Spirit Aerosystems, Inc.

Other

Q-dot, Inc.

Spirit Aerosystems (europe) Limited

Mark Anthony Wadsworth

Stephen D Gaalema

Thomas E Linnenbrink

Rahbar Nasserrafi

Henry Arnold Schaefer

Kerrick Robert Dando

Kevin Lyle Obrachta

Amitabh Vyas

Gerald E Hicks

Brian R Kitt

Roger Edmund Kornfeld

Darrell A Wade

Aaron Rae Heitmann

Alexander Jon Carr

Dennis Lebeda

Khai Nguyen

Mike Hawthorne

Clayton Higgins

Robert Raymond Meinders

Matt D Bickhard

Andi Meyer

Scott E Graves

Floyd Stephen Corby

Ronald Jones

Adrienne M Strohmeyer

A method for fusing thermoplastic composite structures includes placing a thermoplastic substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one metal layer over the substructure and applying an insulation layer over edge portions of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure and applying a vacuum bag that at least partly encloses the skin, the substructure, and the metal layer. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Method of joining molded or three-dimensional printed parts to thermoplastic composite structures

A system and method for forming a composite part with multiple bends or curves, including placing an unformed composite laminate material onto a flexure and placing the flexure onto an engagement surface of a first forming tool. The flexure is a sheet of bendable material. The first forming tool has a first side surface, the first engagement surface, and a first corner between these surfaces. The flexure may have at least one thinned region aligned with the first corner. The method further includes sealing an impermeable membrane around the unformed composite laminate material, the flexure, and at least a portion of the first forming tool and heating them in an oven or autoclave. The method also includes applying a pressure differential to the impermeable membrane, pressing the unformed composite material and/or the flexure against the first side surface and to press the thinned region against the first corner.

Method for using expendable flexures for forming composite laminates

A method of manufacturing a complex-shaped composite part, including the steps of applying a metallic sheath around a composite laminate workpiece and applying an electric current through the metallic sheath to heat the workpiece. The metallic sheath may be sealed around the composite laminate workpiece, with air or atmosphere evacuated therefrom. The method also includes shaping the workpiece in the metallic sheath into a complex-shaped composite part while it is being heated. The shaping can be performed between two ceramic dies or using other techniques for forming complex shapes and curvatures into the workpiece. The method then may include cooling the complex-shaped composite part and removing the metallic sheath from the complex-shaped composite part. This method minimizes cycle times and reduces breakage of fiber reinforcement of the composite laminate. The method also helps avoid tearing, buckling, or wrinkling of the workpiece during formation via the structural support provided.

Method of forming composites by joule heating of enveloping metallic sheets

A system for fusing thermoplastic composite structures includes a skin and a substructure on an inner surface of the skin. The system also includes a shaping surface of a tool, with the skin laid up on the shaping surface. The shaping surface is configured to maintain the shape of an outer mold line. The system further includes at least one insulation layer applied over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and a vacuum bag at least partly enclosing the skin and the substructure. Heat can be applied to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

System for fusing thermoplastic composite structures

A method for manufacturing a composite part includes forming an initial radius filler on a composite panel. The initial radius filler is formed from a plurality of plies of composite material stacked on the composite panel. The method includes forming a radius of curvature on at least one side of the initial radius filler, positioning a composite stiffener on the composite panel, wherein the composite stiffener is contoured to define a radius gap when joined with the composite panel, positioning the composite stiffener against the at least one side of the initial radius filler, compressing the composite stiffener, composite panel, and initial radius filler via vacuum bag, and heating the initial radius filler to at least one of a cure temperature, a melting temperature, or a fusing temperature to form, from the initial radius filler, a radius gap filler in the radius gap.

Composite parts, and methods of manufacturing

A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.

System and method for promoting inter-ply slippage

A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

Method and apparatus for fabricating reformable stiffening elements

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. An injection device may also move behind the plate and reciprocally inject a polymer between the first and second faying surfaces to provide toughness and crack arresting properties.

System and method for welding thermoplastic components to create composite structure

Tooling, systems, and methods for forming composite parts. The system includes a mold having a first mold portion with a molding surface, a second mold portion with a molding surface, and at least one laminate sheet opening. When the mold is in a closed, molding configuration, the first molding surface and the second molding surface collectively at least partially form an internal cavity defining an outer contour of the composite part. The system also comprises an injection molding nozzle that injects resin into the internal cavity and a laminate sheet supporting frame. The laminate sheet supporting frame supports at least one laminate sheet such that a portion of the at least one laminate sheet is permitted to pass through the at least one laminate sheet opening and conform to at least one of the first molding surface and the second molding surface during the forming of the composite part.

System for forming a composite part

An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

Bulb stiffener with sinusoidal web

A system for peen-forming of thermoplastic composite material is provided. The system includes a tool, a heater, and a peen-forming device. The thermoplastic composite material is positioned on the tool, which supports the thermoplastic composite material as it is being process. The tool has a surface to which a portion of the thermoplastic composite material is intended to conform. The heater is configured to heat the thermoplastic composite material while it is positioned on the tool to make the thermoplastic composite material more malleable. The peen-forming device directs particles against the thermoplastic composite material positioned on the tool so that the portion of the thermoplastic composite material conforms to the surface of the tool.

Peen-forming of thermoplastic composite material

Tooling assembly and pressure vessel thereof for forming composite components such as aircraft stringers and the like. In addition to the pressure vessel, the tooling assembly may include a conveying apparatus and a forming tool for stacking plies on the forming tool and conveying the plies and the forming tool through the pressure vessel. The pressure vessel includes an entrance opening and an exit opening, which are sized and shaped to permit the forming tool supporting the plies to pass through the pressure vessel. The pressure vessel may further include an interior chamber housing multiple spheres. The spheres press against the plies as the forming tool is conveyed through the pressure vessel, thereby pressure treating the plies and forming the composite part.

Continuous manufacturing process for composite parts

A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having a thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.

Growing community of inventors

Sedan, KS, United States of America

Mark Anthony Wadsworth