The Boeing Company

Remmelt Andrew Staal

Justin H Register

Arne Kenneth Lewis

Gary D Oakes

Gregory Jonathon Smith

Blake Anthony Bertrand

Narbeh Nersessian

John F Spalding, Jr

Pradeep Krishnaswamy

Jay Patel

Larry Dean Ridgeway

Ernie Fidgeon

Glory C Edwards

Ryan C Schwartz

Michael J Caprini

Cezar Chirila

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 method of making a reinforcement part for a vehicle includes applying a release film directly onto a surface of the vehicle, applying a first metallic layer directly or indirectly onto the release film, applying a curable bonding layer directly onto the first metallic layer, and applying a second metallic layer directly onto the curable bonding layer. The method also includes applying pressure to the first metallic layer, the curable bonding layer, and the second metallic layer so that the first metallic layer, the curable bonding layer, and the second metallic layer are compressed against the surface. The method further includes curing the curable bonding layer when pressure is applied to the curable bonding layer to form the reinforcement part. The method additionally includes, after curing the curable bonding layer, removing the reinforcement part from the surface.

Methods of making a reinforcement part and reinforcing a vehicle

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

Composite laminates fabricated from one or more respective laminae of composite material (e.g., fiber-reinforced polymers) may be pre-formed and fully cured, yet configured to be selectively conformable to a desired radius of curvature. To repair a damaged composite structure, a plurality of such composite laminates may be bonded together to form a repair part that may be bolted to or otherwise secured to the damaged composite structure, thereby repairing the structure using repair parts that may match the parent material of the damaged composite structure. Methods of forming said repair parts from a plurality of such composite laminates may provide advantages in costs and lead time, over conventional techniques. Kits may include a plurality of such pre-formed and cured composite laminates that may be stacked and combined together in a plurality of different arrangements to create a customizable repair part for a given damaged composite structure.

Methods of fabrication of composite repair parts and related kits

The present disclosure provides a method of repairing a hat stringer. The method includes arranging a repair stringer in a mounting location that is one of a plurality of possible mounting locations along a cross section of a hat stringer. In each of the plurality of possible mounting locations, at least a portion of an internal profile of the repair stringer matches at least a portion of a profile of an internal cavity defined by the hat stringer. A cross-sectional area of the repair stringer as viewed along a first direction is less than a total cross-sectional area of the hat stringer as viewed along the first direction. The method also includes coupling the repair stringer with a stringer of the hat stringer in the mounting location. Repair stringers and repaired hat stringers are also provided.

Repairing a hat stringer

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

Disclosed herein is a method of repairing damage to a fuselage barrel, having a one-piece construction, of an aircraft. The method includes determining at least a first virtual splice line and a second virtual splice line along the fuselage barrel in a direction parallel to a longitudinal axis of the fuselage barrel. The method also includes detecting damage in a first section of the fuselage barrel between the first virtual splice line and the second virtual splice line. The method further includes cutting through the fuselage barrel along the first virtual splice line and the second virtual splice line to physically separate the first section from a main section of the fuselage barrel. The method also includes removing the first section from the main section of the fuselage barrel, and splicing a new section to the main section of the fuselage barrel in place of the first section.

Method of repairing damage to fuselage barrel and associated apparatus and system

An apparatus is provided for analysis of a repair for a structure by identifying component parts of the structure that have common material properties and geometric constraints, and based thereon determining a generic repair component for the component parts that also have the common material properties and the geometric constraints. A set of loads are extracted from a loads model of the undamaged structure and redistributed in a loads redistribution model at a damaged or defective portion of the component part. The set of redistributed loads indicate loading incurred by the generic repair component under an external load. The apparatus then uses the redistributed loads to perform an analysis to determine a margin of safety of the generic repair component and, in instances in which the margin of safety is positive, outputs the material properties and geometric constraints of the generic repair component to a fabrication system for production thereof.

Growing community of inventors

Shoreline, WA, United States of America

Remmelt Andrew Staal