A composite laminate for an airframe lifting surface including: at least two sides and one ramp area defined by a decreasing staggered laminate extended along a ramp direction, wherein the composite laminate includes: first plies formed by tapes arranged parallel to the ramp direction, second plies formed by tapes arranged orthogonal to the ramp direction, third plies formed by tapes arranged in a first laying up direction, being the first laying up direction different from the ramp direction and the direction orthogonal to the ramp direction, and fourth plies formed by tapes arranged in a second laying up direction, being the second laying up direction different from the ramp direction, the direction orthogonal to the ramp direction and the first laying up direction; wherein in the ramp area, the tapes forming the third and/or fourth plies are extended from one laminate side to another laminate side.

A bonded joint for use in bonding composite materials is provided and includes a composite rib having electrically conductive properties and a composite structure having electrically conductive properties. An electrically conductive preform is provided that facilitates a bond between the composite rib and the composite structure. A mesh composition that bonds the composite rib to the preform and that bonds the preform to the composite structure is provided and is electrically conductive to conduct current between the composite rib and the composite structure.

In one aspect, there is a method of making a composite skin for a tiltrotor aircraft including providing a first skin in a mold, the first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; providing a plurality of honeycomb panels having an array of large cells onto the first skin, each cell having a width of at least 1 cm; assembling the plurality of honeycomb panels along the longitudinal axis of the first skin to form a honeycomb core having an outer perimeter within the periphery of the first skin; positioning a second skin onto the honeycomb core, the second skin having an outer perimeter within the periphery of the first skin; and curing an adhesive to create a bond between the first skin, the honeycomb core, and the second skin to form a composite skin.

Embodiments are directed to systems and methods for two or more cured composite assemblies that are bonded together to form a tubular composite structure, wherein each of the cured composite assemblies do not have a tubular shape. The tubular composite structure may form a spar for an aerodynamic component, for example. The two or more cured composite assemblies may comprise carbon or fiberglass composite materials or a combination of materials. Each of the cured composite assemblies may further comprise axial edges that are configured to be bonded to another of the cured composite assemblies, wherein the axial edges have a sloped shape. An adhesive agent may be applied on the axial edges for bonding two cured composite assemblies. Alternatively, or additionally, one or more fasteners may be used to attach the axial edges of at least two cured composite assemblies.

Provided are methods and devices for supporting of variety of different pre-cured composite stringers after forming and prior to curing. A post-forming processing device comprises a base with a channel for receiving hat portions of different stringers. The device also comprises a support structure, at least partially extending within the channel. The support structure is configured to conform to different hat portions and to retain the shape of these hat portions. For example, the support structure is made from a flexible material, which conforms to any shape variations. In some examples, the support structure is made from a jamming material that is reshaped together with each of the pre-cured composite stringers. A post-forming processing device is used for supporting different pre-cured composite stringers while various operations are performed on these stringers, such as stringer trimming, inspection, installation of bladders and noodles, and the like.

A joint structure includes a reinforcement portion that is formed by joining a composite material and a reinforcing material through an adhesive. The composite material includes a plate portion that is formed by laminating a plurality of fiber sheets, and a raised portion that is formed by laminating a plurality of fiber sheets in addition to the plurality of fiber sheets of the plate portion, and surfaces of the plate portion and the raised portion are covered with a single fiber sheet. The reinforcement portion includes the raised portion and the reinforcing material that is bonded to the raised portion through an adhesive. A first boundary between the plate portion and the raised portion and a second boundary between the raised portion and the reinforcing material are located at different positions in an in-plane direction of a laminated interface between the fiber sheets that are laminated.

Methods, systems, and apparatuses are disclosed for the manufacture of composite components having incorporated reinforcing structures machined into composite material substrates, and composite components manufactured according to disclosed methods, and assemblies and larger structures comprising the composite material components.

A lightning strike protection layer for an aircraft is disclosed having a first portion and a second portion, the first portion includes a first fibre reinforced polymer composite layer and a first electrically conductive metal layer and the second portion includes a second fibre reinforced polymer composite layer and a second electrically conductive metal layer, and the first and second portions are joined at a butt joint, with the first and second fibre reinforced polymer composite layers abutting and the first and second electrically conductive metal layers abutting; and a butt-strap extending across the butt joint, the butt-strap comprising a third electrically conductive metal layer electrically connected to the first and second electrically conductive metal layers.

Systems and methods for a caul plate for an irregular surface. One embodiment is a caul plate for co-curing or co-bonding a first composite part and a second composite part. A body of the caul plate includes a lower surface to face a top surface of the first composite part, a reference edge to locate the second composite part on the first composite part, and an upper surface that is opposite to the lower surface. The lower surface includes one or more bends to match one or more slopes in the top surface of the first composite part. The one or more bends correspond with ply changes in the first composite part.

An example method of joining a first structure and a second structure is described that includes forming a bond cavity between a first structure and a second structure, placing a semi-permeable breather material at one or more exits of the bond cavity, placing a vacuum bag around the bond cavity and the semi-permeable breather material, evacuating the bond cavity via a vacuum port and forcing adhesive into the bond cavity via an adhesive port while the bond cavity is evacuated, and curing the adhesive via one or more heaters to bond the first structure to the second structure.