Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).

Abstract: An induction welding assembly and inductive welding method is disclosed. A tooling block includes a workpiece zone, a conductive heat generation and transfer member, and a heat shield, with the conductive heat generation and transfer member being disposed between the workpiece zone and the heat shield. A first workpiece and a second workpiece may be disposed within the workpiece zone such that the first workpiece is disposed between the conductive heat generation and transfer member and the second workpiece. The heat shield, conductive heat generation and transfer member, first workpiece, and second workpiece may be pressed together. An induction coil may be positioned in spaced relation to the heat shield and may be operated to heat the conductive heat generation and transfer member. Heat is conductively transferred by the conductive heat transfer member to the first workpiece to weld the first workpiece and the second workpiece together.

Abstract: Methods and apparatus' for induction welding a first workpiece to a second workpiece at a welding region may include a metallic strip. The metallic strip may be a mesh. The properties of the metallic strip, such as, for example, pore size, thickness, and density, may be configured to conduct heat uniformly across the welding region and prevent eddy current formation across a workpiece. The metallic strip may be embedded in a workpiece or may be fixed to an induction welding tool that acts on the welding region during induction welding. A removable polymer tape may be disposed between a workpiece and a metallic strip fixed to an induction welding tool. The workpieces may be thermoplastic composite structures and thermoplastic composite stiffeners in aircraft structures.

Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).

Abstract: During a manufacturing method, an induction welder is provided that includes a concentrator and a coil extending through a receptacle in the concentrator. The receptacle projects into the concentrator from a face surface of the concentrator. A first thermoplastic body arranged with a second thermoplastic body are provided. The first thermoplastic body is located next to the face surface. The first thermoplastic body is induction welded to the second thermoplastic body to provide a weld seam between the first thermoplastic body and the second thermoplastic body. The concentrator extends along a portion of the weld seam. The induction welding includes: generating an electromagnetic field with the coil; and concentrating a portion of the electromagnetic field with the concentrator onto a region of the first thermoplastic body.

Abstract: An assembly is provided for induction welding. This assembly utilizes a plurality of heat shields (e.g., mica heat shields) that are aligned/disposed in end-to-end relation, with each such heat shield having a recess. An induction welding coil may be disposed within a heat shield recess during induction welding operations and is movable along a welding path while proceeding along the recesses of the various heat shields. This welding path may be axially extending or may be curved. The induction welding assembly may be used to induction weld a stiffener to a curved skin or shell, for instance where a base of the recess for each heat shield is curved such that the induction welding coil may be moved along a curved welding path and while maintaining a constant spacing between the induction welding coil and the recess base of the various heat shields.

Abstract: An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.

Abstract: A tacking device may comprise: a handle; a main body extending from a first end of the handle to a second end of the handle; and a plurality of soldering irons, each soldering iron in the plurality of soldering irons extending from a first side of the main body through the main body to a second side of the main body, each soldering iron in the plurality of soldering irons including a piercing end disposed on the second side of the main body.

Abstract: An assembly is provided for induction welding. This induction welding assembly includes a fixture. The fixture includes a first support structure and a second support structure. The second support structure includes a frame and a plurality of trunks. Each of the trunks is connected to and repositionable on the frame. The fixture is configured to secure a workpiece vertically between the first support structure and the second support structure using the trunks during induction welding of the workpiece.

Abstract: A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.

Abstract: A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

Abstract: Methods and apparatus' for induction welding a first workpiece to a second workpiece at a welding region may include a metallic strip. The metallic strip may be a mesh. The properties of the metallic strip, such as, for example, pore size, thickness, and density, may be configured to conduct heat uniformly across the welding region and prevent eddy current formation across a workpiece. The metallic strip may be embedded in a workpiece or may be fixed to an induction welding tool that acts on the welding region during induction welding. A removable polymer tape may be disposed between a workpiece and a metallic strip fixed to an induction welding tool. The workpieces may be thermoplastic composite structures and thermoplastic composite stiffeners in aircraft structures.

Abstract: During a manufacturing method, an induction welder is provided that includes a concentrator and a coil. The concentrator includes a receptacle and a face surface. The receptacle projects vertically into the concentrator from the face surface to an end of the receptacle. The receptacle extends laterally within the concentrator between opposing sides of the receptacle. The receptacle extends longitudinally within the concentrator along a centerline. The coil is seated and extends longitudinally along the centerline within the receptacle. A first thermoplastic body arranged with a second thermoplastic body are provided. The first thermoplastic body is located vertically next to the face surface. The first thermoplastic body is induction welded to the second thermoplastic body. The induction welding includes: generating an electromagnetic field with the coil; and concentrating the electromagnetic field with the concentrator onto a region of the first thermoplastic body.

Abstract: Systems and methods for induction welding a stiffener to a thermoplastic composite structure using a removeable metal mask to reduce excess heat along the edges of the stiffener generated from an electromagnetic field of an induction welding tool.

Abstract: During a manufacturing method, an induction welder is provided that includes a concentrator and a coil extending through a receptacle in the concentrator. The receptacle projects into the concentrator from a face surface of the concentrator. A first thermoplastic body arranged with a second thermoplastic body are provided. The first thermoplastic body is located next to the face surface. The first thermoplastic body is induction welded to the second thermoplastic body to provide a weld seam between the first thermoplastic body and the second thermoplastic body. The concentrator extends along a portion of the weld seam. The induction welding includes: generating an electromagnetic field with the coil; and concentrating a portion of the electromagnetic field with the concentrator onto a region of the first thermoplastic body.

Abstract: An assembly is provided for induction welding. This assembly utilizes a heat shield (e.g., a mica heat shield) with a recess. An induction welding coil may be disposed within this heat shield recess during induction welding operations. The wall thickness of the heat shield within the recess may be reduced to enhance heat transfer to a workpiece during induction welding operations. Members may engage the heat shield on opposite sides of the recess (and that have an increased wall thickness) to support both the heat shield and the workpiece during induction welding operations, during which a biasing force may be exerted on both the heat shield and workpiece.

Abstract: A system and method for welding thermoplastic components is provided. The system includes a component positioning system and a welding subsystem. The component positioning system includes a trailing force applicator having first and second lateral side trailing force applicators disposed on opposite lateral sides of a weld line. The welding subsystem is configured to weld the thermoplastic components together at a weld zone. The first and second lateral side trailing force applicators are laterally spaced apart from the weld zone, and at least a portion of the first and second lateral side trailing force applicators are disposed aft of the weld zone. During welding the first and second lateral side trailing force applicators and a welding subsystem probe are moved relative to the thermoplastic components, or vice versa.

Abstract: An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.

Abstract: A tacking device may comprise: a handle; a main body extending from a first end of the handle to a second end of the handle; and a plurality of soldering irons, each soldering iron in the plurality of soldering irons extending from a first side of the main body through the main body to a second side of the main body, each soldering iron in the plurality of soldering irons including a piercing end disposed on the second side of the main body.

Abstract: An assembly is provided for induction welding. This induction welding assembly includes a fixture. The fixture includes a first support structure and a second support structure. The second support structure includes a frame and a plurality of trunks. Each of the trunks is connected to and repositionable on the frame. The fixture is configured to secure a workpiece vertically between the first support structure and the second support structure using the trunks during induction welding of the workpiece.