A thermoplastic composite structure is produced by extruding a bead of composite material to a desired cross sectional shape. An extruder extrudes the polymer bead containing reinforcing fibers, using a low compression first extruder stage where the polymer is mixed and de-gassed, and a high compression second stage where the polymer is consolidated and extruded. The cross sectional profile of the polymer bead may be altered using a variable extruder gate.

Systems and methods are described for applying a self-heating structural adhesive to components of aircraft or other structures. A conductive scrim can be placed in between layers of adhesive for use in joining two components together. Leads can be provided to apply an electrical current to the scrim, which can raise the temperature of the system and cure the adhesives, creating a strong bond with a conductive layer there between.

Provided is a joint and an aircraft structure wherein it is possible to position a member relative to a preform with high accuracy. A groove into which a plate member (30) is inserted is formed in a pi-shaped joint (20) provided on the preform (21), and the preform (21) and the plate member (30) are connected by being bonded. Moreover, a fitting shape (32A-1) into which the plate member (30) is fitted is formed on the pi-shaped joint (20) on the whole groove bottom face. Additionally, a fitting shape (32A-2) into which the plate member (30) is fitted is formed on a portion of the groove bottom face. Furthermore, fitting shapes (32B-1, 32B-2), into which the groove bottom face that is formed on the pi-shaped joint (20) is fitted, are formed on the surface of the plate material (30) that is fitted with the pi-shaped joint (20).

A joint (20) joins a plate member (26) with a preform (22), wherein an inclined part (28), which is inclined relative to a surface that is orthogonal to the direction in which a tensile load is applied to the plate member (26), is formed on a surface (25) that joins with the preform (22). Moreover, an indented part (38) corresponding to the shape of the inclined part (28) is formed on the preform (22) so that the inclined part (28) of the joint (20) is embedded into the indented part (38). The joint (20) is embedded in and bonded to the preform (22).

A method for manufacturing a shell element reinforced with support elements comprises providing a skin element that has an outer surface and an inner surface opposite the outer surface, providing a first support element that has an attaching side and a free side opposite the attaching side, attaching the first support element on the skin element such that the attaching side of the first support element faces the inner surface of the skin element. A first recess is introduced into the first support element that proceeds from the free side of the first support element and extends transversely to the first axis. A second support element is provided that has a support side and a front side opposite the support side. The second support element is inserted into the first recess of the first support element such that the support side faces the inner surface of the skin element.

Two composite laminates are joined together by a bondline having portions exposed to the ambient environment. The bondline contains scrim having an electrical conductivity and impedance matched to that of the laminates in order to mitigate effects of lightning strikes.

Forming a cured composite structure may include assembling pre-cure members about a variable volume support member to form a pre-cure assembly, applying an internal pressure from within the pre-cure assembly by maintaining the variable volume support member at an expanded volume, and curing the pre-cure members by applying heat while the variable volume support member is in the expanded volume to form a cured composite structure.

An adhesive (B) of solvent containing adhesive as a suspension of low viscosity is prepared by adding a solvent MIBK to a one-part epoxy adhesive of a dicyandiamide-curable type (A). Metal shaped articles (M1 to M5) as adherends are prepared each of which, through various surface treatment, has specific surface configuration of roughened face and/or ultrafine irregularities and the surface is entirely covered with a thin layer of ceramics such as a metal oxide or metal phosphate. The specified face of each metal shaped article (M1 to M5) is painted with the solvent containing adhesive (B). The faces painted with the adhesive of two metal shaped articles (M1 to M5) are caused to abut each other, the articles are heated to cure the one-epoxy adhesive to accomplish adhesion. With one of the adherends replaced by a CFRP shaped article (P2), a composite of a metal and CFRP can be formed.

An apparatus includes a first thermoset layer that includes a first fibrous material embedded in a first thermoset matrix. The apparatus also includes a second thermoset layer that includes a second fibrous material embedded in a second thermoset matrix. The second thermoset layer is coupled to the first thermoset layer to form a joint. Further, a gap is defined between the first thermoset layer and the second thermoset layer. The apparatus also includes a thermoplastic filler that is made from a thermoplastic material. The thermoplastic filler is positioned within the gap.

The sealing device includes a heatable base plate that cooperates with a heatable split plate to simultaneously form three intersecting seal lines. The split plate includes an alpha plate and a beta plate. The alpha plate and the beta plate each include a first heated surface that cooperate with the base heated surface to form a pair of co-linear seal lines. In addition, the alpha plate and the beta plate each include a second heated surface that cooperate together to form a third seal line that extends in a direction perpendicular to the co-linear seal lines and intersects the co-linear seal lines. A method of forming a complex seal joint is also described.