System and method for manufacturing monolithic structures using expanding internal tools

摘要

A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

主权项

1. A method of manufacturing a composite article, comprising;
providing an outer mold line (OML) tool having an OML tool surface; loading an inner mold line (IL) tool within the OML tool encapsulating the IML tool, the IML tool having an IML tool surface having a hollow internal shell and a layer of expandable material on at least a portion of an exterior of the hollow internal shell; providing a composite assembly between the OML tool surface and the IML tool surface, the OML tool having a gas flow channel extending from the OML tool surface to an exterior of the OML tool; applying a vacuum bag over a portion of the OML tool at a location of the gas flow channel; drawing a vacuum on the vacuum bag; heating the layer of expandable material to cause expansion thereof, drawing at least one of air, gas, and volatiles through the gas flow channel from the tool interior to the exterior of the OML tool using the vacuum drawn on the vacuum bag; and applying, using the IML tool, an internal compaction pressure on the composite assembly against the OML tool surface during the expansion of the layer of expandable material.