Expandable tooling systems and methods

1. A method of manufacturing a composite workpiece, comprising:

adding a thermally-activated expandable element and a heat-generating substance to an internal volume of a constraining container proximate to an uncured composite workpiece supported on a rigid form, the thermally-activated expandable element being configured to expand when a temperature of the element is raised to at least a predetermined temperature;

expanding the thermally-activated expandable element by heating the thermally-activated expandable element to at least the predetermined temperature using the heat-generating substance, so that an expansion of the thermally-activated expandable element applies a resulting pressure to the workpiece supported on the rigid form within the internal volume; and

curing the composite workpiece while the resulting pressure is applied to the workpiece supported on the rigid form.

2. The method of claim 1 , wherein the heat-generating substance is selected to heat the thermally-activated expandable element to at least the predetermined temperature by undergoing an exothermic change of state, or undergoing an exothermic chemical reaction.

3. The method of claim 1 , wherein adding the thermally-activated expandable element includes adding a plurality of expandable pellets, where the expandable pellets are configured to undergo volumetric expansion when heated to at least the predetermined temperature.

4. The method of claim 3 , further comprising adding a lubricating agent to the expandable pellets to decrease adhesion between pellets before and/or after volumetric expansion of the expandable pellets.

5. The method of claim 1 , further comprising inserting a contractible element into the internal volume of the constraining container with the thermally-activated expandable element, the contractible element being configured to volumetrically contract when a predetermined change is produced in an attribute of the contractible element.

6. The method of claim 1 , further comprising inserting a plurality of volumetrically invariant adjuncts into the internal volume of the constraining container with the thermally-activated expandable element.

7. The method of claim 6 , wherein inserting the plurality of volumetrically invariant adjuncts into the internal volume of the constraining container includes combining a plurality of volumetrically invariant beads or rods with the thermally-activated expandable element.

8. The method of claim 1 , further comprising applying a removable barrier film to an outer surface of the uncured composite workpiece before adding the thermally-activated expandable element to the internal volume of the constraining container.

9. A method of manufacturing a composite workpiece, comprising:

adding a thermally-activated expandable element to an internal volume of a constraining container proximate to an uncured composite workpiece supported on a rigid form, the thermally-activated expandable element being configured to expand when a temperature of the element is raised to at least a predetermined temperature, and the thermally-activated expandable element including a plurality of expandable pellets having surface regions of increased crystallinity in order to decrease adhesion between pellets before and/or after volumetric expansion of the expandable pellets;

expanding the thermally-activated expandable element by heating the thermally-activated expandable element to at least the predetermined temperature, so that an expansion of the thermally-activated expandable element applies a resulting pressure to the workpiece supported on the rigid form within the internal volume; and

curing the composite workpiece while the resulting pressure is applied to the workpiece supported on the rigid form.

10. The method of claim 9 , wherein heating the thermally-activated expandable element to at least the predetermined temperature within the internal volume of the constraining container includes externally heating the constraining container.

11. The method of claim 9 , further comprising inserting a contractible element into the internal volume of the constraining container with the thermally-activated expandable element, the contractible element being configured to volumetrically contract when a predetermined change is produced in an attribute of the contractible element.

12. The method of claim 9 , further comprising inserting a plurality of volumetrically invariant adjuncts into the internal volume of the constraining container with the thermally-activated expandable element.

13. The method of claim 9 , further comprising applying a removable barrier film to an outer surface of the uncured composite workpiece before adding the thermally-activated expandable element to the internal volume of the constraining container.

14. A method of repairing a composite component, comprising:

adding a thermally-activated expandable element to an internal volume of a constraining container housing a damaged composite component supported on a rigid form;

inserting a contractible element into the internal volume of the constraining container with the thermally-activated expandable element, the contractible element being configured to volumetrically contract when a predetermined change is produced in an attribute of the contractible element;

positioning the expandable element between the contractible element and the damaged composite component;

expanding the thermally-activated expandable element by heating the thermally-activated expandable element to at least a predetermined temperature; and

curing an uncured composite patch on the damaged composite component within the internal volume of the constraining container while the expanded element applies pressure to the composite component;

effecting the predetermined change in the attribute of the contractible element; and

removing the contracted element and the expanded element from the internal volume of the constraining container.

15. The method of claim 14 , wherein expanding the thermally-activated expandable element by heating the thermally-activated expandable element to at least a predetermined temperature includes producing a predetermined pressure against the damaged composite component when the thermally-activated expandable element is heated to at least the predetermined temperature.

16. The method of claim 14 , wherein adding the thermally-activated expandable element to the internal volume of the constraining container includes adding a plurality of thermally-expandable pellets to the internal volume of the constraining container while the pellets are retained within a flexible bag.

17. The method of claim 14 , wherein heating the thermally-activated expandable element includes heating the thermally-activated expandable element with a heat-generating substance added to the internal volume of the constraining container.

18. The method of claim 14 , wherein the composite component is a composite aircraft component.

19. The method of claim 14 , wherein the step of curing the composite component within the internal volume of the constraining container is carried out in the absence of an autoclave.

20. The method of claim 14 , wherein the contractible element is a bladder containing a fluid.