Northrop Grumman Systems Corporation

Orbital Atk, Inc.

Talbot P Thrasher

Timothy E Dominick

Vernon M Benson

Steven J Floyd

Timothy R Stone

Chesley Lane

Eric G Barnes

Kenneth Johnson

Brett A Poor

Clinton R Isaac

Adam Naramore

Michael D Lajczok

Joseph Bellotte

Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing ('AM') (e.g., “3D printing”) with a filament drawn from a spool. The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

Additive manufacturing methods for forming high-temperature composite structures and related structures

A tube element including a first set of spaced apart tape strips helically wound in one direction, and a second set of spaced apart tape strips helically wound in an opposite direction as the first set of tape strips so that the tape strips in the first set periodically cross the tape strips in the second set, where the first and second sets of tape strips define a tube. A set of spaced apart straight tape strips are provided along the length of the tube. An end fitting is secured to an end of the first and second sets of tape strips at one end of the tube, and another end fitting is secured to an end of the first and second sets of tape strips at an opposite end of the tube, where the fittings are configured to be coupled to an end fitting of another tube element.

Tubular support element

A machine for manufacturing tube elements comprised of tape strips. The machine includes a shaft, a disk mounted to one end of the shaft, a motor coupled to an opposite end of the shaft, and a plate mounted to the shaft. The plate includes a plurality of spools mounted to the plate, where a separate one of the strips is wound on each spool. In one embodiment, the machine further includes a rail positioned adjacent to the disk, a slide slidably secured to the rail and including an end support configured to hold ends of the tape strips, and an indexer configured to pull the slide on the rail away from the disk. The tape strips are unwound from the spools when the indexer pulls the slide in a manner so that the tape strips ride in a spaced apart manner around the disk to form the tube element.

Structural tube element fabricator

Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000&#xb0; F. (1093&#xb0; C.)) include forming precursor structures by additive manufacturing ('AM') (e.g., '3D printing'). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

Process for reinforcing continuous fiber additively manufactured laminates

An assembly formed by additive manufacturing comprises a top face sheet, a bottom face sheet, and a core structure between the top face sheet and the bottom face sheet, the core structure comprising a plurality of cells, wherein structural elements of the core structure defining the plurality of cells exhibit at least one electrical property in at least one direction varying from at least one electrical property in a second, different direction and at least one structural property in at least one direction varying from at least one structural property in a second, different direction, wherein at least a portion of the structural elements comprises a radar absorbing structure, the structural elements comprising a matrix material and at least one additive dispersed in or on the matrix material. Related radar absorbing structures and related methods of fabricating the radar absorbing structures are also disclosed.

Assemblies formed by additive manufacturing, radar absorbing structures, and related methods

A thrust-vectoring rocket motor nozzle includes a forward assembly having a forward shell with a flange configured for connection to a motor and a throat portion opposite the flange. A ball joint sleeve may be disposed proximate the throat portion, and an exit cone assembly may include a ball joint socket configured to mate with the ball joint sleeve to allow movement of the exit cone assembly about one or more axes relative to the forward assembly. A thermal barrier may be disposed in a gap between the forward assembly and the exit cone assembly. The forward assembly may include a throat insulator mechanically locked within the forward shell. Related methods include forming thrust-vectorable rocket motor nozzles. Rocket motors may include such nozzles.

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Newark, DE, United States of America

Talbot P Thrasher