The Boeing Company
COMPOSITE SPARS WITH INTEGRATED SACRIFICIAL SURFACES

Abstract:

Composite assemblies are described that include composite spars that are co-cured with one or more sacrificial members on their flanges, forming an integrated sacrificial surface for the composite spars. In one embodiment, the composite assembly includes a composite spar having a web and flanges that project from sides of the web. The composite assembly further includes a sacrificial member of composite materials co-cured with the composite spar on an outer surface of at least one of the flanges. In addition, the sacrificial member has an outer surface that has been machined into conformance with an inner surface of at least one skin panel for an aircraft structure to form a contact surface with the at least one skin panel.