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 manufacturing a composite structure, including expanding a foam mixture in desired cells of a core member until the foam mixture becomes an expanded foam without expanding the foam mixture into undesired cells of the core member, machining the core member, laying a composite skin onto a surface of the core member, and curing the composite skin with heat and pressure. The core member may be machined so that a ramp portion thereof contains the expanded foam in the cells.