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A method for fabricating a one-piece composite fuselage section that minimizes out-of-plane fiber distortion. This is accomplished by fabricating a mandrel having a coefficient of thermal expansion in the hoopwise direction that is sufficiently greater than that of the laid-up composite ply assembly

A method for fabricating a one-piece composite fuselage section that minimizes out-of-plane fiber distortion. This is accomplished by fabricating a mandrel having a coefficient of thermal expansion in the hoopwise direction that is sufficiently greater than that of the laid-up composite ply assembly. As a result of this differential in the coefficients of thermal expansion in the hoopwise direction, the laid-up composite ply assembly is stretched circumferentially as the mandrel expands radially during cure, thereby eliminating or reducing out-of-plane fiber distortion. At the same time, the mandrel and part being fabricated should have substantially the same coefficient of thermal expansion in the lengthwise direction. As the outer surface of the mandrel increases in circumference, the circumferentially oriented reinforcing fibers of the inner plies are stretched, while the circumferentially oriented reinforcing fibers of the outer plies do not reduce in circumference and thus do not form waves or wrinkles.

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1. A method for fabricating a one-piece composite barrel section, comprising the following steps: (a) molding a plurality of mandrel segments made of composite material, each mandrel segment having a plurality of longitudinal grooves on its outer circumferential surface, each groove having a contour

1. A method for fabricating a one-piece composite barrel section, comprising the following steps: (a) molding a plurality of mandrel segments made of composite material, each mandrel segment having a plurality of longitudinal grooves on its outer circumferential surface, each groove having a contoured profile in cross section determined by axial ribs on an interior surface of a mold, the mandrel segments being made of composite material comprising reinforcing fibers that follow the contours of the grooves in a manner that increases the coefficient of thermal expansion in a hoopwise direction in the areas of the grooves as compared to the coefficient of thermal expansion in the hoopwise direction in ungrooved areas of the mandrel;(b) separating each mandrel segment from the mold interior surface;(c) arranging the plurality of mandrel segments to form a mandrel;(d) laying a composite ply assembly around the mandrel; and(e) raising the temperature and pressure within a volume surrounding the composite ply assembly, the temperature increase being sufficient to cause the circumference of said mandrel to expand,the mandrel and the composite ply assembly having a not insubstantial difference in coefficients of thermal expansion in a hoopwise direction and an insubstantial difference in coefficients of thermal expansion in a lengthwise direction, the coefficient of thermal expansion of the mandrel in said hoopwise direction being greater than the coefficient of thermal expansion of said composite ply assembly in said hoopwise direction such that one or more plies of the composite ply assembly is stretched during step (e). 2. The method as recited in claim 1, further comprising the steps of: lowering the temperature and pressure within the volume; andseparating the mandrel from the composite ply assembly after the latter has cooled. 3. The method as recited in claim 1, wherein during and after expansion, the circumference of one or more outermost plies of the composite ply assembly does not decrease by an amount sufficient to cause significant waviness or wrinkling in the composite ply assembly. 4. The method as recited in claim 1, wherein during expansion, the mandrel and the composite ply assembly expand in a lengthwise direction by substantially the same amount. 5. The method as recited in claim 1, wherein layup comprises the following steps: (i) placing a portion of a respective hat stringer in a respective one of said plurality of grooves, each hat stringer being made of multiple plies of composite material;(ii) placing a respective bladder in said portion of said respective hat stringer after step (i) has been performed;and(iii) laying multiple plies of composite material around the outer circumferential surface of the mandrel and the bladders. 6. The method as recited in claim 1, wherein each ply of the composite ply assembly comprises reinforcing fibers or fabric and polymeric material. 7. The method as recited in claim 1, wherein an outer circumferential portion of the mandrel comprises reinforcing fabric and polymeric material. 8. The method as recited in claim 1, further comprising the following steps, performed after step (a) and before step (b): surrounding the composite ply assembly with a sealed air-impermeable sheet to form an evacuable space; andevacuating the evacuable space. 9. The method as recited in claim 1, wherein step (a) comprises: laying a composite ply assembly on an interior surface of a mold having a plurality of axial ribs spaced at angular intervals and extending in generally lengthwise directions; andcuring the composite ply assembly while in contact with the interior surface of the mold to form a segment of a mandrel. 10. A method for fabricating a one-piece composite barrel section, comprising the following steps: (a) molding a plurality of mandrel segments made of composite material, each mandrel segment having a plurality of longitudinal grooves on its outer circumferential surface determined by axial ribs on an interior surface of a mold, each groove having a contoured profile in cross section, the mandrel segments being made of composite material comprising reinforcing fibers that follow the contours of the grooves in a manner that increases the coefficient of thermal expansion in a hoopwise direction in the areas of the grooves as compared to the coefficient of thermal expansion in the hoopwise direction in ungrooved areas of the mandrel;(b) separating each mandrel segment from the mold interior surface;(c) arranging the plurality of mandrel segments to form a mandrel;(d) laying a composite ply assembly around the mandrel; and(e) raising the temperature and pressure within a volume surrounding the composite ply assembly, the temperature increase being sufficient to cause the circumference of the mandrel to expand, which in turn causes the length of reinforcing fibers in one or more plies of the composite ply assembly to increase due to a difference in the coefficients of thermal expansion of the mandrel and the composite ply assembly in the hoopwise direction. 11. The method as recited in claim 10, further comprising the steps of: lowering the temperature and pressure within the volume; andseparating the mandrel from the composite ply assembly after the latter has cooled. 12. The method as recited in claim 10, wherein during and after expansion, the length of reinforcing fibers in one or more outermost plies of the composite ply assembly does not decrease by an amount sufficient to cause significant waviness or wrinkling in the composite ply assembly. 13. The method as recited in claim 10, wherein during expansion, the mandrel and the composite ply assembly expand in a lengthwise direction by substantially the same amount. 14. The method as recited in claim 10, wherein layup comprises the following steps: (i) placing a portion of a respective hat stringer in a respective one of said plurality of grooves, each hat stringer being made of multiple plies of composite material;(ii) placing a respective bladder in said portion of said respective hat stringer after step (i) has been performed;and (iii) laying multiple plies of composite material around the outer circumferential surface of the mandrel and the bladders. 15. The method as recited in claim 10, wherein an outer circumferential portion of the mandrel comprises reinforcing fabric and polymeric material. 16. The method as recited in claim 10, wherein step (a) comprises: laying a composite ply assembly on an interior surface of a mold having a plurality of axial ribs spaced at angular intervals and extending in generally lengthwise directions; andcuring the composite ply assembly while in contact with the interior surface of the mold to form a segment of a mandrel. 17. A method for fabricating a one-piece composite barrel section, comprising the following steps: fabricating a mandrel having a plurality of longitudinal grooves on its outer circumferential surface by laying a composite ply assembly on an interior surface of a mold having a plurality of axial ribs spaced at angular intervals and extending in generally lengthwise directions, and then curing the composite ply assembly while in contact with the interior surface of the mold, each groove in the mandrel having a contoured profile in cross section, the mandrel being made of composite material comprising reinforcing fibers that follow the contours of the grooves in a manner that increases the coefficient of thermal expansion in a hoopwise direction in the areas of the grooves as compared to the coefficient of thermal expansion in the hoopwise direction in ungrooved areas of the mandrel;removing the mandrel from the mold;laying a composite ply assembly around the mandrel; andraising the temperature and pressure within a volume surrounding the composite ply assembly, the temperature increase being sufficient to cure the composite ply assembly and cause the circumference of said mandrel to expand,the mandrel and the composite ply assembly having a not insubstantial difference in coefficients of thermal expansion in a hoopwise direction and an insubstantial difference in coefficients of thermal expansion in a lengthwise direction, the coefficient of thermal expansion of the mandrel in said hoopwise direction being greater than the coefficient of thermal expansion of said composite ply assembly in said hoopwise direction such that one or more plies of the composite ply assembly is stretched during curing. 18. A method for fabricating a one-piece composite barrel section, comprising the following steps: (a) arranging a plurality of composite mandrel segments to form a composite mandrel comprising alternating first mandrel portions and second mandrel portions arranged along a circumference of said mandrel, said first mandrel portions comprising plies lying in circumferential planes and said second mandrel portions comprising plies lying in planes disposed parallel to a longitudinal axis of said mandrel and perpendicular to the circumferential planes;(b) laying a composite ply assembly comprising plies around the mandrel; and(c) raising the temperature and pressure within a volume surrounding the composite ply assembly, the temperature increase being sufficient to cure the composite ply assembly,the mandrel and the composite ply assembly having a not insubstantial difference in coefficients of thermal expansion in a hoopwise direction and an insubstantial difference in coefficients of thermal expansion in a lengthwise direction, the coefficient of thermal expansion of the mandrel in said hoopwise direction being greater than the coefficient of thermal expansion of said composite ply assembly in said hoopwise direction such that one or more plies of the composite ply assembly is stretched during curing. 19. The method as recited in claim 18, wherein said second mandrel portions comprise respective lips of said mandrel segments. 20. The method as recited in claim 18, wherein said second mandrel portions comprise respective spacing blocks disposed between adjacent mandrel segments.