Method of repairing, splicing, joining, machining, and stabilizing honeycomb core using pourable structural foam and a structure incorporating the same

摘要

A method of the present disclosure includes of repairing a core stiffened structure with structural foam. Another method includes splicing core members together using structural foam. Another method includes joining a core member to a structure using structural foam. Another method includes using structural foam to stabilize a core member during a machining process. Another method includes stabilizing a core member with structural foam to prevent the core member from crushing in autoclave pressure. The present disclosure further includes a core stiffened structure have a core member with structural foam therein.

主权项

1. A method of manufacturing a machined core member, the method comprising:
providing a cavity having a first depth preselected to correlate with a first desired density of an expanded foam and having a second depth preselected to correlate with a second desired density of the expanded foam, the second depth being less than the first depth, and the second desired density being greater than the first desired density; pouring a foam mixture into the cavity and expanding the poured foam mixture to rise upwardly into cells of a stock core member and to become the expanded foam having both the first density and the second density extending laterally across the stock core member, the stock core member being arranged entirely over the cavity during said expanding, and the first and second densities of the foam within the stock core member corresponding to first and second cavity depth locations respectively; and machining the stock core member with the expanded foam in the cells.