Abstract: A thermoplastic composition includes a thermoplastic polymer and a polyaryletherketone polymer in admixture with the thermoplastic polymer.

Abstract: A thermoplastic composition includes a thermoplastic polymer and electrically conductive particles dispersed in the thermoplastic polymer.

Abstract: A thermoplastic composition includes a thermoplastic polymer and a polyaryletherketone polymer in admixture with the thermoplastic polymer.

Abstract: A method of manufacturing a composite structure includes accessing design data for the composite structure that is manufactured according to a process including forming a layup of plies of fibers using a machine tool. The method includes applying the design data to an ANN classifier to classify a localized inconsistency of a type of inconsistency on the composite structure, the localized inconsistency spatially referenced to a location on the composite structure. The method includes performing a root cause analysis to identify one or more of process parameters as a potential cause of the type of inconsistency, and modifying one or more of the geometric model, the layup design, or values of the one or more of the process parameters to address the potential cause.

Abstract: Systems and methods are provided for controlling welding. One embodiment is a method for controlling welding. The method includes initiating induction welding by operating an induction coil along a weld interface of a first composite part comprising a matrix of thermoplastic reinforced by fibers, in order to join the first composite part to a second composite part, determining a measured magnetic field strength at a location distinct from the induction coil, and determining a welding temperature at the weld interface of the first composite part based on the measured magnetic field strength.

Abstract: A method for joining a first thermoplastic substrate and a second thermoplastic substrate, each including a polyaryletherketone material having a first melting temperature. The method includes co-consolidating a first semicrystalline thermoplastic film with the first thermoplastic substrate to yield a first co-consolidated structure. The first semicrystalline thermoplastic film defines a first bonding surface of the first co-consolidated structure and includes a polyaryletherketone material having a second melting temperature that is less than the first melting temperature. The method further includes co-consolidating a second semicrystalline thermoplastic film with the second thermoplastic substrate to yield a second co-consolidated structure. The second semicrystalline thermoplastic film defines a second bonding surface of the second co-consolidated structure and includes a polyaryletherketone material having a third melting temperature that is less than the first melting temperature.

Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.

Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.

Abstract: Systems and methods are provided for controlling welding. One embodiment is a method for controlling welding. The method includes initiating induction welding by operating an induction coil along a weld interface of a first composite part comprising a matrix of thermoplastic reinforced by fibers, in order to join the first composite part to a second composite part, determining a measured magnetic field strength at a location distinct from the induction coil, and determining a welding temperature at the weld interface of the first composite part based on the measured magnetic field strength.

Abstract: An apparatus for thermoplastic welding includes at least one tool configured to support first and second thermoplastic composite parts in a first welding position having one or more joint lines between the first and second thermoplastic composite parts. The tool includes a plurality of induction coils. The apparatus further includes a susceptor removably positioned along the one or more joint lines. The susceptor is configured to heat the one or more joint lines when exposed to a magnetic flux generated by the plurality of induction coils to bond the first and second thermoplastic composite parts along the one or more joint lines. The apparatus also includes a susceptor removal device coupled to the susceptor and configured to remove the susceptor during bonding of the first and second thermoplastic composite parts.

Abstract: An elongate thermoplastic composite member is fabricated by a continuous molding process. A pre-consolidated thermoplastic laminate is softened by heating it to a temperature below its melting layup, and is fed substantially continuously through multiple sets of tool dies. The tool dies incrementally mold portions of softened laminate over a mandrel to form the laminate into a shape having a closed cross section.

Abstract: An apparatus for thermoplastic welding includes at least one tool configured to support first and second thermoplastic composite parts in a first welding position having one or more joint lines between the first and second thermoplastic composite parts. The tool includes a plurality of induction coils. The apparatus further includes a susceptor removably positioned along the one or more joint lines. The susceptor is configured to heat the one or more joint lines when exposed to a magnetic flux generated by the plurality of induction coils to bond the first and second thermoplastic composite parts along the one or more joint lines. The apparatus also includes a susceptor removal device coupled to the susceptor and configured to remove the susceptor during bonding of the first and second thermoplastic composite parts.

Abstract: Thermoplastic laminates are fabricated in a continuous compression molding production line. A lay-up of laminate plies is placed in a recess on a carrying tool, and the tool is moved through successive forming operations on the line, including preforming and consolidation operations. The tool is separated from the fully formed part at the end of the line and may be reused. Use of the carrying tool reduces material scrap.

Abstract: A method and apparatus for forming a stiffened thermoplastic panel is presented. The method may comprise placing a number of forming tools within a number of concave areas of a thermoplastic preform. The method may also place the thermoplastic preform with the number of forming tools within the number of concave areas on a thermoplastic lay-up to form a workpiece. The method may also position the workpiece within a tool. The tool may have a number of die liners configured to generate heat in response to a magnetic field. The method may also consolidate the workpiece to form the stiffened thermoplastic panel. Consolidating may comprise applying a magnetic field to the number of die liners to heat the workpiece to a consolidation temperature.

Abstract: Thermoplastic laminates are fabricated in a continuous compression molding production line. A lay-up of laminate plies is placed in a recess on a carrying tool, and the tool is moved through successive forming operations on the line, including preforming and consolidation operations. The tool is separated from the fully formed part at the end of the line and may be reused. Use of the carrying tool reduces material scrap.

Abstract: A method and apparatus is presented. A method may comprise positioning a metallic bladder within a tool, the tool having a number of die liners that generate heat when exposed to a magnetic field; applying the magnetic field to the number of die liners to heat the metallic bladder; and pressurizing the metallic bladder.

Abstract: A device changes the shape of a die used to compression mold a part. The device includes a sleeve placed between the die and a charge to be molded. The sleeve has an inner face generally conforming to a face of the die, and a outer face for molding a part.

Abstract: A fabrication method of forming thermoplastic composite laminate parts with tailored and varying thickness in a continuous process. Automated equipment or hand lay-up are used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.

Abstract: Thermoplastic composite parts having integrated metal fittings are manufactured using a continuous compression molding process. Automated equipment or hand lay-up are used to collate composite material plies and metal fittings into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Multiple lay-ups may be cut from each stack. The lay-ups are placed in tooling containing part features and are continuously fed through a performing station where the lay-ups are preformed into the approximate shape of the finished part. Following pre-forming, the tooling is moved incrementally through a consolidation station where a compression press presses successive sections of the tooling to form a single integrated thermoplastic composite laminate part having integrated metal fittings, which may include areas of differing thickness.

Abstract: A method and apparatus for forming a stiffened thermoplastic panel is presented. The method may comprise placing a number of forming tools within a number of concave areas of a thermoplastic preform. The method may also place the thermoplastic preform with the number of forming tools within the number of concave areas on a thermoplastic lay-up to form a workpiece. The method may also position the workpiece within a tool. The tool may have a number of die liners configured to generate heat in response to a magnetic field. The method may also consolidate the workpiece to form the stiffened thermoplastic panel. Consolidating may comprise applying a magnetic field to the number of die liners to heat the workpiece to a consolidation temperature.