The Boeing Company

Spirit Aerosystems, Inc.

Brian R Kitt

John Michael Welch

Thomas D Popp

Robert F Wikstrom

Terry W Stratton

Mark Anthony Wadsworth

John Thomas Strunk

Darrell Clyde Jundt

David Michael Gayle

Russell A Barrett

Kenneth E Garrett

Matt D Bickhard

Timothy L Holdeman

Donald D Ruebke

Kenneth C Stewart

Sandra L Jansen

Floyd Stephen Corby

Brett E Russell

Jon J Fischer

An acoustic perforation method and assembly for forming holes or perforations into a face sheet of a sandwich panel without damaging a honeycomb core thereof. The method may include photographing or otherwise scanning the face sheet bonded to the honeycomb core after cure, then detecting locations of cell walls of the honeycomb core via image processing or analysis of scan data obtained. For example, discolorations on the face sheet or coatings applied thereto may indicate locations of the cell walls of the honeycomb core. A perforation pattern may then be generated or altered based on the detected locations of the cell walls, and a perforation device may be commanded to perforate the face sheet in accordance with the perforation pattern at locations where the cell walls are not located.

Method and apparatus for acoustic perforation of core sandwich panels

A method for splicing honeycomb core together to form a core structure, such as an acoustic panel for an aircraft. The core structure may comprise a first honeycomb core, a second honeycomb core, and an intermediate bonding part disposed between the first and second honeycomb cores. The intermediate bonding part may comprise a syntactic core wrapped with or sandwiched between a non-foaming film adhesive. The syntactic core sandwiched between a first and second layer of film adhesive and a first and second honeycomb core is then compressed by vacuum and cured to bond the honeycomb cores together, forming the core structure.

Method for bonding honeycomb cores

A computer-implemented method for providing on-line ultrasonically scanned images of composite parts for immediate feedback in a manufacturing environment is discussed. The scanned images are edited to indicate each deficiency that has been repaired on a previously assembled composite part. Quality assurance personnel enter data associated with each composite part and verify the data content. Repair personnel enter data associated with correcting an identified deficiency of the composite part. Historical data suitable for developing statistics and trends are stored for each type of composite part. When queries are launched, the statistical and trend data is filtered to produce reports that are displayed. That is, reports are generated that identify particular statistics and trends. The scan image and data associated with a composite part are linked together for cross-referencing and stored in a database that is accessible by client and server computers on a network. Images produced by an ultrasonic scanner(s) coupled to the network are stored for retrieval.

Method and system for providing feedback from a non-destructive inspection of a composite part

An acoustic panel (,) for the nacelle (,) of a high bypass jet engine. The acoustic panel (,) has a perforated composite inner sheet (,), an outer composite sheet (,), and a honeycomb-core material (,) sandwiched therebetween. The acoustic panel (,) includes an integral forward ring (,) and integral wedge fairings (,).

Engine nacelle acoustic panel with integral wedge fairings and an integral forward ring

An improved acoustic panel (26) for the nacelle (20) of a high bypass jet engine. The acoustic panel (26) has a perforated composite inner sheet (54), an outer composite sheet (96, 98), and a new reinforcement structure, or pre-cured doubler (62) therein. The pre-cured doubler (62) is arranged to receive a load applied to the acoustic panel (26), and includes a face sheet (64) connected to a structural attachment area (52) of the perforated composite inner sheet (54). A structurally-reinforced core (63) is connected the face sheet (64). Preferably, the width of the face sheet (64) in an air flow direction of the acoustic panel (26) is substantially equal to the width of the structurally reinforced core (63) in the air flow direction. The pre-cured doubler (62) provides increase acoustic area in parts of the acoustic panel adjacent to attachment fittings (46). Expanded epoxy (87a) is also used to reinforce side edges and selected areas of the acoustic core (60) for the acoustic panel (26).

Reinforcing structure for engine nacelle acoustic panel

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Wichita, KS, United States of America

Brian R Kitt