Blade stringer forming methods and tooling

1 . A forming and curing tool for a blade stringer, wherein the forming and curing tool comprises:

a forming lid;

a stiffener connected to and perpendicular to the forming lid;

a number of flexible bladders surrounding the stiffener;

a first die and a second die configured to:

clamp cut and kitted materials; and

engage with the forming lid; and

a wedge connected to the stiffener and configured to spread the cut and kitted materials.

2 . The forming and curing tool of claim 1 , wherein the wedge has a geometry of a noodle to be placed in the blade stringer.

3 . The forming and curing tool of claim 1 , wherein the wedge is inflatable.

4 . The forming and curing tool of claim 1 , wherein the stiffener is porous.

5 . The forming and curing tool of claim 1 , wherein the number of flexible bladders comprises a number of air paths for compacting components of a blade stringer.

6 . The forming and curing tool of claim 1 , further comprising a number of seals on the forming lid configured to seal the forming lid to the first die and the second die.

7 . The forming and curing tool of claim 6 , further comprising a forming chamber formed between the forming lid and the first die and the second die.

8 . The forming and curing tool of claim 7 , further comprising:

a press configured to hold and move the first die and the second die, and the forming lid relative to each other.

9 . A forming and curing tool for a blade stringer, wherein the forming and curing tool comprises:

a first die with a number of vacuum paths through the first die and a first forming surface, wherein the first forming surface comprises:

a first blade face; and

a first flange face;

a second die with a number of vacuum paths and a second forming surface, wherein the second forming surface comprises:

a second blade face; and

a second flange face;

the second die and the first die configured to clamp cut and kitted materials between the first forming surface and the second forming surface; and

a number of flexible bladders positioned above the first die and the second die, connected to a stiffener connected to and perpendicular to a forming lid;

a wedge connected to the stiffener and configured to spread the cut and kitted materials, wherein the number of flexible bladders are configured to simultaneously form the number of cut and kitted materials and then simultaneously compress a first cut and kitted material of the number of cut and kitted materials against the first flange face and a second cut and kitted material of the number of cut and kitted materials against the second flange face.

10 . The forming and curing tool of claim 9 , wherein the stiffener connects the forming lid and the number of flexible bladders.

11 . The forming and curing tool of claim 10 , wherein the wedge having a geometry of a noodle is joined into the blade stringer.

12 . The forming and curing tool of claim 9 , further comprising a tool lid configured to seal against the first die and the second die to create a curing chamber.

13 . The forming and curing tool of claim 12 , wherein the tool lid comprises a number of resin inlets.

14 . The forming and curing tool of claim 9 , wherein the first die and the second die are integrally heated.

15 . The forming and curing tool of claim 9 , further comprising:

a press configured to hold and move: the first die, the second die, and the number of flexible bladders relative to each other.

16 . A forming and curing tool for a blade stringer, wherein the forming and curing tool comprises:

a first die with a first forming surface comprising a first blade face and a first flange face and a number of vacuum paths through the first die;

a second die with a number of vacuum paths and a second forming surface comprising a second blade face and a second flange face, the second die configured to clamp a number of cut and kitted materials between the first blade face and the second blade face for forming a number of cut and kitted materials against the first flange face and the second flange face;

a forming lid configured to seal against the first die and the second die to create a curing chamber;

a stiffener connected to and perpendicular to the forming lid;

a number of flexible bladders surrounding the stiffener; and

a wedge connected to the stiffener and configured to spread the cut and kitted materials.

17 . The forming and curing tool of claim 16 , wherein the forming lid comprises a number of resin inlets.

18 . The forming and curing tool of claim 16 , wherein the forming lid is configured to seal against the first die and the second die to create a forming chamber.

19 . The forming and curing tool of claim 16 , further comprising:

a press configured to hold and move the first die, the second die, and the forming lid relative to each other.

20 . A method of forming a blade stringer, the method comprising:

placing a first cut and kitted material against a second cut and kitted material and clamping them together between a first die and a second die;

driving, with a forming lid connected to a stiffener between flexible bladders, a wedge connected to the stiffener between the first cut and kitted material against the second cut and kitted material;

forming the first cut and kitted material onto a first flange face of a first forming surface on the first die and forming the second cut and kitted material onto a second flange face of a second forming surface on the second die while the first cut and kitted material and the second cut and kitted material are clamped between the first forming surface and the second forming surface;

inflating the flexible bladders and compacting the first cut and kitted material against the first forming surface and the second cut and kitted material against the second forming surface; and

curing, while the composite stringer preform is against the first forming surface and the second forming surface, a composite stringer preform and forming the blade stringer, the composite stringer preform comprising the first cut and kitted material, the second cut and kitted material, a noodle, and a base material.

21 . A method of forming a blade stringer, the method comprising:

clamping a first cut and kitted material and a second cut and kitted material between a first die and a second die;

driving, with a forming lid connected to a stiffener between flexible bladders, a wedge connected to the stiffener between the first cut and kitted material against the second cut and kitted material;

forming, while the first cut and kitted material and the second cut and kitted material are clamped, by inflating one of the flexible bladders and pressing the first cut and kitted material and the second cut and kitted material against the first die and simultaneously inflating a second of the flexible bladders and pressing the second cut and kitted material against the second die;

applying a noodle and base material over the first cut and kitted material and second cut and kitted material; and

curing a composite stringer preform comprising the first cut and kitted material, the second cut and kitted material, the noodle, and the base material while the composite stringer preform is against the first die and the second die.

22 . A method of forming a blade stringer comprising:

clamping a first end of a first cut and kitted material and a first end of a second cut and kitted material together to form blade portions;

separating, using a wedge connected to a stiffener between flexible bladders and connected to a forming lid, a second end of the first cut and kitted material and a second end of the second cut and kitted material;

forming, by inflating one of the flexible bladders, the second end of the first cut and kitted material into a first flange portion with a formed radius and forming, by simultaneously inflating a second of the flexible bladders, the second end of the second cut and kitted material into a second flange portion with a formed radius;

applying a noodle between the formed radius of the first cut and kitted material and the formed radius of the second cut and kitted material; and

placing a base material over the second end of the first cut and kitted material, the noodle, and the second end of the second cut and kitted material.

23 . A forming and curing tool for a blade stringer, wherein the forming and curing tool comprises:

a first die with a first forming surface that comprises a first blade face and a first flange face;

a second die with a second forming surface that comprises a second blade face and a second flange face, the second die and the first die configured to clamp a number of cut and kitted materials between the first forming surface and the second forming surface;

a stiffener connected to and perpendicular to a forming lid;

a number of flexible bladders surrounding the stiffener;

a wedge connected to the stiffener and configured to spread the cut and kitted materials, wherein the stiffener, the flexible bladders, and the wedge, are positioned above the first die and the second die and configured to simultaneously form the number of cut and kitted materials and then simultaneously compress a first cut and kitted material of the number of cut and kitted materials against the first flange face and a second cut and kitted material of the number of cut and kitted materials against the second flange face;

a tool lid configured to seal against the first die and the second die to create a curing chamber; and

a press configured to hold and move the first die, the second die, the forming device, and the tool lid relative to each other.

24 . A method of forming a blade stringer, the method comprising:

clamping a first end of a first cut and kitted material and a first end of a second cut and kitted material together between a first die and a second die to form blade portions;

forming flanges, by driving, with a forming lid connected to a stiffener between flexible bladders, a wedge connected to the stiffener between the first cut and kitted material against the second cut and kitted material, respective radiuses into the first cut and kitted material and the second cut and kitted material at the same time while maintaining the clamping;

compacting the first cut and kitted material and the second cut and kitted material after forming the flanges;

applying a noodle and a base material onto the first cut and kitted material and the second cut and kitted material;

compacting the noodle and the base material on the first cut and kitted material and the second cut and kitted material; and

curing first cut and kitted material, the second cut and kitted material, the noodle, and the base material while the blade portions are clamped.

25 . A method of forming a blade stringer, the method comprising:

clamping a blade of the blade stringer between a first die and a second die;

driving, with a forming lid connected to a stiffener between flexible bladders, a wedge connected to the stiffener between the first cut and kitted material against the second cut and kitted material and simultaneously forming flange portions of the blade stringer onto the first die and the second die while the blade is clamped; and

curing a composite stringer preform comprising the blade and the flange portions while the blade and the flange portions are in contact with the first die and the second die.