Method for fabricating an advanced composite aerostructure article having an integral co-cured fly away hollow mandrel
First Claim
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1. A method of fabricating an article from fiber-reinforced composite material comprising the steps ofassembling on a composite bond jig a first uncured composite layer in the shape of at least one surface of the article, the first composite layer having at least one uncured resin-impregnated laminate layer;
- providing at least one elongated hollow mandrel, the at least one hollow mandrel being of a stiffened graphite fabric having upper, lower and side surfaces and being of a predetermined cross section;
securing on the upper surface of the first composite layer the at least one hollow mandrel with the lower surface thereof in engagement with the upper surface of the first composite layer;
assembling a second uncured composite layer on the bond jig over the upper and side surfaces of the at least one hollow mandrel and at least a portion of the upper surface the first uncured composite layer, the second uncured composite layer having at least one uncured resin-impregnated layer; and
subjecting the lay up assembled on the composite bond jig to a cycle of predetermined pressure and temperature to cure the resin-impregnated layers so as to form a unitary co-cured one-piece article.
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Abstract
An article is made by co-curing a lay up on a composite bond jig of fiber-reinforced composite materials having a lower layer, at least one elongated hollow mandrel of a stiffened graphite fabric having its lower surface adhered to the upper surface of the lower layer, and an upper layer adhered to the top and side surfaces of the hollow mandrel and at least portions of the upper surface of the bottom layer.
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Citations
20 Claims
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1. A method of fabricating an article from fiber-reinforced composite material comprising the steps of
assembling on a composite bond jig a first uncured composite layer in the shape of at least one surface of the article, the first composite layer having at least one uncured resin-impregnated laminate layer; -
providing at least one elongated hollow mandrel, the at least one hollow mandrel being of a stiffened graphite fabric having upper, lower and side surfaces and being of a predetermined cross section;
securing on the upper surface of the first composite layer the at least one hollow mandrel with the lower surface thereof in engagement with the upper surface of the first composite layer;
assembling a second uncured composite layer on the bond jig over the upper and side surfaces of the at least one hollow mandrel and at least a portion of the upper surface the first uncured composite layer, the second uncured composite layer having at least one uncured resin-impregnated layer; and
subjecting the lay up assembled on the composite bond jig to a cycle of predetermined pressure and temperature to cure the resin-impregnated layers so as to form a unitary co-cured one-piece article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of fabricating an article from fiber-reinforced composite material comprising the steps of
providing a first uncured composite layer in the shape of at least one surface of the article, the first composite layer having at least one uncured resin-impregnated laminate layer; -
providing at least one elongated hollow mandrel, the at least one hollow mandrel being of a stiffened graphite fabric having upper, lower and side surfaces and being of a predetermined cross section;
securing on the upper surface of the first composite layer the at least one hollow mandrel with the lower surface thereof in engagement with the upper surface of the first composite layer;
providing a lay up by providing a second uncured composite layer over the upper and side surfaces of the at least one hollow mandrel and at least a portion of the upper surface the first uncured composite layer, the second uncured composite layer having at least one uncured resin-impregnated layer;
inserting in at least one end of the at least one hollow mandrel a tooling block that permits communication of the interior of the at least one hollow mandrel with the exterior of a vacuum bag and which precisely fits within the interior of the end of the at least one hollow mandrel for a predetermined distance;
subjecting the lay up to a cycle of predetermined pressure and temperature to cure the resin-impregnated layers so as to form a unitary co-cured one-piece article; and
removing the tooling block and attaching a mechanical attachment to the end of at least one hollow mandrel that received the tooling block. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification