A device and a process for manufacturing a composite part, the device comprising four molding mandrels that can be arranged in a mold arrangement in which they form a mold for the composite part, as well as a locking mandrel configured to lock the molding mandrels in the mold arrangement and to be extracted from between the molding mandrels to release the molding mandrels from their mold arrangement. The locking mandrel extends from one longitudinal end of the molding mandrels to another opposite longitudinal end of the molding mandrels.

A core according to one aspect of the present disclosure is a core that is inserted into a space between a skin and a stringer in a step of integrally molding the skin and the stringer, the skin including fiber-reinforced resin, the stringer having a hat-shaped section that is open toward the skin. The core includes: a first die that extends along a longitudinal direction of the stringer and contacts the skin; a second die that extends along the longitudinal direction of the stringer, is adjacent to the first die, and contacts the skin; and a third die that extends along the longitudinal direction of the stringer, is located at an opposite side of the skin across the first die and the second die, and contacts both the first die and the second die.

Methods and apparatus for securing an autoclave bag to a composite fixture are disclosed. An example apparatus includes a flange sealing device including a forward flange at a first end and an aft flange at a second end, and a composite fixture including a forward groove to locate and seal with the forward flange of the flange sealing device to affix an autoclave bag, an aft groove to locate and seal with the aft flange of the flange sealing device to affix the autoclave bag, and an aft locating ring to position the autoclave bag.

Sinusoidal shaped member units and support member units are parts that form pre-stressed assemblies having flexural properties. Sinusoidal shaped members are relaxed material members that have been elastically deformed. Support members maintain the elastically deformed state of the sinusoidal shaped members. The sinusoidal shaped members and support members are organized into pre-stressed curvilinear assemblies containing stored elastic potential energy that is equal to the work done by the forces that deformed their pre-stressed structure. The assemblies' sinusoidal shaped members and support members are adapted to use materials having exceptional mechanical properties and flexural strength. This includes nano-composites. The assemblies' pre-stressed state enhances its mechanical, electrical and structural performance. The size, number, density and possible geometric configurations of the sinusoidal shaped member units and support member units within an assembly/structure is vast. Products of this sinusoidal building system have mechanical and structural applications and can be manufactured using an automated process.

An example mandrel for processing a part is described including an inner core having a material with first thermal properties, and an outer layer surrounding the inner core. The outer layer includes a material with second thermal properties different than the first thermal properties to enable uniform pressure distribution within the mandrel. An example method for fabricating a composite part is described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing the base composite layer and the skin such that during curing a pressure due to thermal expansion of one of the inner core and the outer layer is distributed by the other, and removing the mandrel from the cavity of the tooling surface following the curing.

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.

A core according to one aspect of the present disclosure is a core that is inserted into a space between a skin and a stringer in a step of integrally molding the skin and the stringer, the skin including fiber-reinforced resin, the stringer having a hat-shaped section that is open toward the skin. The core includes: a first die that extends along a longitudinal direction of the stringer and contacts the skin; and a second die that extends along the longitudinal direction of the stringer and is located at an opposite side of the skin across the first die. The second die includes a material that is softer than the first die. The second die includes a slit perpendicular to the longitudinal direction of the stringer.

A method is provided, comprising: forming a porous body from an additive manufacturing powder and binder mixture, the porous body including opposing surface portions comprising top and bottom surface portions; placing the porous body on a vacuum table, wherein the vacuum table causes a negative air pressure within the porous body; and applying a tooling gel coat to the top surface portion, wherein the tooling gel coat is drawn into the porous body by the negative air pressure. In another aspect, a RTM tool is provided, comprising: a cavity and a core; wherein the cavity and the define a hollow; wherein the cavity and the core are formed as a porous body, wherein the cavity and core include a forming surface, wherein the cavity and core are each placed upon a vacuum table after which a tooling gel coat is applied to the forming surface.

A composite golf club head and a method for manufacturing the same are provided. The composite golf club head has a carbon fiber composite body and a striking face. The carbon fiber composite body is formed by multiple carbon fiber prepreg materials or multiple composite prepreg materials including carbon fiber with stacking, a positive pressure, a vacuum negative pressure, and heating. The striking face is made of a carbon fiber composite or metal material, and is fixedly glued to a front opening portion of the carbon fiber composite body. A weight of the carbon fiber composite body is reduced. Center of gravity and moment of inertia can be adjusted easily according to striking distances or feel of striking of different golf club heads for enhancing a striking performance of the composite golf club head.

A system for manufacturing a composite part including a conductive flexible facesheet and an automated tape layup (ATL) machine for laying up composite tape onto the facesheet that is laid flat on a flat surface. The system also includes a curved tooling surface for transferring the facesheet with the composite material thereon to the curved tooling surface for attachment of substructures and curing into the composite part. System may also include insulation placed below the facesheet and insulation placed above the composite material, as well as a source of electricity and heat for heating the conductive facesheet to cure, melt, or fuse the composite tape and substructures without heating the tooling surface and other tooling used in the composite curing process. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to conductive wires attached at opposing ends to the facesheet.