Described herein are methods of forming uncured sealant assemblies and also methods of forming seals between various parts using such assemblies. In some examples, an uncured sealant assembly comprises two protective layers and an uncured sealant layer, disposed in between. The uncured sealant assembly is stored and provided at a cure-inhibiting temperature, selected to minimize the curing rate of the uncured sealant layer. The size and the shape of the uncured sealant layer are specifically selected to ensure the complete coverage of the faying surfaces, filling of all gaps and voids between the faying surfaces, and controlling the shape and size of uncured sealant squeeze out between the faying surfaces. In some examples, the size and shape of the uncured sealant layer maybe be specifically selected to have no uncured sealant squeeze out between parts.

The invention relates to a process (100) for manufacturing an object (1) made of thermoplastic polymer composite from at least two parts (10) made of thermoplastic polymer composite, said thermoplastic polymer composite comprising a fibrous reinforcement and a thermoplastic polymer matrix, said process comprising the steps of: arranging (120) the two parts (10) made of thermoplastic polymer composite adjacently or overlapping at an assembly interface zone (11), and heating (130) to melt the thermoplastic polymer matrix at said assembly interface zone (11), so as to form an object (1) made of thermoplastic polymer composite comprising a welded interface (12).

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.

One aspect of a method of manufacturing a honeycomb core includes positioning a first thermoplastic columnar cell adjacent a second thermoplastic columnar cell, modifying a thermoplastic property of the first thermoplastic columnar cell, wherein the modified thermoplastic property permits joining a circumferential surface of the first thermoplastic columnar cell to a circumferential surface of the second thermoplastic columnar cell. The method also includes joining the circumferential surface of the first thermoplastic columnar cell having the modified thermoplastic property to the circumferential surface of the second thermoplastic columnar cell resulting in the honeycomb core.

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 of manufacturing a flexible element configured for pressing against composite material received on a mold surface of a mold during cure, including placing a porous material over the mold surface, forming a sealed enclosure containing the mold surface and the porous material, infusing a curable liquid material such as silicone in liquid form into the enclosure under vacuum and through the porous material, curing the liquid material to form the flexible element, and opening the enclosure and disengaging the flexible element from the mold. In a particular embodiment, the flexible element is a pressure pad.

One aspect of a process of forming an aircraft component includes bonding a first end of a honeycomb structure to a surface of an aircraft skin member, the honeycomb structure including multiple connected cells. Foam is sprayed on a second end of the honeycomb structure opposite the first end. The process also includes curing the foam on the second end of the honeycomb structure.

An apparatus is proposed for applying and removing protective caps (1) to and from the ends of elongate members (6). The protective cap (1) has a hard base portion (5) and a cover portion (2) of flexible, resilient material, extending from the base portion (5) and operative to cover a portion of an outer surface of the elongate member (6). The apparatus comprises: a gripping mechanism (44) operative to grip the hard base portion (5) of the protective cap (1); a drive mechanism, connected to the gripping mechanism (44), operative to move the protective cap (1) to and from the end of the elongate member (6); and a tool operative to perform at least one of the operations of (i) unfurling the cover portion to secure it to the outer surface of the elongate member, (ii) furling the cover portion to detach it from the outer surface of the elongate member.

In one embodiment, a method includes fastening a plurality of components of a composite structure in an assembly fixture, wherein the assembly fixture comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands, and wherein the assembly fixture further comprises an anisotropic thermal expansion property based on an orientation of the plurality of reinforcement fibers within the assembly fixture; and heating the assembly fixture in an autoclave to bond the plurality of components of the composite structure.

Layers of plies of composite material are laid on a convex tool surface. A first layer is placed with a first ply of a first section having a gap edge adjacent a gap edge of a first ply of a second section, the edges being parallel and a contraction distance from each other. A second layer is placed with a second ply of the first section having a gap edge adjacent a gap edge of a second ply of the second section, the edges being parallel and a contraction distance from each other, the second ply of the second section overlapping onto the first ply of the first section by a splice distance. Consolidation and curing cause contraction of the layers toward the tool, allowing the adjacent gap edges of each layer to be in close proximity or in contact after moving toward each other during the contraction.