Abstract: A method for forming a thermoplastic part includes sulfonating a thermoplastic film by exposing the thermoplastic film to a sulfonation fluid to form a sulfonated thermoplastic film and forming the thermoplastic part with a plurality of stacked thermoplastic film layers. The plurality of stacked thermoplastic film layers include at least one sulfonated thermoplastic film layer of the sulfonated thermoplastic film and a plurality of unsulfonated thermoplastic film layers. The at least one sulfonated thermoplastic film layer forms a first exterior thermoplastic film surface of the thermoplastic part.

Abstract: An apparatus and method for welding a thermoplastic composite component is provided. The apparatus includes a tool and a power source. The tool includes a heating device energized by the power source and a susceptor spaced from the heating device. The susceptor is configured for use in welding thermoplastic composite material and has a Curie temperature close to a susceptor temperature specified to be used during welding. The susceptor is disposed on the tool and includes a susceptor length extending longitudinally along the tool. The heating device is configured to induce an electromagnetic field within a susceptor length first portion and second portion. The heating device is configured to heat the first portion to the susceptor temperature and heat the second portion to a second temperature different than the susceptor temperature. The heating device longitudinally overlaps the first portion.

Abstract: A method for applying a sulfonation treatment to a thermoplastic part includes installing a gas sulfonation assembly on one or more surfaces of the thermoplastic part by forming a vacuum bag on the one or more surfaces. The vacuum bag forms a sealed cavity between the vacuum bag and a treatment portion of the one or more surfaces. The method further includes drawing a vacuum in the sealed cavity with the gas sulfonation assembly, directing a sulfonating gas into the sealed cavity with the gas sulfonation assembly to sulfonate the treatment portion, removing the sulfonating gas from the sealed cavity with the gas sulfonation assembly, removing the gas sulfonation assembly from the thermoplastic part, applying a neutralizing agent to the treatment portion, and applying at least one coating to the treatment portion.

Abstract: A formation method is provided. During the method, a thermoplastic composite (TPC) skin and a lightning strike protection (LSP) layer are provided. The TPC skin is arranged with the LSP layer on a tool to provide a material stack, and the material stack is consolidated to form a consolidated TPC structure. A thin film (TF) layer on the consolidated TPC structure using a plasma treatment process. The LSP layer may be configured as or otherwise include LSP material, and the TF layer may include a TF material configured as or otherwise including an amine functional group or an epoxy functional group.

Abstract: A method is provided during which a first thermoplastic body is provided. The first thermoplastic body includes first fiber-reinforcement with a first electrical conductivity. A second thermoplastic body is provided. The second thermoplastic body includes second fiber-reinforcement with a second electrical conductivity that is greater than the first electrical conductivity. The second thermoplastic body is arranged with the first thermoplastic body. The second thermoplastic body is induction welded to the first thermoplastic body using an induction welding coil. The second thermoplastic body is arranged between the first thermoplastic body and the induction welding coil.

Abstract: A thermoplastic part for an aircraft includes a thermoplastic skin, a conductive metal layer, a thermoplastic resin film, and a paint coating. The thermoplastic skin includes an inner skin side and an outer skin side. The conductive metal layer includes an inner layer side and an outer layer side. The inner layer side is disposed at the outer skin side of the thermoplastic skin. The thermoplastic resin film including an inner film side and an outer film side. The inner film side is disposed at the outer layer side of the conductive metal layer. The thermoplastic resin film includes a sulfonated thermoplastic resin material forming a sulfonated region of the thermoplastic resin film at the outer film side. The paint coating is disposed on the outer film side of the thermoplastic resin film coincident with the sulfonated region.

Abstract: A method for applying a sulfonation treatment to a thermoplastic part includes forming a sulfonation barrier on the thermoplastic part by applying a sealant tape onto the thermoplastic part, applying a sulfonation fluid to a portion of a thermoplastic surface of the thermoplastic part to sulfonate the thermoplastic part at the thermoplastic surface, removing the sulfonation fluid from the portion of the thermoplastic surface, applying a neutralizing agent to the portion of the thermoplastic surface, washing the portion of the thermoplastic surface, and applying at least one coating to the portion of the thermoplastic surface.

Abstract: A method for applying a sulfonation treatment to a thermoplastic part includes installing a gas sulfonation assembly on one or more surfaces of the thermoplastic part by forming a vacuum bag on the one or more surfaces. The vacuum bag forms a sealed cavity between the vacuum bag and a treatment portion of the one or more surfaces. The method further includes drawing a vacuum in the sealed cavity with the gas sulfonation assembly, directing a sulfonating gas into the sealed cavity with the gas sulfonation assembly to sulfonate the treatment portion, removing the sulfonating gas from the sealed cavity with the gas sulfonation assembly, removing the gas sulfonation assembly from the thermoplastic part, applying a neutralizing agent to the treatment portion, and applying at least one coating to the treatment portion.

Abstract: A method is provided during which a first thermoplastic body is provided. The first thermoplastic body includes first fiber-reinforcement with a first electrical conductivity. A second thermoplastic body is provided. The second thermoplastic body includes second fiber-reinforcement with a second electrical conductivity that is greater than the first electrical conductivity. The second thermoplastic body is arranged with the first thermoplastic body. The second thermoplastic body is induction welded to the first thermoplastic body using an induction welding coil. The second thermoplastic body is arranged between the first thermoplastic body and the induction welding coil.