment adjacent to a second pre-casted blade segment, b) arranging a fiber lay-up in a connection region between the first pre-casted blade segment and the second pre-casted blade segment, c) covering the connection region with a vacuum cover, d) applying vacuum to a space covered by the vacuum cover, and e) infusing the connection region with a resin and curing the resin.

Manufacturing the wind turbine blade by connecting pre-casted segments with each other by vacuum-assisted infusion of resin of added fibers and curing the resin simplifies the manufacturing process. This is in particular the case for very large blades.

A layup mandrel including a rib structure comprising ribs defining a lofted surface; and a skin attached to and supported by the rib structure. The skin has a surface having a curvature of the lofted surface; the ribs are disposed to at least partially shape the curvature molding a part pressed against the surface during curing of the part; and the part comprises or consists essentially of a composite material.

There is provided a laminated composite structure having improved impact damage resistance and improved strength. The laminated composite structure has a plurality of stacked layers of a composite material. The plurality of stacked layers have one or more interlaminar corrugations formed within the plurality of stacked layers. Each interlaminar corrugation has a substantially sinusoidal shaped profile, and has a depth and a length dependent on a size of the laminated composite structure formed. The laminated composite structure with the one or more interlaminar corrugations has improved strength and improved impact damage resistance at an exposed edge of the laminated composite structure, when the exposed edge is subjected to an impact force.

A method of shaping a preform includes: laminating plural dry tape members each including a binder and fiber while partly heat-sealing the dry tape members with the binder to provisionally fasten each dry tape member to an adjacent dry tape member; bending the dry tape members having been provisionally fastened, along a bending line; and heat-sealing the dry tape members having been bent with the binder to manufacture a shaped dry preform. At the laminating, at least one of the followings is satisfied: (i) an amount of heat-sealing with the binder is changed in an area along the bending line, (ii) an amount of heat-sealing with the binder is different between portions adjacent to and on opposite sides of the area along the bending line, or (iii) an amount of heat-sealing with the binder is different between portions adjacent to each other at the bending line as a border.

A method for contour forming in a fiber placement system. The method includes painting multiple sliced layers on a stationary form to create a composite component. The sliced layers include multiple hoop tows. One or more overlap splices are formed in each of the hoop tows. The method includes applying a layup heat to multiple target areas on the sliced layers during the painting. The target areas are spatially arranged to permit a slippage in the splices. The method further includes draping the composite component on a curved tool with the hoop tows oriented perpendicular to an axis of curvature of the curved tool, and applying a curing heat to the composite component after the composite component has been contoured by the curved tool. The curing heat inhibits a further slippage in the overlap splices.