Systems and methods for sealing a bond cavity between structural components

A method of sealing a bond cavity, the method comprising:

• placing, by one or more robotic devices using an injection nozzle, an adhesive around a perimeter of a first structure to be joined to a second structure, wherein the first structure is a stringer of a wing of an aircraft and the second structure is a wing skin;
• positioning, by the one or more robotic devices, the first structure relative to the second structure such that the adhesive is disposed between the first structure and the second structure;
• merging, by the one or more robotic devices, the first structure and the second structure until the first structure and the second structure are separated by a desired gap for bonding;
• heating the perimeter to at least partially cure the adhesive to form a leak-proof bond cavity perimeter between the first structure and the second structure;
• performing a set of tests to check for leaks from the leak-proof bond cavity perimeter between the first structure and the second structure, wherein performing the set of tests to check for leaks involves at least a first test comprising injecting a gas into the leak-proof bond cavity to detect for leaks and a second test to check for leaks that differs from the first test;
• based on the set of tests indicating that the leak-proof bond cavity perimeter does not leak, evacuating a cavity formed between the first structure, the second structure, and the leak-proof bond cavity perimeter;
• puncturing a small hole proximate the cavity using a hypodermic needle;
• forcing a de-aerated adhesive into the cavity via the hypodermic needle, wherein the de-aerated adhesive is an adhesive paste with bubbles evacuated;
• and
• curing the adhesive forced into the cavity.