The Boeing Company

Justin H Register

Remmelt Andrew Staal

Gregory Jonathon Smith

Megan Nicole Watson

Arne Kenneth Lewis

Meredith M Bird

Ernie Fidgeon

Glory C Edwards

Andrew Elmer Modin

Richard Alexander Prause

Richard E Heath

David H Reed

Eric Carlton Anderson

Caleb J Handolescu

Michael C Hargrove

Alice R Arnold

Michael J Caprini

Cezar Chirila

Andrew Staal

Dorekia Martin

Ryan C Schwartz

Megan N Watson

Disclosed herein are a repair apparatus, system, and method for structurally reinforcing an abnormal composite structural member. The repair is suited for reinforcing a cured composite structure that defines a strength tolerance and has an abnormality that reduces the structural strength relative to the strength tolerance of the cured composite. The structural reinforcement repairs the abnormality in the cured composite and provides the repair strength so that the repaired composite has a structural strength that meets or exceeds the strength tolerance. The structural reinforcement has a composite patch that is coupled to the cured composite over the abnormality and is covered by pressure-sensitive tape.

Apparatus, system, and method for reinforcing composite structure

The present disclosure provides repair systems, repair components, and methods for repairing composite structure systems using a set number of prefabricated repair components including a repair component and various shims which are fabricated to repair multiple composite members in a composite structure system.

Composite repair components with customizable shims

A heater for heating a contoured surface of a structural member includes a bladder, a granular material within the bladder, where the granular material is capable of exhibiting granular jamming when air is removed from the bladder, and a heating element positioned within the bladder and in contact with the granular material.

System for heating contoured surface of structural member

A method for curing a patch. The method includes generating the patch according to a negative of a scan of a scarf in a composite material. The method also includes pre-curing the patch.

System for curing a patch

A method of forming a composite part from a mufti-ply prepreg composite charge comprises reducing pressure inside a bladder, located in a chamber that is at atmospheric pressure, below the atmospheric pressure. The method also comprises placing the multi-ply prepreg composite charge, having a first shape, in the chamber and reducing pressure inside the chamber below the atmospheric pressure. The method additionally comprises, while maintaining pressure inside the chamber below the atmospheric pressure, expanding the bladder within the chamber by increasing pressure inside the bladder to the atmospheric pressure, so that the multi-ply prepreg composite charge is compressed between the bladder and a forming tool, which is located inside the chamber, and the multi-ply prepreg composite charge is configured by the forming tool to a second shape, different from the first shape. The method also comprises curing the multi-ply prepreg composite charge, having the second shape.

Methods and apparatuses for forming composite parts from multi-ply prepreg composite charges

A method for repairing a composite member includes assembling a composite stack on a surface. The composite stack includes a first book nested with a second book. An adhesive is disposed between the first book and the second book. At least one of the first book and the second book includes a first pattern of slots. The method further includes setting the composite stack to yield a composite repair piece. The method further includes attaching the composite repair piece to the composite member. Also disclosed is a composite repair piece. The composite repair piece includes a first book and a second book. The second book is stacked on top of the first book. An adhesive is disposed between the first book and the second book. At least one of the first book and the second book includes a first pattern of slots.

Structures and methods for repairing composite members

A method for repairing a composite structure using pre-cured plugs. In accordance with one method, composite material is removed from a first composite laminate to form a cavity bounded by a tapered internal surface that extends from an opening at an outer mold line surface of the first composite laminate. In addition, a second composite laminate is machined to form a plug having a tapered surface. Then the plug is placed so that the tapered surface of the plug opposes the tapered internal surface of the first composite laminate. Thereafter, the tapered surface of the plug is bonded to the tapered internal surface of the first composite laminate. Optionally, a hole is drilled in the plug for receiving a fastener.

Methods for repairing composite material using pre-cured plugs

Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

Apparatus, system, and method for repairing composite sandwich panels

A rework part for a composite structure is described. The rework part comprises an upper composite layer comprising an upper perimeter that extends beyond a damaged area of the composite structure, and a bottom composite layer between the composite structure and the upper composite layer, the bottom composite layer comprising a bottom perimeter that extends beyond the upper perimeter of the upper composite layer. The rework part further comprises a bottom adhesive layer adhering the bottom composite layer to the composite structure, and a rework part adhesive layer bonding the upper composite layer to either the bottom composite layer or to an intermediate composite layer.

Rework part for composite structure

Method for curing a patch

A method for manufacturing a tool including assembling a stack-up that includes a plurality of precured composite laminates, the stack-up having an engagement surface, wherein each precured composite laminate of the plurality of precured composite laminates is flexible, and wherein an adhesive is positioned between adjacent precured composite laminates of the plurality of precured composite laminates, and placing the engagement surface of the stack-up onto a target surface of a substrate.

Tool and associated method for manufacturing the same

Methods, apparatuses and systems are disclosed for making and applying composite material rework parts to rework composite substrates by partially forming a composite material rework part before staging the rework part onto the composite substrate. An approximate geometry is imparted to the partially formed rework part, with the final composite material rework part geometry imparted by the composite substrates requiring rework, as the rework part is finally shaped and cured in situ on the composite substrate.

Composite material rework parts and methods of making composite rework parts

Systems and methods are provided for forming composite parts. One embodiment is an apparatus that includes a forming tool. The forming tool includes a body, which includes an exterior that defines a shape for forming a laminate that will be cured into a composite part. The body also includes elements of phase change material that provide rigidity to the body below a threshold temperature, and that exhibit a phase change above the threshold temperature causing the body to become pliable. Further, the body includes flexible material that encloses the elements of phase change material.

Support tooling for composite parts

Within examples, a mandrel is configured to be inserted into a cavity defined by an interior wall of a structural member to support the structural member during processing. The mandrel includes a first bladder containing a material, the material being capable of exhibiting granular jamming when air is removed from the first bladder. The mandrel further includes a second bladder configured to expand and apply a force to the first bladder. Systems and methods that relate to the mandrel are also described within examples.

Mandrel for supporting structural member during processing

Methods and apparatuses for electromagnetic support tooling for use in composite part curing are described. In one example, a support tooling, such as a mandrel, includes an elastomeric housing that has ferromagnetic components. The mandrel also has electro-magnetic coils positioned within the elastomeric housing and operable to generate magnetic fields to repel or attract the ferromagnetic components of the elastomeric housing to the electro-magnetic coils. When the ferromagnetic components of the elastomeric housing are repelled by the electro-magnetic coils, the elastomeric housing has a rigid surface state. When the ferromagnetic components of the elastomeric housing are attracted to the electro-magnetic coils, the elastomeric housing is collapsed.

Growing community of inventors

Charleston, SC, United States of America

Justin H Register