A plugged stringer on a surface of a part, and a method and assembly for production of the plugged stringer. The plug has opposite first and second axial end faces. The plug also has a radially outer margin defined by a radially outer bottom face, radially outer first and second opposite side faces, and a radially outer top face. The plugged stringer also includes a covering overlaying the radially outer top face and the first and second opposite side faces of the plug and extending away from the plug along an axis to form a stringer having first and second segments delineated by the plug. The radially outer margin of the plug is at least partly covered by an adhesive. The radially outer bottom face is adhered to the surface of the part, and the covering is adhered to the radially outer first and second opposite side faces and the radially outer top face. The first and second segments of the stringer respectively define first and second fluid passages separated by the plug. The first fluid passage is fluidly isolated from the second fluid passage by the plug.
1. A method for co-bonding a plug and a stringer on a surface of a part, the method comprising:
providing a first mandrel having a first end and a length extending along an axis;
providing a second mandrel having a second end and a length extending along the axis;
providing a plug having opposite first and second axial end faces;
joining the first end of the first mandrel with the first axial end face of the plug;
joining the second end of the second mandrel with the second axial end face of the plug, the assembled plug and respective adjacent portions of the first end and the second end together defining a pre-cure plug form;
positioning the first mandrel, the second mandrel and the plug along the surface of the part in substantial alignment with a dimension of the part;
laying a stringer ply over the pre-cure plug form and the remainder of each of the first end and the second end, with the laid stringer ply overlapping the surface of the part; and
curing the stringer ply to create a stringer bisected by the plug.
2. The method of claim 1 , wherein—
the first end of the first mandrel and the first axial end face of the plug comprise complementary shapes that are keyed together to join the first end of the first mandrel with the first axial end face of the plug,
the second end of the second mandrel and the second axial end face of the plug comprise complementary shapes that are keyed together to join the second end of the second mandrel with the second axial end face of the plug.
3. The method of claim 2 , wherein the first end of the first mandrel and the second end of the second mandrel are tapered, and the opposite axial end faces of the plug each form a respective complementarily-shaped socket.
4. The method of claim 3 , wherein the curing includes applying vacuum pressure to the stringer ply, the respective tapered ends of the mandrels substantially supporting the respective sockets of the plug to maintain a shape of the pre-cure plug form throughout the curing within a manufacturing tolerance.
5. The method of claim 1 , wherein, after the curing, the stringer ply exhibits a coefficient of thermal expansion within five percent (5%) of a coefficient of thermal expansion exhibited by the plug.
6. The method of claim 5 , wherein the stringer ply and the plug each comprise carbon fiber material.
7. The method of claim 6 , wherein the first and second mandrels each comprise an elastomeric material.
8. The method of claim 1 , wherein the stringer and the plug each have a cross-sectional shape of a HAT stringer.
9. The method of claim 1 , further comprising removing the first mandrel and the second mandrel from the stringer.
10. The method of claim 1 , wherein—
each of the first mandrel, the second mandrel and the plug has a radially outer margin,
the radially outer margin of each of the first mandrel and the second mandrel is at least partly covered by a nonstick coating,
the radially outer margin of the plug is at least partly covered by an adhesive.